1287238 A7 B7 五、發明說明 【發明領域】 本發明疋有關於一種電感元件及其製造方法與模具 特別疋私一種製造時無須加工黏合之製造方法及模具。 【習知技藝說明】 一般電感凡件的構造設計，會隨所需求之特性與規格 如頻率、電流、體積、電感值…等的差異而有所不同，如 第一、一圖所不之習知電感元件構造，是包含有由導磁材 料如鐵合金所製成之一包覆體1〇，及一被包覆在該包覆體 内之線圈1 3。 該包覆體10包括有可一下一上對應蓋合之 與一頂板12。s亥底座H具有一由其一頂面往下凹陷之容槽 m，及一直立地設立在該容槽lu中央處之軸柱ιι〇。該 容槽111具有二側開口端i 12。該頂蓋12概略成平板狀， 具有二由其一頂面兩相反侧往下凹陷之間隔凹槽i2i，該頂 蓋12對應蓋合在該底座u上之製造方式，是採用在頂蓋 12與底座.11接合處塗部黏膠，而將該二構件黏接成一體。 該線圈13具有—由—長條扁平狀導線等半徑地沿一中 心轴線彎繞預定圈數而成之繞圈部131，及二分別由該繞圈 部兩端往外延伸之延伸部132。組裝時該繞圈部⑶是 在頂蓋12黏合於底座u以前’先對應容置在該底座η之 容槽111 Θ ’並軸裝套合在底座u之軸柱11〇夕卜部，而該 二延伸部132是一高一低地分別對應穿出該容肖⑴之該 等側開口端U2’接著便可藉由前述頂i 12黏合在該底座 11頂面’而將線圈13固定限位在頂蓋12與底座u間。又1287238 A7 B7 V. OBJECTS OF THE INVENTION [Invention] The present invention relates to an inductor element, a method of manufacturing the same, and a mold, which are particularly advantageous in a manufacturing method and a mold which are manufactured without bonding. [Explanation of Skills] The structural design of general inductors will vary with the characteristics and specifications such as frequency, current, volume, inductance, etc., as in the first and the first. The inductive element structure is composed of a covering body 1 made of a magnetic conductive material such as an iron alloy, and a coil 13 covered in the covering body. The covering body 10 includes a top plate 12 corresponding to the upper cover and the corresponding cover. The s-hai base H has a recess m which is recessed from a top surface thereof, and a shaft column ιι〇 which is always standing at the center of the pocket lu. The pocket 111 has two open ends i 12 . The top cover 12 is substantially in the form of a flat plate, and has two spaced grooves i2i recessed from opposite sides of a top surface thereof. The top cover 12 is correspondingly mounted on the base u, and is used in the top cover 12 Adhesive is applied to the joint of the base 11. and the two members are bonded together. The coil 13 has a winding portion 131 formed by bending a predetermined number of turns along a central axis by a radius of a flat wire, and an extending portion 132 extending outward from both ends of the winding portion. In the assembly, the winding portion (3) is correspondingly received in the receiving groove 111 of the base η before the top cover 12 is adhered to the base u, and the shaft is assembled on the shaft column 11 of the base u. The two extension portions 132 are respectively high and low, respectively corresponding to the side open ends U2 ′ of the escaping (1), and then the top surface 12 of the pedestal 11 is adhered to the top surface of the base 11 to fix the coil 13 Between the top cover 12 and the base u. also
1287238 A7 __B7五、發明說明（2 ) ，如第二圖所示，該二延伸部132之外端，可視需要往上 並相向彎折地貼覆在頂蓋12之該二凹槽m内。 上述習知電感元件之製造過程中，除了該包覆體之 底座11與頂蓋12所進行的點膠黏合加工，會造成其作業 較為麻煩並增加成本以外’其線圈13套裝在底座11之容 槽111内的設置構造，由於線圈13以套合方式容置在底座 11與頂蓋12間，難免會存在空隙，而兩側開口端〖丨2更是 一無法避免的導磁缺隙，因此除了容易產生振動與噪音外 ’並會造成較大的磁損’且電感的品質因素（QUaHty ，簡稱Q值）會下降。 【發明概要】 因此，本發明之目的，即在提供一種將導磁材料一體 成型包覆在線圈外部，使導磁材料與線圈間完全不會存在 空隙之電感元件及其製造方法與模具。 於是’本發明電感元件之製造方法所製造出的電感元 件’是具有一線圈及一包覆在該線圈外部之包覆體，該線 圈具有一由一長條導線彎繞預定圈數而成之繞圈部，及二 分別由該繞圈部兩端往外延伸之延伸部，該製造方法包含 :(A)將該線圈放置在由一上模與一下模對應蓋合所界定出 之一容裝空間中，使線圈之二延伸部受失持定位於上、下 模間’且使線圈之繞圈部是懸空地容置於該容裝空間内。 (B) 將含有鐵合金粉末之流態包覆流體，注入並充滿該容裝 空間内，以凝結形成包覆所述繞圈部之一固態包覆體。及 (C) 烘烤該結合一體之線圈與包覆體，使該包覆體硬化定型 本紙張尺度適用中國國家標準（CNS) A4規格（210x 297公爱1 ' ----— 第4頁 1287238 A7 B71287238 A7 __B7 V. Inventive Note (2), as shown in the second figure, the outer ends of the two extending portions 132 may be attached to the two grooves m of the top cover 12 as needed and upwardly and oppositely bent. In the manufacturing process of the above-mentioned conventional inductive component, in addition to the adhesive bonding processing performed by the base 11 and the top cover 12 of the covering body, the operation thereof is troublesome and the cost is increased, and the coil 13 is placed on the base 11 In the arrangement of the slots 111, since the coils 13 are accommodated between the base 11 and the top cover 12 in a nesting manner, there is inevitably a gap, and the open ends of the two sides are an unavoidable magnetic flux gap. In addition to being prone to vibration and noise, 'and causing large magnetic losses' and the quality factor of the inductance (QUaHty, Q for short) will decrease. SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide an inductance element in which a magnetically permeable material is integrally molded on the outside of a coil so that there is no gap between the magnetic conductive material and the coil, a method for manufacturing the same, and a mold. Thus, the 'inductive element produced by the manufacturing method of the inductor element of the present invention has a coil and a covering body coated on the outside of the coil, and the coil has a predetermined number of turns by a long wire. The winding portion, and the extension portion extending outward from the two ends of the winding portion respectively, the manufacturing method comprises: (A) placing the coil in a one of the upper and lower molds corresponding to the cover In the space, the two extension portions of the coil are misaligned and positioned between the upper and lower molds, and the coil portion of the coil is suspended in the accommodation space. (B) A fluid-coated fluid containing a ferroalloy powder is injected and filled into the containing space to condense to form a solid covering body covering the winding portion. And (C) baking the integrated coil and the covering body, so that the coating is hardened and shaped. The paper size is applicable to the Chinese National Standard (CNS) A4 specification (210x 297 public 1' ----- Page 4 1287238 A7 B7
五、發明說明 【圖式之簡單說明】 本發明之其他特徵及優點，在以下配合參考圖式之較 佳實施例的詳細說明中，將可清楚的明白，在圖式中： 第一圖是一習知電感元件的立體分解圖； 第二圖是該習知電感元件的組合剖視圖； 第三圖是本發明之製造方法的一第一較佳實施例所製 成之一電感元件的立體圖； 第四圖是一製造模具之簡略立體分解圖，說明本發明 該第一較佳實施例之製造方法； 第五圖是第四圖中該製造模具的一組合右側剖視圖， «兒明一線圈受模具夾持定位在一容置空間内； 第六圖是一類似於第五圖之視圖，說明該線圈被注入 該容置空間内之包覆體包覆；及 第七圖是一製造模具之簡略立體分解圖，說明本發明 該第二較佳實施例之製造方法。 【較佳實施例之詳細說明】 在較佳實施例被描述以前，要注意的是，在以下的說 明書之内容中，類似之元件是以相同的編號來表示。 參閱第三圖，本發明第一實施例之製造方法所製造出 的電感元件2具有一線圈21，及一包覆在該線圈21外部之 包覆體22。該線圈21具有一由一長條扁平狀導線等半^地 沿一中心軸線彎繞預定圈數而成之繞圈部 χ 5亥、’堯圈部2 11兩端往外延伸之延伸部212。 本紙張尺度適用中國國家標準（CNS) Α4規格（21〇χ 297公幻--------- 1287238 A7BRIEF DESCRIPTION OF THE DRAWINGS [0009] Other features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments illustrated herein An exploded perspective view of a conventional inductive component; a second cross-sectional view of the conventional inductive component; and a third perspective view of an inductive component formed by a first preferred embodiment of the manufacturing method of the present invention; The fourth figure is a simplified perspective exploded view of a manufacturing mold, illustrating a manufacturing method of the first preferred embodiment of the present invention; and the fifth drawing is a combined right side sectional view of the manufacturing mold of the fourth drawing, The mold clamping is positioned in an accommodating space; the sixth figure is a view similar to the fifth figure, illustrating that the coil is covered by the covering body injected into the accommodating space; and the seventh figure is a manufacturing mold A simplified perspective view of the manufacturing method of the second preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Before the preferred embodiments are described, it is noted that in the following description, like elements are denoted by the same reference numerals. Referring to the third embodiment, the inductance element 2 manufactured by the manufacturing method of the first embodiment of the present invention has a coil 21 and a covering body 22 covering the outside of the coil 21. The coil 21 has an extending portion 212 which is formed by a long flat wire or the like which is bent by a predetermined number of turns along a central axis, and the ends of the ring portion 2 11 extend outward. This paper scale applies to China National Standard (CNS) Α 4 specifications (21〇χ 297 幻幻--------- 1287238 A7
1287238 A7 B7 五、發明說明（5 ) 41之底面往下同體延伸的長方框形上圍壁42。該上基壁 一 $ 一貫穿其頂、底面用來注入所述包覆體22之注入孔 1每一上圍壁42具有平行之前、後壁段421、422 ,及 連接於則、後壁段421、422兩末端間之側壁段423，並 由4上圍壁42與上基壁41共同界定出一開口朝下之上模 八43 ,且上圍壁42之形狀是與前述下模3之下圍壁3ι形 成可對應蓋合之互補形狀，亦即該上圍壁42之該等側壁段 423與則壁段421突出程度相同，僅該後壁段之突出程 度較小。 配合第五圖所示，當前述下模3之該等下圍壁32上皆 跨置有線圈21時，可接著將上模4對應蓋合在下模3頂面 此時藉上模4之該等上圍壁42，分別密抵壓合在下模3 之該等下圍壁32上，而將每一線圈21之二延伸部212分 別夾持定位於所對應上、下圍壁42、32之前壁段421、321 間與後壁段422、322間，此時並由上、下模4在每一上 下圍壁42、32間，共同界定出一由上、下模穴43 33連 通而成之容裝空間5，使線圈21之繞圈部211懸空地容置 於該容裝空間5内。 如第六圖所示，在各線圈21被夾持定位於上、下模4 3間以後’接著將含有鐵合金粉末所製成之流態包覆用流 體’由上模4之注入孔411注入並充滿該容裝空間$内， 以凝結形成包覆所述繞圈部2 11之固態包覆體2 2。此處包 覆流體可由鐵合金粉末流體加上助流作用之溶劑所製成， 由該等注入孔411注入上、下模4、3間之容裝空間5内， 本紙張尺度適用中國國家標準（CNS) A4規格（210x 297公釐） 第7頁 1287238 五、發明說明（（/ 使各線圈2 1之〇 4 t f 所包覆。 、°卩11被事便凝結成固態之包覆體22 接者’供烤該等纟士人一體之綠 .σ 之線圈21與包覆體22，使 匕设體硬化定型，如此便可製成所要之電感元件2。 ^外’為了整體線圈21定位的需要，可在線圈21置 下核3日守M更藉由加工機台上所預設之二指塊6(可見於 、圖）阻擋於下板3之該二下定位槽似、325末端處外 側’以使後續作業在注入包覆體22期間，避免線圈η之 二延伸部212受包覆體22的流動推擠影響而前後位移。 又，值得一提的是’本實施例所製成之電感元件2的 二延伸部212末端，可另外進行彎製加工，而往上並相向 彎折貼覆i包覆冑22 & 丁頁面，其變折狀態與前述第二圖所 示相同，當然配合使此一需求，另可在上模4之上基板41 底面搭配設置往下突出之部位，以便在包覆體22頂面形成 對應之凹槽’在此不另以圖式作顯示。 由本貫化例上述製造方法可知，在製造過程中確實不 需要進行如習知方法所進行的黏合加工之組裝作業，因此 可降低製造成本，而且所製成的電感元件2,由於其包覆體 22是一體成型地包覆在線圈2 i之繞圈部2丨丨外部，繞圈部 211與包覆體22間不會存在空隙，因此可避免產生振動與 噪音、減少磁損，及提升電感的Q值。而在製造過程中， 該線圈21亦能被穩定地定位，使其與模具内壁的距離充分 隔開而固定，確保導磁體（包覆體22)的規格厚度。 如第七圖所示，本發明第二實施例之製造方法所欲製 本紙張尺度適用中國國家標準（CNS) A4規格（210x 297公釐） 1287238 A7 B7 五、發明說明（7 ) 造電感元件所採用的線圈21與前述實施例不同，線圈21 是由長條圓線狀導線彎繞而成，而且其二延伸部2丨2是等 南水平延伸狀態，而約位在繞圈部2丨丨的中間高度處。為 了因應線圈21形狀的差異，本實施例之製造模具中，該下 核3之下圍壁32的前、後、側壁段321、322、323的突伸 程度相同’且前、後壁段321、322之下定位槽324、325 疋设计成與延伸部2 12的半邊形狀配合的半圓形截面，使 二延伸部212可對應跨置在該二下定位槽324、325上。而 該上模4之每一上圍壁42的前、後、側壁段421、422、 423的大伸程度也相同，並在前、後壁段42丨、422皆具有 一凹陷於其底面且分別對應於前述二下定位槽324、325之 上定位槽424、425，而能將呈截面呈圓形的該等延伸部 212 ’夾持定位於上、下模4、3之該等上、下定位槽間。 歸納上述，本發明之製造方法藉由鐵合金粉末所製成 之包覆體22 —體成型包覆在線圈21外部，使所製成結合 一體之包覆體22與線圈21間，不會存在空隙，而可降低 製^成本’並有效提升所製成的電感元件的品質，故確實 能達到發明之目的。 惟以上所述者，僅為本發明之較佳實施例而已，當不 能以此限定本發明實施之範圍，即大凡依本發明申請專利 範圍及發明說明書内容所作之簡單的等效變化與修飾，皆 應仍屬本發明專利涵蓋之範圍内。 本紙張尺度適用中國國家標準（CNS) A4規Ρ21〇χ 297公^_)-—-- 1287238 A7 B7 五、發明說明（8 ) 【元件 標號i 针J 误】 2 電 感 元件 33 下 模 穴 21 線 圈 4 上 模 211 繞 圈 部 41 上 基 壁 212 延 伸 部 411 注 入 孔 22 包 覆 體 42 上 圍 壁 3 下 模 421 前 壁 段 31 下 基 壁 422 後 壁 段 32 下 圍 壁 423 側 壁 段 321 前 壁 段 424〜425 上 定 位 槽 322 後 壁 段 43 上 模 穴 323 側 壁 段 5 容 置 空 間 324〜325下 定 位槽 6 擋 塊 本紙張尺度適用中國國家標準（CNS) A4規格（210x 297公釐） 笛 1Π 百1287238 A7 B7 V. INSTRUCTION DESCRIPTION (5) The long square-shaped upper wall 42 of the bottom surface of the 41 is extended downward. The upper base wall has a top and bottom surface for injecting the injection body 22 into the injection hole 1. Each of the upper walls 42 has parallel front and rear wall sections 421, 422, and is connected to the rear wall section. The side wall section 423 between the two ends of the 421 and 422, and the upper wall 42 and the upper base wall 41 jointly define an opening downwardly facing the upper die 83, and the shape of the upper surrounding wall 42 is the same as that of the lower die 3 The lower wall 3i forms a complementary shape that can correspond to the cover, that is, the side wall segments 423 of the upper surrounding wall 42 and the wall segments 421 protrude to the same extent, and only the rear wall segments are less protruded. As shown in the fifth figure, when the coils 21 are spanned on the lower surrounding walls 32 of the lower mold 3, the upper mold 4 can be correspondingly covered on the top surface of the lower mold 3, and the mold 4 is borrowed. The upper walls 42 are respectively pressed against the lower surrounding walls 32 of the lower mold 3, and the two extending portions 212 of each coil 21 are respectively clamped and positioned before the corresponding upper and lower surrounding walls 42, 32. Between the wall segments 421, 321 and the rear wall segments 422, 322, at this time, the upper and lower molds 4 are defined between each of the upper and lower walls 42 and 32 to form a communication between the upper and lower mold holes 43 33. The accommodating space 5 is such that the coil portion 211 of the coil 21 is suspended in the accommodating space 5. As shown in the sixth figure, after the coils 21 are sandwiched and positioned between the upper and lower molds 41, 'the fluid for coating fluids prepared by the ferroalloy powder is then injected' from the injection holes 411 of the upper mold 4. And filled in the containing space $, to form a solid covering body 22 covering the winding portion 2 11 by condensation. Here, the coating fluid can be made of a ferroalloy powder fluid plus a solvent for facilitating flow, and the injection holes 411 are injected into the accommodation space 5 between the upper and lower molds 4 and 3. The paper scale is applicable to the Chinese national standard ( CNS) A4 size (210x 297 mm) Page 7 1287238 V. Invention description ((/ Make each coil 2 1 〇 4 tf covered. °°卩11 will be condensed into a solid body 22 The 'coil 21 and the cover 22 for baking the gentleman's green. σ are used to harden and shape the body, so that the desired inductance element 2 can be made. ^External 'position for the overall coil 21 If necessary, the core 21 can be placed on the coil 21, and the second finger block 6 (visible to the figure) preset on the processing machine block can be blocked at the end of the lower plate 3 at the end of the 325. The outer side is such that during the subsequent injection of the covering body 22, the second extension portion 212 of the coil η is prevented from being displaced back and forth by the flow pushing of the covering body 22. Again, it is worth mentioning that the present embodiment is made. The ends of the two extensions 212 of the inductive component 2 can be additionally bent and bent upward and opposite each other. The i-clad 22 & butyl page is attached, and the folded state is the same as that shown in the second figure. Of course, in order to meet this requirement, the bottom surface of the substrate 41 on the upper mold 4 can be arranged to protrude downward. In order to form a corresponding groove on the top surface of the covering body 22, it is not shown in the drawings. According to the above manufacturing method of the present invention, it is not necessary to perform bonding as in the conventional method in the manufacturing process. The assembly work of the processing can reduce the manufacturing cost, and the manufactured inductor element 2 is integrally formed on the outer portion of the coil portion 2 of the coil 2 i by the covering body 22, and the winding portion 211 is There is no gap between the covering bodies 22, so vibration and noise can be avoided, magnetic loss can be reduced, and the Q value of the inductor can be improved. In the manufacturing process, the coil 21 can also be stably positioned to the inner wall of the mold. The distance is sufficiently spaced and fixed to ensure the specification thickness of the magnetizer (the covering body 22). As shown in the seventh figure, the manufacturing method of the second embodiment of the present invention is applicable to the Chinese National Standard (CNS) A4. Specifications (210x 297) 1287238 A7 B7 V. INSTRUCTION DESCRIPTION (7) The coil 21 used for the inductor element is different from the foregoing embodiment, and the coil 21 is formed by bending a long round wire, and the two extensions 2丨2 are etc. The south horizontally extended state is about at the intermediate height of the winding portion 2丨丨. In order to cope with the difference in the shape of the coil 21, in the manufacturing mold of the embodiment, the front wall 32 of the lower core 3 is front and rear, The sidewall segments 321 , 322 , 323 have the same degree of protrusion 'and the positioning grooves 324 , 325 之下 under the front and rear wall sections 321 , 322 are designed to have a semicircular cross section with the half shape of the extension portion 12 12 , so that the two extensions The portion 212 can be correspondingly spanned on the two lower positioning slots 324, 325. The front and rear side wall sections 421, 422, and 423 of the upper wall 42 of the upper mold 4 have the same extent, and the front and rear wall sections 42A and 422 have a recessed surface and Corresponding to the positioning grooves 424, 425 above the two lower positioning grooves 324, 325, respectively, the extending portions 212' having a circular cross section can be clamped and positioned on the upper and lower molds 4, 3, Lower the positioning slot. In summary, in the manufacturing method of the present invention, the covering body 22 made of the iron alloy powder is integrally molded on the outside of the coil 21 so that there is no gap between the integrally formed covering body 22 and the coil 21. However, the cost of the manufacturing process can be reduced and the quality of the manufactured inductive component can be effectively improved, so that the object of the invention can be achieved. The above is only the preferred embodiment of the present invention, and the scope of the present invention is not limited thereto, that is, the simple equivalent changes and modifications made by the scope of the invention and the description of the invention are All should remain within the scope of the invention patent. This paper scale applies to China National Standard (CNS) A4 Regulation 〇χ 21〇χ 297 gong ^_)---- 1287238 A7 B7 V. Invention Description (8) [Component Number i Needle J Error] 2 Inductive Element 33 Lower Mould 21 Coil 4 Upper die 211 Winding section 41 Upper base wall 212 Extension 411 Injection hole 22 Covering body 42 Upper wall 3 Lower die 421 Front wall section 31 Lower base wall 422 Rear wall section 32 Lower wall 423 Side wall section 321 Front Wall section 424~425 Upper positioning groove 322 Rear wall section 43 Upper cavity 323 Side wall section 5 accommodating space 324~325 Lower positioning groove 6 Stopper The paper size is applicable to China National Standard (CNS) A4 specification (210x 297 mm) Flute 1 Π 100