TWI404088B - Novel process for molding composite inductors - Google Patents

Abstract

The present invention provides a process for shaping composite inductors, including intaglioing grooves for accepting terminal pieces on a surface of a terminal piece accepting tray, combining an electric heating device on the back face of the tray to accept the terminal pieces on the grooves through vibration; setting a plurality of coil throw-in holes on the surface of a coil arrangement tray at positions corresponding to the grooves, and throwing the coils into the coil throw-in holes through vibration; overlapping the coil arrangement tray on the terminal piece accepting tray and integrating; heating the terminal piece accepting tray by the electric heating device to past adhesive paper on the back face of the terminal pieces that the terminal piece accepting tray is removed after the terminal pieces are molten to the conductor of the coil, separating multiple coil-terminal piece assemblies from the coil arrangement tray; placing multiple assemblies pasted on the adhesive paper in an inductor shaping mold, so as to once shape together with metal magnetic powder; cutting and separating composite inductors from the shaped body.

Description

New method of forming composite inductor Technical field

SUMMARY OF THE INVENTION The present invention is directed to a novel method of forming a composite inductor, and more particularly to a method of forming a composite inductor that can be automated and produced at a time.

Background technique

The simplest and most representative method for forming a composite inductor including an element such as an electrical terminal, which has been known so far, is, for example, a method in which the steps are schematically shown in the first (A) to (D) diagrams. Hereinafter, the concept of the conventional method will be briefly explained with reference to Fig. 1.

In the conventional method, a mold (mold) M composed of a body portion 2, a base portion 3, and a component molding portion 4 is provided, wherein the body portion 2 is provided with a hollow portion 1, and the base portion 3 and the bottom surface of the body portion 2 are detachably In combination, the component molding portion 4 is provided with two coil insertion holes 4a and 4b for inserting the hollow coil lead, and is detachably provided in the hollow portion 1. In the conventional method, the coil leads 5a, 5b are inserted into the coil insertion holes 4a, 4b, and the coil element 5 is placed at a predetermined position (Fig. 1 (a)). First, a predetermined amount of magnetic material is added thereto. That is, the metal magnetic powder is added and the vibration is appropriately operated to form a predetermined powder layer 6 (Fig. 1 (b)), followed by a pressurizing device P (for example, an air compressor or a hydraulic press) provided at the upper portion of the mold M. And applying a predetermined pressure to pressurize the metal magnetic powder body into a single body (first (c) diagram), and after demolding the thus obtained press-formed part, the respective coil leads 5a, 5b are cut off correspondingly. For the appropriate length, perform the necessary processing such as terminal soldering to complete the inductor I (1st). That is, although not shown, each of the coil leads 5a and 5b is subjected to an appropriate method to remove the outer layer, and is processed by a known suitable welding method such as resistance spot welding to be bonded to the electrical terminals Ta and Tb. After that, the inductor I is finally processed as a product by thermal hardening or the like. (Refer to Patent Document 1)

Patent Document 1: Korean Patent Registration No. 861103

However, in the conventional method described above, since the entire process of the first (A) to (D) diagrams is performed by hand by one hand, not only a highly skilled worker is required, but also the steps are long and difficult to make. The disadvantage of uniform quality of each product. Therefore, in the technical field, a method for solving the disadvantages of the aforementioned conventional methods and obtaining a plurality of composite inductors of uniform quality at a time is sought for a long time.

Accordingly, the present invention has an object and a technical object to provide a simple new forming method capable of producing a large number of uniform quality composite inductors at one time and having reliability.

The inventors have made a long review in order to complete the present invention in response to such a request in the technical field.

In order to achieve the above object and technical problem, the present invention provides a method of forming a plurality of composite inductors at a time, comprising: a first step of vibrating a disk for accommodating an electrical terminal piece on a vibration device, the housing The electrical terminal piece is provided with a plurality of one set (one pair) of electrical terminal piece receiving grooves which are gravure-processed to conform to the shape of the predetermined electrical terminal piece, and are connected to the back by a usual method. In the electric heating mechanism, a predetermined plurality of electrical terminal pieces that are put into the tray for accommodating the electrical terminal piece are automatically housed and arranged in the respective electrical terminal piece receiving grooves. In the second step, the arrangement is hollow. The coil pallet is vibrated on the vibrating device, wherein the plurality of predetermined air-core coil insertion holes are provided on the surface of the position corresponding to the positions of the two terminal electrical storage tabs. And a predetermined plurality of air-core coils which are solder-treated on both sides of the lead wire are put on the surface of the tray for arranging the air-core coils, thereby automatically forming the hollow coil In the third step, the arrangement of the aligned air-core coils in the second step is superimposed and integrated on the tray for accommodating the electrical terminal piece in the first step; The electric terminal piece is heated to a solder melting temperature or higher by the electric heating means, and the electric terminal piece is welded to the lead wire of the air-core coil, and the tray for accommodating the electric terminal piece is removed. The back surface of the electrical terminal piece is pasted with a paper to separate the plurality of coil-terminal assembly from the aforementioned arrangement of the air-core coil; in the fifth step, the plurality of coil-terminal assembly of the fourth step is Putting a predetermined inductive forming die in contact with the paper, and performing press forming together with the metal magnetic powder in an existing manner, whereby a molded article including a predetermined plurality of composite inductors can be formed at a time; In the sixth step, the composite member including the plurality of composite inductors formed in the fifth step is used to cut and separate the individual composite inductors of a predetermined shape.

Compared with the conventional method of forming a composite inductor which is formed by hand work and which is generally of a non-uniform quality, according to the present invention, the following effects can be obtained: a large number of quality improvements can be easily produced at one time to be uniform Composite inductor.

[Preferred form for carrying out the invention]

Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

Fig. 2(a) is a perspective view of a pallet for housing an electrical terminal piece (hereinafter simply referred to as "terminal pallet") 10 for carrying out the present invention. It is preferable that the terminal pallet 10 is made of a normal copper plate or a bronze plate. The second (B) diagram is a partial cross-sectional view of the A-A line of the second (A) diagram. The upper surface of the terminal pallet 10 is subjected to gravure processing to form two sets (one pair) of terminal piece accommodation grooves 11 and 11 in a rectangular shape as necessary. In the example shown in the second (A) and (B) drawings, the upper surface of the terminal pallet 10 is provided with four sets (four pairs) of terminal piece receiving grooves 11 in the length and width, and 16 groups (16 pairs) are arranged in total. The terminal piece accommodation groove 11 is provided. The specification of each terminal piece accommodation groove 11, that is, the length x width x height of each terminal piece accommodation groove 11 is affected by the specifications of the final product, and is not defined indiscriminately. Further, the interval between the terminal pieces accommodating grooves 11 and 11 of the two sets is also affected by the specifications of the final product such as the air-core coil to be described later. Further, in the example shown in the second (A) and (B) drawings, the planes of the terminal sheet accommodation grooves 11 and 11 including the two sets are square, but this is not a necessary part of the present invention. It varies with the form of the desired product. Further, reference numeral 12 denotes a fastening pin hole that is fastened to a carrier for arranging the air-core coils to be described later.

The terminal pallet 10 is actually used by being attached to a normal diaphragm (not shown). That is, after the terminal pallet 10 is properly joined to the predetermined vibrating device, the vibrating device is actuated to supply an appropriate amount of the predetermined terminal electrical terminal piece 13 on the surface of the terminal pallet 10 by The electric terminal pieces 13 are automatically housed and arranged in the respective terminal piece housing grooves 11 of the terminal pallet 10 by the vibration action. The terminal piece 13 is preferably made of a tin-plated phosphor bronze plate. Although the specification of the electrical terminal piece 13 is substantially corresponding to the specification of the terminal piece accommodation groove 11, as shown in the second (c) diagram, in the practice of the present invention, the thickness of the electrical terminal piece 13 is preferably smaller than that of the terminal piece accommodation groove 11. The depth is slightly thicker to protrude slightly from the surface of the terminal pallet 10. The thickness of the electrical terminal piece 13 is preferably about 1.1 to 1.2 times the depth of the terminal piece accommodation groove 11, but it is not essential and can be appropriately changed. When all of the terminal piece housing grooves 11 accommodate the electrical terminal pieces 13, the excess electrical terminal pieces are removed from the surface of the terminal holding plate 10 in an appropriate manner. This is similar to the principle of using a counting plate provided with a coin receiving groove of this size, for example, in a bank, in order to simply calculate the number of coins. (The above is called "Step 1".)

For heating, the terminal pallet 10 is combined in a conventional manner with a generally suitable electric heating mechanism (refer to symbol 10' of Fig. 4, for example, an electric heater that can be heated up to about 280 ° C to 300 ° C). For those of ordinary skill in the art, there are various options for such a combination with an electric heater, and thus a specific configuration example thereof will be omitted.

Fig. 3(a) is a perspective view for carrying out the pallet for arranging an air-core coil of the present invention (hereinafter, simply referred to as "coil pallet"). It is preferable that the coil tray 20 is made of the same material (copper plate or bronze plate) as the terminal pallet 10. Figure 3(b) is a partial cross-sectional view taken along line B-B of the third (A) diagram. As shown in the third (A) and (B) drawings, the surface of the coil pallet 20 is provided with a cylindrical coil insertion hole 21 for accommodating the air-core coil 23 to be described later. The size (diameter, depth, and the like) of the coil insertion hole 21 is affected by the specifications of the air-core coil 23 to be used. Each of the coil insertion holes 21 is provided at a position that corresponds to the position of the terminal piece accommodation grooves 11 and 11 of the two sets of the second (A) and (B) drawings, respectively, at 1:1. Further, reference numeral 22 denotes a fastening pin corresponding to the fastening pin hole 12 provided in the terminal pallet 10.

The coil pallet 20 is also used in the same manner as the terminal pallet 10, and is used in combination with a normal vibration device (not shown). That is, after the coil pallet 20 is coupled to the vibrating device, the vibrating device is actuated, and an appropriate number of air-core coils 23 are placed on the surface of the coil pallet 20, and the air-core coils 23 are automatically put in by vibration. Arranged in each coil insertion hole 21. The excess air-core coil 23 is removed from the surface of the coil pallet 10 in a suitable manner. As shown in the third (b) diagram, the coil insertion hole 21 has a depth at which the air-core coil 23 can be accommodated freely, and the coil lead support groove 21a for supporting the coil leads 23a (23b), 23b (23a) is provided on the left and right sides of the inlet ( 21b), 21b (21a). As shown in the third (c) diagram, the depth coil coils 23a and 23b of the respective coil lead support grooves 21a and 21b are slightly protruded from the surface of the coil tray 20, and are affected by the specifications of the coil used. The third (c) diagram schematically shows a cross section of the state in which the air-core coil 23 is inserted and arranged in the coil insertion hole 21. (The above is called "Step 2".)

Here, as shown in the S of the third figure (C), the upper surface of each of the coil leads 23a and 23b of the air-core coil 23 is previously solder-bonded to a predetermined thickness.

As described above, the electrical terminal pieces 13 are respectively housed and arranged in the respective terminal piece housing grooves 1 of the terminal tray 10, and the air-core coils 23 are respectively inserted and arranged in the respective coil insertion holes 21 of the air-core coil tray 20, as shown in FIG. As shown in the drawing, the fastening pin 22 of the coil pallet 20 is inserted into each of the fastening pin holes 12 of the terminal pallet 10, and the coil pallet 20 can be integrated into the terminal pallet 10. (The above is called "Step 3".)

In the third step described above, as described earlier, heat is transmitted by the electric heating mechanism 10' coupled to the terminal pallet 10, and each of the electrical terminal pieces 13 is heated to a predetermined temperature. Here, the heating temperature is preferably higher than the melting temperature of the solder, that is, about 280 ° C to 300 ° C, and the heating time is preferably about 1 to 5 seconds in the above temperature range. By the heat transmitted to the electrical terminal piece 13 accommodated in the terminal piece housing groove 11 of the terminal pad 10, the solder S is bonded to the coil lead of the air-core coil 23 of the coil holder 20 contacting the electric terminal piece 13. 23a and 23b, heat is transmitted to the solder S and melted, and the electrical terminal pieces 13 are respectively welded to the coil leads 23a and 23b. Then, after the terminal pallet 10 and the coil pallet 20 are cooled, and the terminal pallet 10 is removed, the terminal of the coil-terminal assembly 31 held in the coil insertion hole 21 of the coil pallet 20 is rearward. The adhesive paper 30 is attached to separate the coil-terminal piece assembly 31 from the coil carrier 20. (The above is called "Step 4".)

The coil-terminal assembly 31, which is separated in this manner and attached to the state of the paper 30, is as shown in Fig. 5. Next, for example, as shown in Fig. 5, the edge portion of the succeeding paper 30 is cut along the one-dot chain lines P-P and Q-Q to prepare for the next step. (The cutting of the edge portion can also be omitted depending on the demand.)

As shown in Fig. 6(a), the coil-terminal sheet assembly 31 attached to the adhesive paper 30 is placed in a suitable molding die 62 when it is attached to the adhesive paper 30. Further, reference numeral 63 is a base for mold release of the attachable and detachable mold 62. Next, as shown in Fig. 6(b), a predetermined amount of metal magnetic powder is added to the hollow portion of the mold 62 to form a metal magnetic powder layer 66, and a predetermined pressure is applied by the pressurizing means P to pressurize After the molding, demolding is performed, whereby a molded article 67 comprising 16 (= 4 × 4) composite inductors can be obtained. The sixth (c) and sixth (d) diagrams are respectively a schematic cross-sectional view and a schematic bottom view of the molded article 67 obtained as described above. (The above is called "Step 5".)

In order to obtain the individual composite inductor CI from the molded member 67, for example, along the respective cutting lines in the longitudinal direction and the wide direction indicated by the one-point lock line in the sixth drawing, the forming member 67 is cut by a suitable cutting method. Cut and separate. (The above is called "Step 6".)

The result obtained in this embodiment is that a total of 16 individual composite inductors CI are formed at a time. An example of a composite inductor CI that has been cut and separated is shown in the two-point lock circle of the sixth (d) diagram.

As indicated above, the specifications and shapes of the final composite inductor CI can be varied depending on the various specifications required for the electrical or electronic device used, and therefore, it will be apparent to those of ordinary skill in the art that The design form of the terminal pallet 10 and the coil pallet 20 can be changed. Further, in the method of the present invention, the order of the first step and the second step may be changed.

Although the above description is made by exemplifying a molded article including a total of 16 (= 4 × 4) composite inductors in a single molding operation, the present invention is not limited thereto, and according to the method of the present invention, as needed At least one molded article including a composite inductor having a predetermined size can be obtained in one molding operation, and in many cases, a molded article including a tens to hundreds of predetermined inductors can be obtained. For example, when 10 pairs of terminal piece accommodation grooves 11 and 10 coil insertion holes 21 are provided in each of the length and width, 100 (= 10 × 10) composite inductors can be obtained at one time.

Therefore, according to the present invention, a composite inductor of uniform quality can be formed in a large number by the following steps: in the first step, the tray for accommodating the electrical terminal piece is vibrated on the vibration device, and the tray for accommodating the electrical terminal piece is attached to the surface Providing a plurality of one set (one pair) of electrical terminal piece receiving grooves 11 which are subjected to gravure processing in accordance with a predetermined shape of the electrical terminal piece, and connecting any of the usual electric heating mechanisms 10' on the back side by a usual method, In this way, a predetermined plurality of electrical terminal pieces 13 that are put into the tray 10 for accommodating the electrical terminal piece are automatically housed and arranged in each of the electrical terminal piece accommodation grooves 11; and in the second step, the arrangement of the air-core coils 20 is arranged. Vibrating on the vibrating device, wherein the array of the air-core coiling trays 20 is provided with a plurality of predetermined air-core coil insertion holes 21 on the surface corresponding to the position of the two sets of the electrical terminal sheet receiving grooves 11, and two The predetermined plurality of air-core coils 23, which are subjected to solder treatment, are placed on the surface of the air-core coil tray 20, whereby the air-core coils 23 are automatically placed and arranged in the air-core coil insertion holes 21; The arrangement of the aligned air-core coils 20 in the second step is superimposed and integrated on the tray 10 for storing the electrical terminal sheets in the first step; and in the fourth step, the electrical terminal sheets are used in the electric heating mechanism 10'. After the tray 10 is heated to a temperature higher than the solder melting temperature, the electrical terminal piece 13 is welded to the leads 23a and 23b of the air-core coil 23, and the back surface of the electrical terminal piece 13 on which the electrical terminal piece holder 10 is removed is attached. 30, the plurality of coil-terminal assembly 31 is separated from the array of the air-core coils 20; in the fifth step, the plurality of coil-terminal assembly 31 of the fourth step is attached to the paper. The predetermined induction molding die 62 is placed under pressure and formed together with the metal magnetic powder in an existing manner, whereby the molding member 67 including a predetermined plurality of composite inductors can be formed at a time; and the sixth step, from the foregoing The forming member 67 including the plurality of composite inductors formed in the fifth step cuts and separates the individual composite inductors CI of a predetermined shape.

[Industrial availability]

By using the method of the present invention in an associated industry, a large number of uniform quality composite inductors can be produced at one time, and the goal of reducing labor or reducing product cost can be easily achieved.

1. . . Hollow part

2. . . Body part

3. . . Base

4. . . Component molding department

4a, 4b. . . Coil insertion hole

5. . . Coil element

5a, 5b. . . Coil lead

6. . . Powder layer

10. . . Storage tray for electric terminal piece

10’. . . Electric heating mechanism

11. . . Terminal piece storage groove

12. . . Fastening pin hole

13. . . Electric terminal piece

20. . . Aligning the coils for air-core coils

twenty one. . . Coil insertion hole

21a, 21b. . . Coil lead support groove

twenty two. . . Fastening pin

twenty three. . . Air core coil

23a, 23b. . . Coil lead

30. . . Then paper

31. . . Coil-terminal assembly

62. . . mold

63. . . Base

66. . . Powder layer

67. . . Formed part

CI. . . Composite inductor

I. . . inductance

M. . . Mold

P. . . Pressurizing device

S. . . solder

Ta, Tb. . . Electrical terminal

Fig. 1 (A) to (D) is a schematic view showing a forming step of a conventional composite inductor in which each product is formed one by one.

Fig. 2(a) is a perspective view of a pallet for accommodating an electrical terminal piece according to the present invention; (b) is a schematic view showing a principle of accommodating an electrical terminal piece in an electric terminal piece accommodating groove, and is a sectional view of a line AA of (a) (C) is a cross-sectional view showing a state in which the electrical terminal pieces are housed and arranged in two sets (one pair) of electrical terminal piece accommodation grooves.

Fig. 3 (a) is a perspective view of the pallet for arranging the air-core coil of the present invention; (b) is a cross-sectional view showing a portion of the BB line of (A) by introducing and storing the air-core coil into the air-core coil accommodating hole; (c) is a cross-sectional view showing a state in which the air-core coils are housed and arranged in the air-core accommodation hole.

Fig. 4 is a view showing the principle of the combination of the pallet for accommodating the electric terminal piece of the present invention and the pallet for arranging the air-core coil.

Fig. 5 is a perspective view showing a state in which a plurality of coil-terminal sheet assemblies are attached to a paper by the present invention, and the self-aligning air-core coils are separated by a pallet.

Fig. 6(a) to (C) are diagrams showing the principle of forming a plurality of composite inductors in a plurality of coil-terminal chip assemblies in an inductor forming mold according to the present invention (for example, corresponding to the first (B) (~) Figure); (D) is a diagram showing the principle of separating individual composite inductors from the thus formed formed part including a plurality of composite inductors.

10. . . Storage tray for electric terminal piece

10’. . . Electric heating mechanism

12. . . Fastening pin hole

13. . . Electric terminal piece

20. . . Aligning the coils for air-core coils

twenty two. . . Fastening pin

twenty three. . . Air core coil

23a, 23b. . . Coil lead

Claims (8)

A novel method for forming a composite inductor, comprising: a first step of vibrating a disk for accommodating an electrical terminal piece on a vibration device, wherein the plurality of intaglio plates are provided on the surface of the plate for storing the electrical terminal piece By processing two sets (one pair) of electrical terminal piece storage grooves that match the shape of the predetermined electrical terminal piece, and connecting any of the usual electric heating mechanisms to the back surface by a normal method, the input is performed in the above-described storage. The electric terminal piece is automatically accommodated and arranged in the predetermined plurality of electrical terminal pieces on the pallet, and is arranged in the electric terminal piece receiving groove; and in the second step, the arrangement of the hollow coil is arranged to vibrate on the vibration device, wherein the arrangement is hollow The coil pallet is provided with a plurality of predetermined hollow coil insertion holes on the surface corresponding to the positions of the two sets of the electrical terminal piece accommodation grooves, and the predetermined plurality of hollows of the both side leads are subjected to solder treatment. The coil is placed on the surface of the tray for arranging the air-core coils, whereby the air-core coils are automatically put into and arranged in the air-core coil insertion holes; and in the third step, In the second step, the arrangement of the air-core coils is overlapped and integrated in the tray for accommodating the electrical terminal piece in the first step, and in the fourth step, the storage terminal block is heated by the electric heating mechanism. After the electric terminal piece is welded to the lead wire of the air-core coil, the back surface of the electric terminal piece for accommodating the electric terminal piece sheet is attached to the back side of the solder to a plurality of coil-terminal pieces. The assembly is separated from the aforementioned arrangement of the air-core coils; in the fifth step, the plurality of coil-terminal assembly of the fourth step is placed in a predetermined inductance forming mold while being attached to the paper. Press forming together with the metal magnetic powder in an existing manner, whereby a molded article including a predetermined plurality of composite inductors can be formed at a time; and a sixth step comprising forming a plurality of composites from the fifth step The molded part of the inductor cuts and separates individual composite inductors of a predetermined shape. A new method for forming a composite inductor according to the first aspect of the invention, wherein the tray for accommodating the electrical terminal piece and the tray for arranging the coil are made of a copper plate or a bronze plate, respectively. A new method for forming a composite inductor according to claim 1, wherein the electrical terminal piece is made of a tin-plated phosphor bronze plate. A new method for forming a composite inductor according to claim 1, wherein the heating in the fourth step is performed at 280 to 300 ° C for 1 to 5 seconds. A new method for forming a composite inductor according to claim 1, wherein the number of inductances formed by one molding operation is at least two. A new method of forming a composite inductor according to claim 1, wherein the first step and the second step are sequentially changed. A new method for forming a composite inductor according to the first aspect of the patent application, which must include the fifth step and the sixth step. A composite inductor obtained by the method of claims 1 to 7 of the patent application.