508598 6348-1 - 3/28 A7 B7 五、發明說明（1) 本發明爲一種「薄形電感器之製造方法」，其係利用 磁性鐵氧體具有較佳之機械強度，可進行硏磨加工之特 性，使得電感器於製程中，鐵心之成型厚度可爲較厚者’ 及至灌膠封裝後，始再予硏磨削薄；藉以，使得鐵心於線 5圈繞設時易於夾持，且在電感器完成灌膠封裝後’可將多 餘之鐵心厚度予以適當之硏磨加工，以達到較小之整體厚 度，使得製成超薄型之電感器成爲可行者。 根據本發明法，製成「開磁路電感器」時’該方法至 少包含以下之步驟：鐵心成型、繞設線圏、焊接出力端 10子、灌膠封裝、及硏磨加工等；其中： 鐵心成型之步驟，係以磁性鐵氧體（Ferrite)爲成型 材質製成一鼓形鐵心，且鼓形鐵心之檔板厚度可爲較厚 者，以易於生產及夾持； 繞設線圏之步驟，係將鼓形鐵心予以夾持’並以線圈 15繞設在鼓形鐵心上； 焊接出力端子之步驟，係將線圈端子與出力端子加以 焊接； 灌膠封裝之步驟，係將鼓形鐵心、線圏、及出力端子 等置入模具中，灌膠封裝而予以包覆固定’且僅將鼓形鐵 20心多餘之檔板厚度予以外露； 硏磨加工之步驟，係將完成灌膠封裝之電感器’予以 適當之硏磨加工，而將鼓形鐵心多餘之檔板厚度予以去 除，以達到較小之整體厚度。 根據本發明法，製成「閉磁路電感器」時’該方法至 本紙張尺度適用中國國家標準（CNS)A4規格（210 χ 297公釐） (請先閱讀背面之注意事項再填寫本頁) 經濟部智慧財產局員工消費合作社印製 -· I I I 1 I 1^I ^ ·Ί — — — — — —— I Awl — — — III — L— — — —-----Ί--- 508598 A7 6348-1 - 4/28 B7 五、發明說明（2 ) 少包含以下之步驟：鐵心成型、繞設線圏、置入套筒、焊 接出力端子、灌膠封裝、及硏磨加工等；其中： (請先閲讀背面之注意事項再填寫本頁) 置入套筒之步驟，係將鼓形鐵心及線圏置入一套筒鐵 心，且套筒鐵心亦爲磁性鐵氧體之成型者，套筒鐵心上端 5並具有兩端子口，可供線圈端子通過，進而形成一閉磁路 之磁場，以構成一閉磁路電感器。 有關習有電感器之製造方法、構成、及技術手段，臚 列於后，謹請參考： ---線· (1 )習有之電感器，其鼓形鐵心之上下檔板有一定 10之成型條件，亦即在成型厚度上有一定之限制，例如：檔 板之成型厚度不可能爲〇.3mm，而需在0.6mm以上方能成 型，因此，上下檔板之總厚度必在1.2mm以上；另外，再 加上鼓形鐵心所需具備之可繞設線圈空間，則鼓形鐵心之 整體厚度較厚；是以，此類習有之電感器，在整體厚度上 15甚難再予縮減，不太可能製成超薄型之電感器。 經濟部智慧財產局員工消費合作社印製 (2)即使0.6mm以下之成型技術成爲可能，而製造 出上下檔板較薄之鼓形鐵心；惟，在實際功效上卻存在有 不易夾持及容易破碎等實用缺失；槪因，鼓形鐵心在繞設 線圏時，會產生一繞線作用力，因此，鼓形鐵心需受到良 20好之夾持固定；當夾持力道較輕時’鼓形鐵心會鬆脫而無 法確實夾持固定；而當夾持力道較重時，鼓形鐵心雖可確 實夾持固定，但由於上下檔板之厚度較薄，因此，上下檔 板極易破碎，鼓形鐵心有損壞之虞；是以，在實際製造 上，確有不利於生產之處，故此種製成方式不盡理想。 -4- 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） 508598 6348-1 - 5/28 A7 B7 五、發明說明（3) (3) 再者，習有之「閉磁路電感器」，在中心線圏 之外圍需設置有一套筒鐵心，因此，中心線圏與套筒鐵心 間會有縫隙；在習用之技術中，係以黏著劑自縫隙上注 入，而令中心線圏與套筒鐵心可接著固定；惟，若注入之 5黏著劑量不足或接著效果不夠牢靠時，會有鬆動之情形發 生；何況，黏著劑注入縫隙之作業並不容易，黏著劑常會 殘留於縫隙之缺口上，此時，只能藉由人工以海綿加以擦 拭；故此種製成方式並不理想，實有待改進。 (4) 此外，習有之SMD式電感器，常將鼓形鐵心之 10下端面直接作爲電感器之出力端子，因此，下檔板在進行 鍍焊錫作業時，易受到熱沖擊之影響，而導致鼓形鐵心產 生裂痕；更進者，乃下檔板在進行鍍焊錫作業前，需先行 施予鍍銀及鍍銀後燒結，不僅工程繁瑣且成本較高；尤 其，在進行鍍焊錫作業中，若鍍銀太薄，銀會有先溶入焊 15錫槽之虞，品質控制不易；是以，在進行焊錫前，有時需 鍍銀二至三次，而增加工時，並耗費成本。 (5) 又，有些接用一底座基板之習式電感器，係將 出力端子以扣片之方式扣在基板之兩側，扣片之上端及線 圈端子以焊鍚接合，再以黏著劑黏接焊鍚連接點；惟，黏 20著劑之用量並不易控制，過多則需擦拭淸除，而過少則接 著強度不足，品質控制不易；且外加底座基板，亦將增加 電感器之整體厚度，故亦有未盡理想之處。 有關習有電感器，因種類繁多，不再贅述，僅列舉數 項產品圖片以資參考，詳如附件一。 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） (請先閱讀背面之注意事項再填寫本頁) 經濟部智慧財產局員工消費合作社印製 , Γ 良 -0 amMKm ϋ n I ϋ^δι、V ϋ ϋ n i·— n 1_ I n 1 ϋ m 1 ϋ n n ft-··· ϋ I t n n 1^1 ' 508598 6348-1 - 6/28 A7 B7 五、發明說明（4 ) 由於上述之習式者，在整體厚度上甚難再予縮減，不 太可能製成超薄型之電感器，且的確存在有若干之實用缺 失’不僅工程繁瑣、成本較高，且品質控制不易，因此， 對於電感器日益精緻且小型化之需求而言，實有亟需替代 5之必要，以因應時代需求。 本發明之主要目的，即爲提供一種薄形電感器之製造 方法，使得電感器於製程中，鐵心之成型厚度可爲較厚 者，及至灌膠封裝後，始再予硏磨削薄，以達到較小之整 體厚度，而製成超薄型之電感器者，且該方法明顯具備下 10列優點、特徵及目的，以優勢取代之： 第一、本發明法之鼓形鐵心，係以磁性鐵氧體成型， 且上下檔板之厚度可爲較厚者，不僅易於生產，且可承受 較大之夾持力，故在繞設線圈時，鼓形鐵心無破碎及鬆脫 之虞。 15 第二、本發明法，係以灌膠封裝之方式，將鼓形鐵 心、線圈、及出力端子等予以封裝包覆，固定效果優異， 沒有黏著劑量不足或接著效果不夠牢靠等缺點，且亦無殘 留黏著劑之虞。 第三、本發明法之出力端子，係與線圈端子相焊接， 20且位於電感器之兩側邊；且本發明法之出力端子僅需鍍焊 錫作業，加工容易，品質均勻；當進行鍍焊錫作業時，熱 沖擊係由封裝之膠體承受，不致波及鼓形鐵心，可防止裂 痕之產生；藉以，提昇產品之品質，並改善習式者將鼓形 鐵心之下端面直接作爲電感器之出力端子，所造成之實用 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） --------------------------- (請先閲讀背面之注意事項再填寫本頁) 經濟部智慧財產局員工消費合作社印製 經濟部智慧財產局員工消費合作社印製 508598 A7 B7__ 6348-1 7/28 五、發明說明（5 ) 缺失。 第四、本發明法在製成「閉磁路電感器」時，係將鼓 形鐵心及線圏置入一套筒鐵心，且套筒鐵心亦爲磁性鐵氧 體之成型者，套筒鐵心上端並具有兩端子口，可供線圏端 5子通過，藉由灌膠封裝，即可達到優異之固定效果；沒有 黏著劑量不足或接著效果不夠牢靠等缺點，且亦無殘留黏 著劑之虞。 第五、本發明法在灌膠封裝後，僅將鼓形鐵心多餘之 檔板厚度予以外露，電感器之結構極爲牢靠，可藉由適當 10之硏磨加工，將鼓形鐵心多餘之檔板厚度予以去除，即可 達到較小之整體厚度；藉此，使得電感器之整體厚度可進 一步再予縮減，而製成超薄型之電感器。 本發明爲了達成上述之目的及功效，該方法所採行之 技術手段包含： 15 (a)鐵心成型之步驟，係以磁性鐵氧體製成一鼓形鐵 心，且鼓形鐵心之上下檔板可具有較厚之厚度； (b) 繞設線圈之步驟，係將鼓形鐵心予以夾持，並以 線圏繞設在繞線軸心上； (c) 焊接出力端子之步驟，係將兩線圈端子與兩出力 20端子加以焊接； (句灌膠封裝之步驟，係將鼓形鐵心、線圏、及兩出 力端子等置入模具中，並灌入絕緣膠體而予以包覆固定， 且將上下檔板待硏磨之多餘厚度予以外露； (e)硏磨加工之步驟，係對上下檔板施予適當之硏磨 -7- 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公爱)"----- (請先閱讀背面之注意事項再填寫本頁) -------訂 _ ^--------線. 508598 6348-1 - A7 B7 五、發明說明（6) 加工，而將多餘之檔板厚度予以去除； 藉此，使得電感器之整體厚度可進一步再予縮減，而 達到較小之整體厚度，以製成一超薄型之電感器。 本發明之特徵、技術手段以及所達成之具體功能、目 5的，茲列舉一較具體實施例，繼以圖式、圖號詳細說明如 后·· 圖式說明如下： 第1圖係爲本發明製成「開磁路電感器」之步驟流程 示意圖； ίο 第2圖係爲本發明製成「開磁路電感器」之立體分解 示意圖； 第3圖係爲本發明第2圖未硏磨前之立體示意圖； 第4圖係爲本發明第2圖未硏磨前之剖面示意圖； 第5圖係爲本發明第3圖已硏磨後之立體示意圖； 15 第6圖係爲本發明第3圖已硏磨後之剖面示意圖； 第7圖係爲本發明製成「開磁路電感器」之磁路示意 圖； 第8圖係爲本發明製成「閉磁路電感器」之步驟流程 示意圖； ’20 第9圖係爲本發明製成「閉磁路電感器」之立體分解 示意圖； 第1 0圖係爲本發明第9圖未硏磨前之立體示意圖； 第1 1圖係爲本發明第9圖未硏磨前之剖面示意圖； 第1 2圖係爲本發明第1 0圖已硏磨後之立體示意 本紙張尺度適用中國國家標準（CNS)A4規袼（210 X 297公釐） (請先閱讀背面之注意事項再填寫本頁) -Aw-------訂-------|線- 經濟部智慧財產局員工消費合作社印製 508598 A7 6348-1 - 9/28 B7 五、發明說明（7) 圖； 第1 3圖係爲本發明第1 0圖已硏磨後之剖面示意 圖； 第1 4圖係爲本發明製成「閉磁路電感器」之磁路示 5 意圖。 鼓形鐵心 多餘之檔板厚度1 la 多餘之檔板厚度12a 繞設線圏步驟2 線圈端子21，22 套筒鐵心30 多餘厚度33 薄銅帶體40 灌膠封裝步驟5 硏磨加工步驟6 開磁路段71 (請先閱讀背面之注意事項再填寫本頁) 圖號說明如下·β 鐵心成型步驟1 上檔板11 下檔板12 繞線軸心13 線圏20 置入套筒步驟3 端子口 31，32 焊接出力端子步驟4 出力端子41，42 絕緣膠體50 磁通路70 磁通路72 經濟部智慧財產局員工消費合作社印製 請參閱第1至6圖所示，根據本發明法，製成「開磁 路電感器」時，該方法至少包含以下之步驟： 鐵心成型之步驟1，係以磁性鐵氧體爲成型材質製成 10 —鼓形鐵心10，且鼓形鐵心1〇之上下檔板11，12之厚度 可爲較厚者； 繞設線圏之步驟2，係將鼓形鐵心10予以夾持，並 -9- 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） 508598 A7 _B7_6348-1 - 10/28 五、發明說明（8 ) 以線圏20繞設在繞線軸心13上； (請先閱讀背面之注意事項再填寫本頁) 焊接出力端子之步驟4，係將兩線圈端子21，22與兩 出力端子41，42加以焊接； 灌膠封裝之步驟5，係將鼓形鐵心10、線圈20、及 5兩出力端子41，42等置入模具中，灌入絕緣膠體50而予 以包覆固定，且上下檔板11，12僅有多餘之檔板厚度 1 la，12a 外露； 硏磨加工之步驟6，係對多餘之檔板厚度lla，12a施 予適當之硏磨加工，而將多餘之檔板厚度lla，12a予以去 10除，以達到較小之整體厚度。 如第2至4圖所示，根據本發明法所製成之「開磁路 電感器」，至少包括：一鼓形鐵心10、一線圏20、兩出 力端子41，42、及絕緣膠體50等構成；其中： 該鼓形鐵心10，係由磁性鐵氧體所成型，且具有上 15下檔板11，12及繞線軸心13 ; 該線圈20，係繞設於繞線軸心13上，且具有兩線圏 端子21，22 ; 經濟部智慧財產局員工消費合作社印製 該兩出力端子41，42，係與兩線圈端子21，22相焊 接； 20 該絕緣膠體50，係於鼓形鐵心10、線圈20、及兩出 力端子41，42等置入模具後灌膠而成； 且藉由硏磨加工，可將灌膠封裝後所外露之多餘檔板 厚度lla，12a予以去除，以達到較小之整體厚度，而製成 如第5至6圖所示之超薄型電感器者。 -10- 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） 508598 6348-1 - 11/28 A7 B7 五、發明說明（9) 此間當予以說明者，乃兩出力端子41，42，係可由一 薄銅帶體40所沖壓製成，鍍焊錫加工容易且品質均勻； 較佳之製造方式，可爲先將薄銅帶體40中間之餘料予以 沖壓去除，再將欲作爲端子之部份予以彎折，即可形成兩 '5出力端子41，42;由於，此方式可製成數對之出力端子 41，42，故本發明方法具有連續加工生產之特性。 此間當再予以說明者，乃上下檔板11，12在硏磨加工 之後，進一步亦可於上下檔板11，12上施予鏡面處理，以 精進產品之品質及外觀；且亦可進一步於上下檔板11，12 10上施予雷射刻字，以標示生產者及產品之型號。 請參閱第7圖所示，乃係爲本發明製成「開磁路電感 器」之磁路示意圖；爲清楚顯示磁路，係以未灌膠封裝之 狀態予以說明，如圖所示，線圈20之外圍可形成一磁通 路7〇，且在鼓形鐵心10之外形成一開磁路段71，而構 15成一開磁路之磁場。 請參閱第8至1 3圖所示，根據本發明法，製成「閉 磁路電感器」時，該方法至少包含以下之步驟： 鐵心成型之步驟1，係以磁性鐵氧體爲成型材質製成 一鼓形鐵心10，且鼓形鐵心10之上下檔板n，12之厚度 20可爲較厚者； 繞設線圈之步驟2，係將鼓形鐵心予以夾持，並 以線圏20繞設在繞線軸心13上； 置入套筒之步驟3，係將鼓形鐵心及線圈2〇置入 一套筒鐵心30，且套筒鐵心30亦爲磁性鐵氧體之成型 -11- 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） I----- - ------ I I I I I ^-1 ------I . (請先閱讀背面之注意事項再填寫本頁) 經濟部智慧財產局員工消費合作社印製 508598 A7 B7 6348-1 - 12/28 五、發明說明（10) 者，套筒鐵心30上端並具有兩端子口 31，32，可供兩線 圈端子21，22通過； (請先閲讀背面之注意事項再填寫本頁) 焊接出力端子之步驟4，係將兩線圏端子21，22與兩 出力端子41，42加以焊接； 5 灌膠封裝之步驟5，係將鼓形鐵心10、線圈20、及 兩出力端子41，42等置入模具中，灌入絕緣膠體50而予 以包覆固定，且僅有上下檔板11，12之多餘檔板厚度 lla，12a，及套筒鐵心30之多餘厚度33外露； 硏磨加工之步驟6，係對上下檔板11，12之多餘檔板 10厚度1 la，12a，及套筒鐵心30之多餘厚度33施予適當之 硏磨加工，而將予以去除，以達到較小之整體厚度。 如第9至1 1圖所示，根據本發明法所製成之「開磁 路電感器」，至少包括：一鼓形鐵心1〇、一線圈20、一 套筒鐵心30、兩出力端子41，42、及絕緣膠體50等構 15成；其中： 該鼓形鐵心1〇，係由磁性鐵氧體所成型，且具有上 下檔板11，12及繞線軸心13 ; 經濟部智慧財產局員工消費合作社印製 該線圈20，係繞設於繞線軸心13上，且具有兩線圈 端子21，22; 20 該套筒鐵心30，係由磁性鐵氧體所成型，且上端並 具有兩端子口 31，32，可供兩線圏端子21，22通過； 該兩出力端子41，42，係與兩線圏端子21，22相焊 接； 該絕緣膠體50，係於鼓形鐵心10、線圏20、套筒鐵 -12- 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） 508598 6348-1 - 13/28 A7 B7 五、發明說明（11) 心30、及兩出力端子41，42等置入模具後灌膠而成； 且藉由硏磨加工，可將灌膠封裝後，上下檔板11，12 及套筒鐵心30所外露之多餘檔板厚度lla，12a及多餘厚 度33予以去除，以達到較小之整體厚度，而製成如第1 5 2至1 3圖所示之超薄型電感器者。 此間當予以說明者，乃兩出力端子41，42，係可由一 薄銅帶體40所沖壓製成，鍍焊錫加工容易且品質均勻； 較佳之製造方式，可爲先將薄銅帶體40中間之餘料予以 沖壓去除，再將欲作爲端子之部份予以彎折，即可形成兩 10出力端子41，42 ;由於，此方式可製成數對之出力端子 41，42，故本發明方法具有連續加工生產之特性。 此間當再予以說明者，乃上下檔板11，12在硏磨加工 之後，進一步亦可於上下檔板11，12上施予鏡面處理，以 精進產品之品質及外觀；且亦可進一步於上下檔板11，12 15上施予雷射刻字，以標示生產者及產品之型號。 請參閱第1 4圖所示，乃係爲本發明製成「閉磁路電 感器」之磁路75意圖；爲淸楚顯TfC磁路，係以未灌膠封裝 之狀態予以說明，如圖所示，線圏20可沿著鼓形鐵心10 及套筒鐵心30形成一磁通路72，且構成一閉磁路之磁 20 場。 此間擬特別強調說明者，乃本發明最主要之創意精神 在於提供一種薄形電感器之製造方法，藉由磁性鐵氧體具 有較佳之機械強度，可進行硏磨加工之特性，使得電感器 於製程中，該鼓形鐵心10之上下檔板11，12之成型厚度 -13- 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） I-----------φ^ί----1 訂1--------線· <請先閱讀背面之注意事項再填寫本頁) 經濟部智慧財產局員工消費合作社印製 M38598 B7 6348-1 - 14/28 1、發明說明（12) 可在0.6mm以上而易於成型，以利於生產製造，並使得 鼓形鐵心10於線圏20繞設時易於夾持，且在灌膠封裝 後，經由適當之硏磨加工，上下檔板11，12之厚度可削薄 至〇.3mm左右，其機械強度約等於1mm之金屬粉末成型 5體’復於封裝包覆之固定下，整體之結構強度安全無虞， 則硏磨削薄後上下檔板11，12之總厚度約可達到0.6mm 左右’因此，電感器之整體厚度得以被進一步縮減，且當 繞線軸心13之高度約在〇.4mm左右時，電感器之整體厚 度約可達到1mm左右，進而製成一超薄型之電感器；故 10實爲電感器製造上之一大突破，且爲本發明創意之精華所 在。 綜上所述，本發明「薄形電感器之製造方法」顯見實 已符合發明專利之成立要件，爰依法提出專利之申請，懇 請早日賜准本案專利，以彰顯專利法獎勵國人創作之立法 15精神，是所至盼。 ! — ！ I J I 訂，.！線 i (請先閱讀背面之注音？事項再填寫本頁) 經濟部智慧財產局員工消費合作社印製 本紙張尺度適用中國國豕標準（CNS)A4規格（210 X 297公釐）508598 6348-1-3/28 A7 B7 V. Description of the invention (1) The present invention is a "manufacturing method for thin inductors", which uses magnetic ferrite to have better mechanical strength and can be honed. Due to the characteristics, the inductor can be made thicker in the manufacturing process of the inductor, and then thinned after the encapsulation. This makes the inductor easier to clamp when winding the wire for 5 turns, and After the inductor is encapsulated, the excess core thickness can be appropriately honed to achieve a smaller overall thickness, making it possible to make ultra-thin inductors. According to the method of the present invention, when the "open magnetic circuit inductor" is made, the method includes at least the following steps: iron core forming, wire winding, welding output terminal 10, potting package, and honing processing, etc .; among them: The iron core forming step is to make a drum-shaped iron core with ferrite as the molding material, and the thickness of the baffle of the drum-shaped iron core can be thicker for easy production and clamping; The steps are to clamp the drum-shaped iron core and wind the coil 15 on the drum-shaped iron core. The step of welding the output terminal is to weld the coil terminal and the output terminal. The step of potting and encapsulating is to drum the core. , Wire reeds, and output terminals are placed in the mold, encapsulated with glue, and covered and fixed ', and only the thickness of the excess baffle plate of the drum-shaped iron 20 core is exposed; the step of honing processing is to complete the glue-filled package The inductors are appropriately honed, and the thickness of the excess baffle of the drum core is removed to achieve a smaller overall thickness. According to the method of the present invention, when the "closed magnetic circuit inductor" is made, the method applies to the Chinese paper standard (CNS) A4 (210 x 297 mm) up to the paper size (please read the precautions on the back before filling this page) Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs-· III 1 I 1 ^ I ^ · Ί — — — — — — — I Awl — — — III — L — — — — — — — 508598 A7 6348-1-4/28 B7 V. Description of the invention (2) The following steps are rarely included: iron core forming, wire winding, inserting sleeves, soldering output terminals, potting and encapsulation, and honing processing; etc .; : (Please read the precautions on the back before filling this page) The step of inserting the sleeve is to put the drum core and the wire coil into a sleeve core, and the sleeve core is also the shape of the magnetic ferrite. The upper end 5 of the sleeve core has two terminal ports, which can be passed by the coil terminals to form a closed magnetic circuit magnetic field to form a closed magnetic circuit inductor. The manufacturing method, structure, and technical methods of conventional inductors are listed below. Please refer to the following: (1) For conventional inductors, the upper and lower baffle plates of the drum core have a certain 10 Forming conditions, that is, there are certain restrictions on the forming thickness. For example, the forming thickness of the baffle cannot be 0.3mm, but it can be formed above 0.6mm. Therefore, the total thickness of the upper and lower baffles must be 1.2mm. In addition, in addition to the coilable space required by the drum core, the overall thickness of the drum core is thicker; therefore, such conventional inductors are difficult to give in the overall thickness of 15 Reduced, it is unlikely to make ultra-thin inductors. Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs (2) Even if the molding technology below 0.6mm becomes possible, the drum core with thinner upper and lower baffle plates can be manufactured; however, it is difficult to clamp and easy to implement Practical lack of fragmentation, etc .; for this reason, the drum-shaped core will generate a winding force when winding the wire. Therefore, the drum-shaped core needs to be clamped and fixed by a good 20; when the clamping force is lighter, the drum The shaped iron core will loose and cannot be clamped and fixed. When the clamping force is heavy, although the drum core can be clamped and fixed, but the upper and lower baffles are thin, so the upper and lower baffles are easily broken. The drum core may be damaged; therefore, in actual manufacturing, there are indeed disadvantages to production, so this method of making is not ideal. -4- This paper size is in accordance with Chinese National Standard (CNS) A4 (210 X 297 mm) 508598 6348-1-5/28 A7 B7 V. Description of the invention (3) (3) Furthermore, the conventional "closed magnetic field" "Road inductors" need a sleeve iron core on the periphery of the center line 圏. Therefore, there will be a gap between the center line 圏 and the sleeve iron core. In conventional technology, an adhesive is injected from the gap to make the center The bobbin and the core of the sleeve can be subsequently fixed; however, if the injected dose of 5 is insufficient or the adhesion effect is not reliable enough, loosening may occur; not to mention, the operation of the adhesive injection into the gap is not easy, and the adhesive often remains in the At this time, the gap can only be wiped manually with a sponge; therefore, this manufacturing method is not ideal and needs to be improved. (4) In addition, the conventional SMD type inductors often use the lower end face of the drum core 10 as the output terminal of the inductor. Therefore, the lower baffle plate is easily affected by thermal shock when soldering, and Lead to cracks in the drum-shaped iron core. Furthermore, the lower baffle plate must be silver-plated and silver-plated and sintered before the soldering operation, which is not only complicated and costly; especially, during the soldering operation If the silver plating is too thin, silver may melt into the 15 solder bath first, and quality control is not easy; therefore, before soldering, it is sometimes necessary to plate silver two to three times, which increases man-hours and costs. (5) In addition, some custom inductors that use a base substrate are used to buckle the output terminals on both sides of the substrate in the form of clips, and the upper ends of the clips and the coil terminals are connected by soldering, and then bonded with an adhesive. Connect the solder joints; however, the amount of adhesive 20 is not easy to control. Too much will need to be wiped away, while too little will be insufficient and the quality will not be easy to control; and the addition of the base substrate will also increase the overall thickness of the inductor. Therefore, there are also unsatisfactory aspects. There are many types of custom inductors, so I wo n’t repeat them here. I only list a few product pictures for reference, as shown in Annex 1. This paper size is in accordance with Chinese National Standard (CNS) A4 (210 X 297 mm) (Please read the notes on the back before filling out this page) Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs, Γ 良 -0 amMKm ϋ n I ϋ ^ δι, V ϋ ϋ ni · — n 1_ I n 1 ϋ m 1 ϋ nn ft- ·· ϋ I tnn 1 ^ 1 '508598 6348-1-6/28 A7 B7 V. Description of the invention (4) Due to the above-mentioned practice, it is difficult to reduce the overall thickness, it is not possible to make ultra-thin inductors, and there are indeed some practical shortcomings. Not only is the engineering complicated, the cost is high, and the quality control is not easy. Therefore, for the increasingly sophisticated and miniaturized inductors, there is an urgent need to replace 5 to meet the needs of the times. The main purpose of the present invention is to provide a method for manufacturing a thin inductor, so that the inductor can be formed with a thicker core during the manufacturing process, and after the encapsulation, it can be thinned by grinding, so that Those who have achieved a small overall thickness and made ultra-thin inductors, and this method obviously has the following 10 advantages, features and purposes, which are replaced by advantages: First, the drum core of the method of the present invention is based on The magnetic ferrite is formed, and the thickness of the upper and lower baffles can be thicker, which is not only easy to produce, but also can withstand a large clamping force. Therefore, when the coil is wound, the drum core does not have to be broken or loosened. 15 Second, the method of the present invention is a method of encapsulating the drum core, coil, and output terminals by means of potting and encapsulation. The fixing effect is excellent, and there are no shortcomings such as insufficient adhesive dose or insufficient bonding effect. No residual adhesive. Third, the output terminal of the method of the present invention is welded to the coil terminal, and is located on both sides of the inductor; and the output terminal of the method of the present invention only requires soldering, which is easy to process and has uniform quality; During operation, the thermal shock is borne by the encapsulated colloid, which will not spread to the drum core, which can prevent the occurrence of cracks. As a result, the quality of the product is improved, and the habitual person who uses the lower end of the drum core as the output terminal of the inductor directly The resulting practical paper size is applicable to the Chinese National Standard (CNS) A4 specification (210 X 297 mm) -------------------------- -(Please read the notes on the back before filling this page) Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs Printed by the Employee Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs Printed by 508598 A7 B7__ 6348-1 7/28 V. Description of the Invention (5) Is missing. Fourth, when the method of the present invention is made into a "closed magnetic circuit inductor", the drum core and the wire coil are placed in a sleeve core, and the sleeve core is also a shape of the magnetic ferrite, and the upper end of the sleeve core And it has two terminal ports, which can be used for the 5 terminals of the wire end. By potting, it can achieve excellent fixing effect; there is no shortcomings such as insufficient adhesive dose or insufficient bonding effect, and there is no risk of residual adhesive. Fifth, the method of the present invention only exposes the thickness of the excess baffle plate of the drum core after the potting is encapsulated, and the structure of the inductor is extremely reliable. The excess baffle plate of the drum core can be processed by honing properly If the thickness is removed, a smaller overall thickness can be achieved; thereby, the overall thickness of the inductor can be further reduced to make an ultra-thin inductor. In order to achieve the above-mentioned objects and effects of the present invention, the technical means adopted by the method include: 15 (a) the step of forming the iron core, which is made of magnetic ferrite to form a drum-shaped iron core; It can have a thicker thickness; (b) the step of winding the coil is to clamp the drum core and wind it on the winding axis; (c) the step of welding the output terminal is to The coil terminals are welded with the two output 20 terminals; (The step of filling the plastic package is to put the drum core, the wire coil, and the two output terminals into a mold, and then pour them into the insulating gel to cover and fix them. The excess thickness of the upper and lower baffles to be honing is exposed; (e) The honing process is to apply appropriate honing to the upper and lower baffles. 7- This paper size applies to Chinese National Standard (CNS) A4 (210 X 297 public love) " ----- (Please read the notes on the back before filling in this page) ------- Order_ ^ -------- line. 508598 6348-1-A7 B7 V. Description of the invention (6) Processing to remove the excess thickness of the baffle plate; by doing so, the overall thickness of the inductor can be increased It is further reduced to achieve a smaller overall thickness to make an ultra-thin inductor. Features, technical means, and specific functions achieved of the present invention, item 5, a more specific embodiment is enumerated, Following the detailed description with diagrams and numbers, the diagrams are explained as follows: Figure 1 is a schematic flow chart of the steps of making an "open magnetic circuit inductor" according to the present invention; 3D exploded schematic diagram of the "open magnetic circuit inductor"; Figure 3 is a schematic perspective view before the honing in Figure 2 of the present invention; Figure 4 is a schematic sectional view before the honing in Figure 2 of the present invention; Figure 5 Figure 3 is a schematic perspective view after honing in Figure 3 of the present invention; Figure 15 is a schematic sectional view after honing in Figure 3 of the present invention; Figure 7 is an "open magnetic circuit inductor" made according to the present invention Figure 8 is a schematic flow chart of the steps for making a "closed magnetic circuit inductor" according to the present invention; '20 Figure 9 is a three-dimensional exploded schematic view for the "closed magnetic circuit inductor" made according to the present invention; Figure is a schematic perspective view before honing in Figure 9 of the present invention; Figure 11 is a schematic cross-sectional view before honing in Figure 9 of the present invention; Figure 12 is a three-dimensional illustration after honing in Figure 10 of the present invention. The paper dimensions are subject to the Chinese National Standard (CNS) A4. (210 X 297 mm) (Please read the notes on the back before filling out this page) -Aw ------- Order ------- | Line-Printed by the Employees' Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs 508598 A7 6348-1-9/28 B7 V. Description of the invention (7) Figure; Figure 13 is a schematic cross-section diagram after honing of Figure 10 of the invention; Figure 14 shows the invention made " The magnetic circuit of the "closed magnetic circuit inductor" shows 5 intentions. Thickness of the extra baffle of the drum core 1 la Thickness of the extra baffle 12a Winding step 2 Coil terminals 21, 22 Sleeve core 30 Excess thickness 33 Thin copper strip 40 Encapsulation step 5 Honing step 6 Open Magnetic circuit section 71 (Please read the precautions on the back before filling in this page) The figure numbers are explained as follows: β Iron core forming step 1 Upper baffle plate 11 Lower baffle plate 12 Winding shaft center 13 Coil 20 Insert into the sleeve Step 3 Terminal port 31, 32 Welding output terminals Step 4 Output terminals 41, 42 Insulation gel 50 Magnetic path 70 Magnetic path 72 Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs Please refer to Figures 1 to 6, according to the method of the present invention, "Open the magnetic circuit inductor", the method includes at least the following steps: Step 1 of iron core molding is made of magnetic ferrite as the molding material 10-drum core 10, and the drum core 10 upper and lower baffles The thickness of 11 and 12 can be thicker. Step 2 of winding the coils is to hold the drum core 10, and this paper size applies to China National Standard (CNS) A4 (210 X 297 mm) %) 508598 A7 _B7_6348-1-10/28 V. Description of the invention (8) Winding coil 20 is installed on winding axis 13; (Please read the precautions on the back before filling this page) Step 4 of welding output terminals is to connect two coil terminals 21, 22 and two output terminals 41 , 42 are welded; step 5 of potting and encapsulation involves placing the drum core 10, coils 20, and 5 output terminals 41, 42 into a mold, and pouring into the insulating gel 50 to cover and fix it. The plates 11 and 12 only have the thickness of the excess baffles 1 la and 12a exposed; the step 6 of the honing process is to perform the appropriate honing processing on the thicknesses of the excess baffles 11a and 12a, and the thickness of the excess baffles 11a , 12a is divided by 10 to achieve a smaller overall thickness. As shown in Figures 2 to 4, the "open magnetic circuit inductor" made according to the present invention includes at least: a drum core 10, a wire 20, two output terminals 41, 42, and an insulating gel 50, etc. Composition: Among them: the drum core 10 is formed by magnetic ferrite, and has upper and lower 15 baffles 11, 12 and winding axis 13; the coil 20 is wound on the winding axis 13 , And has two wire terminals 21 and 22; the consumer cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs printed the two output terminals 41 and 42 to be welded to the two coil terminals 21 and 22; 20 the insulating gel 50 is connected to a drum shape The core 10, the coil 20, and the two output terminals 41, 42 are filled with glue after being placed in a mold; and by honing processing, the thickness of the excess baffles 11a and 12a exposed after the glue is packaged can be removed to To achieve a small overall thickness, and make ultra-thin inductors as shown in Figures 5 to 6. -10- This paper size is in accordance with China National Standard (CNS) A4 (210 X 297 mm) 508598 6348-1-11/28 A7 B7 V. Description of the invention (9) Those who should explain here are two output terminals 41 42 is made from a thin copper strip body 40, which is easy to process with solder plating and uniform quality. The preferred manufacturing method is to first remove the remaining material in the middle of the thin copper strip body 40, and then use the The part of the terminal is bent to form two '5 output terminals 41, 42. Since this method can be made into several pairs of output terminals 41, 42, the method of the present invention has the characteristics of continuous processing and production. It should be explained here that after the honing of the upper and lower baffles 11, 12 can be further mirror-polished on the upper and lower baffles 11, 12 to further improve the quality and appearance of the product; Laser markings are applied to the baffles 11, 12 and 10 to indicate the manufacturer and product model. Please refer to Figure 7, which is a schematic diagram of the magnetic circuit of the "open magnetic circuit inductor" made according to the present invention. In order to clearly show the magnetic circuit, it is explained in an unfilled package state. As shown in the figure, the coil A magnetic path 70 can be formed at the periphery of 20, and an open magnetic path section 71 is formed outside the drum core 10, and 15 forms an open magnetic field magnetic field. Please refer to FIGS. 8 to 13. According to the method of the present invention, when the “closed magnetic circuit inductor” is manufactured, the method includes at least the following steps: Step 1 of forming the core is made of magnetic ferrite as the molding material. A drum-shaped iron core 10 is formed, and the thickness 20 of the upper and lower baffles n, 12 of the drum-shaped iron core 10 may be thicker; Step 2 of winding the coil is to hold the drum-shaped iron core and wind it with a wire coil 20 It is set on the winding shaft core 13; Step 3 of inserting the sleeve is to put the drum core and the coil 20 into a sleeve core 30, and the sleeve core 30 is also a shape of magnetic ferrite-11- This paper size applies to China National Standard (CNS) A4 (210 X 297 mm) I ------------ IIIII ^ -1 ------ I. (Please read the Please fill out this page again) Printed by 508598 A7 B7 6348-1-12/28 of the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economy Can be used for two coil terminals 21 and 22; (Please read the precautions on the back before filling this page) Step 4 of welding the output terminal is to connect the two-wire terminal 21 22 and two output terminals 41, 42 are welded; 5 step 5 of potting encapsulation, the drum core 10, the coil 20, and the two output terminals 41, 42 are placed in a mold, filled with insulating gel 50 and wrapped The cover is fixed, and only the excess thicknesses 11a, 12a of the upper and lower baffles 11, 12 and the excess thickness 33 of the sleeve iron core 30 are exposed; Step 6 of the honing process is for the excess gears of the upper and lower baffles 11, 12 The thickness 10 la, 12a of the plate 10, and the excess thickness 33 of the sleeve core 30 are subjected to appropriate honing, and will be removed to achieve a smaller overall thickness. As shown in Figures 9 to 11, the "open magnetic circuit inductor" made according to the method of the present invention includes at least: a drum core 10, a coil 20, a sleeve core 30, and two output terminals 41 , 42, and insulating colloid 50, etc .; Among them: The drum core 10 is made of magnetic ferrite and has upper and lower baffles 11, 12 and winding axis 13; Intellectual Property Bureau of the Ministry of Economic Affairs The consumer cooperative prints the coil 20, which is wound on the winding axis 13 and has two coil terminals 21, 22; 20 The sleeve core 30 is formed by magnetic ferrite, and the upper end has two The terminal ports 31 and 32 can be passed by the two-line cymbals 21 and 22; the two output terminals 41 and 42 are welded to the two-line cymbals 21 and 22; the insulating gel 50 is connected to the drum core 10 and the wire圏 20. Sleeve iron-12- This paper size is applicable to China National Standard (CNS) A4 (210 X 297 mm) 508598 6348-1-13/28 A7 B7 V. Description of the invention (11) Heart 30, and two The output terminals 41, 42 are filled with glue after being placed in the mold; and by honing, the glue can be encapsulated, and the upper and lower baffles 11, 12, and The excess baffle thickness 11a, 12a and the excess thickness 33 exposed from the sleeve core 30 are removed to achieve a smaller overall thickness, and an ultra-thin inductor as shown in Figures 15 2 to 13 is manufactured. . It should be explained here that the two output terminals 41 and 42 can be stamped from a thin copper strip body 40. The soldering process is easy and the quality is uniform. The preferred manufacturing method is to first place the thin copper strip body 40 in the middle. The remaining material is punched and removed, and then the part to be used as a terminal is bent to form two 10 output terminals 41, 42. Since this method can be made into several pairs of output terminals 41, 42, the method of the present invention Has the characteristics of continuous processing and production. It should be explained here that after the honing of the upper and lower baffles 11, 12 can be further mirror-polished on the upper and lower baffles 11, 12 to further improve the quality and appearance of the product; Laser markings are applied to the baffles 11, 12 and 15 to indicate the manufacturer and product model. Please refer to Figure 14 for the intention of making the magnetic circuit 75 of the "closed magnetic circuit inductor" according to the present invention; for the Chu Chuxian TfC magnetic circuit, it is explained in an unfilled state, as shown in the figure It is shown that the coil 20 can form a magnetic path 72 along the drum core 10 and the sleeve core 30 and form a magnetic 20 field of a closed magnetic circuit. It is intended to particularly emphasize the explanation here, which is the main creative spirit of the present invention is to provide a method for manufacturing a thin inductor. The magnetic ferrite has better mechanical strength and can be honed to make the inductor In the manufacturing process, the forming thickness of the upper and lower baffles 11 and 12 of the drum core 10 is -13- This paper size applies to China National Standard (CNS) A4 (210 X 297 mm) I --------- --φ ^ ί ---- 1 Order 1 -------- line · < Please read the notes on the back before filling out this page) Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs M38598 B7 6348- 1-14/28 1. Description of the invention (12) It can be easily molded above 0.6mm to facilitate production and make the drum core 10 easy to be clamped when the coil 20 is wound, and after the potting and encapsulation, After proper honing processing, the thickness of the upper and lower baffles 11, 12 can be reduced to about 0.3mm, and the metal strength of the metal powder is about 1mm, and the body is formed into a five-piece body. It is safe, and the total thickness of the upper and lower baffles 11, 12 after honing and grinding can reach about 0.6mm ' Therefore, the overall thickness of the inductor can be further reduced, and when the height of the winding axis 13 is about 0.4 mm, the overall thickness of the inductor can reach about 1 mm, thereby making an ultra-thin inductor ; 10 is therefore a major breakthrough in the manufacture of inductors, and is the essence of the invention. In summary, the "manufacturing method for thin inductors" of the present invention has clearly met the requirements for the establishment of an invention patent, and has applied for a patent application in accordance with the law. Spirit is what we want. ! —! I J I Order,.! Line i (Please read the note on the back? Matters before filling out this page) Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs This paper size applies to China National Standard (CNS) A4 (210 X 297 mm)