TWI407463B - A method for fabricating a molding coil structure and a molding coil structure - Google Patents

Abstract

A method for fabricating a molding coil structure and a molding coil structure are provided. The method comprises the steps of: providing a metal coil comprising two ends; performing a squeezing process to form a winding structure on each of the two ends of the metal coil; performing an immersion plating to form a layer of metal on the winding structures; providing a conductive means comprising two conductive plates and a central connecting part, wherein the two conductive plates comprises a first end and a second end respectively and the central connecting part connects the first end of the two conductive plates; performing a welding process to connects the two ends having the winding structures to the first ends of the two conductive plates; and cutting the central connecting part to make the two conductive plates only electrically connects to each other through the metal coil.

Description

Method for manufacturing a molded coil structure and die-cast coil structure

This invention relates to a molded coil structure, and more particularly to a method of making a molded coil structure and a molded coil structure.

Inductance is an important component in the circuit, which can achieve the functions of filtering, energy storage, energy dissipation and resonance. In the increasingly miniaturized electronic products, portable, high-density components, the inductive components have developed rapidly, and under the consideration of electromagnetic compatibility, the elimination of electromagnetic interference of electronic products has become the basic requirement of electronic products. Many regulations are constrained, and only when they meet the requirements can they be sold, which is more important for inductors and applications.

A common inductor element is manufactured as shown in FIG. 1A, which is a top view of one of the inductors 10 and the two conductive sheets 11 and 12, and the two ends 100 and 101 of a coil 10 are directly placed. The two conductive sheets 11 and 12 are respectively connected to the first end points 110 and 120 for soldering. FIG. 1B is a perspective view of the inductor element 1 after the coil 10 and the two conductive sheets 11 and 12 are filled with a magnetic material by a high-voltage process to form a cladding structure 13 and then externally packaged. . In this way, since the two end points 100 and 101 are directly placed on the first end points 110 and 120 for welding, it is easy to have no supporting force because the two end points 100 and 101 are relatively weak, and thus the magnetic material is used in the filling process. The extrusion causes the two end points 100 and 101 to break and deform. Moreover, the above-mentioned design has a small contact area between the two terminals 100 and 101 and the first terminals 110 and 120, so that the electrical connection between the coil and the two conductive sheets is poor, which affects the yield of the inductor component manufacturing. And important factors of performance.

Therefore, how to design a new die-cast coil structure can strengthen the connection between the two conductive sheets and the coil and increase the conductive characteristics, and further improve the inductance characteristics of the molded coil structure, which is an urgent problem to be solved in the industry.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a method of fabricating a molded coil structure comprising the steps of: providing a metal coil having two end points; performing a press-bonding process on the two end points, respectively forming a curved structure; An immersion plating process is performed on the two ends of the curved structure, and a metal is immersed on the curved structure; a conductive member is provided, including two conductive sheets and an intermediate connecting portion, wherein the two conductive sheets respectively have a first end point And a second end, the intermediate connecting portion is connected to the first end of the two conductive sheets; respectively, connecting a second end having a curved structure to the first end of the two conductive sheets by a soldering process; and cutting the intermediate connection The second conductive sheet is electrically connected only by the metal coil.

Another object of the present invention is to provide a method of manufacturing a molded coil structure comprising the steps of: providing a metal coil having two end points; performing a welding process at the two ends, and respectively welding an electrode sheet to the second electrode Providing a conductive member, comprising two conductive sheets and an intermediate connecting portion, wherein the two conductive sheets respectively have a first end point and a second end point, and the intermediate connecting portion is connected to the first end point of the two conductive sheets The electrode sheets of the two end points of the metal coil are respectively connected to the first end points of the two conductive sheets by a soldering process; and the intermediate connecting portions are cut, so that the two conductive sheets are electrically connected only by the metal coils.

Yet another object of the present invention is to provide a molded coil structure, package The invention comprises: a metal coil having two end points, wherein each of the two ends has a curved structure, the curved structure further comprises a layer of immersion metal; and the two conductive sheets respectively comprise a first end point and a second end point; An intermediate connecting portion, wherein the intermediate connecting portion is connected to the two conductive sheets of the first end point, and is welded to the two end points of the metal coil, the middle connecting portion further comprises a cutting opening; and a covering structure comprising a magnetic The material and the covering structure are coated with two conductive sheets and metal coils; wherein the second ends of the two conductive sheets are exposed outside the covering structure, and are electrically connected to an external circuit.

A further object of the present invention is to provide a molded coil structure comprising: a metal coil having two end points, wherein each of the two end points has an electrode sheet, and the two electrode sheets are formed at two end points by a welding process The two conductive sheets respectively comprise a first end point, a second end point and an intermediate connecting portion, wherein the intermediate connecting portion is connected to the two conductive sheets of the first end point, and is soldered to the two electrode sheets, and the middle connecting portion is centrally Further comprising a cutting opening; and a covering structure comprising a magnetic material, the covering structure is covering the two conductive sheets and the metal coil; wherein the second end of each of the two conductive sheets is exposed to the covering structure, respectively, respectively Connected to an external circuit.

The object of the present invention, as well as the technical means and embodiments of the present invention, will be apparent to those skilled in the art in view of the appended claims.

Referring to FIG. 2A, a perspective view of a molded coil structure 2 according to a first embodiment of the present invention is shown. The molded coil structure 2 includes a metal coil 20, two conductive sheets 21, 22, and a covering structure 23. Metal coil 20 in this In the embodiment, it is a copper coil 20. The copper material of the copper coil 20 is formed of a copper material having a purity of at least 99.9%, wherein the copper material can withstand a temperature of 150-250 degrees. As shown in FIG. 2B, it is a plan view of one of the copper coil 20 and the two conductive sheets 21 and 22. The copper coil 20 includes both end points 201 and 202. The two end points 201, 202 are respectively formed into a curved structure by a pressing process. As shown in FIGS. 3A to 3C, respectively, a side view of the copper coil 20, the curved structure may be a flat wave shape as in FIG. 3A, or a cylindrical shape of a spiral sawtooth as in FIG. 3B, In an embodiment, as shown in FIG. 3C, in addition to the flat wave shape, a positioning structure 30 and 31 are included at the two end points, so that the copper coil 20 and the two conductive sheets 21 and 22 can be provided during the soldering process. A fixed role. The copper coil 20 is an enameled wire structure. After removing the patent leather outside the copper wire, a immersion tin plating is formed on the curved structure by a dip coating process for use as an electrode. In other embodiments, other conductive metals may be used as the electrode metal. The inductance value of the copper coil is determined by the outer diameter of the coil, the central aperture of the coil, the height of the coil, and the number of coil turns.

The conductive sheets 21 and 22 respectively include first end points 210 and 220, second end points 211 and 221, and intermediate connecting portions 212 and 222. The intermediate connecting portions 212 and 222 are substantially integrated, and after the conductive sheets 21 and 22 and the copper coil 20 are welded together, they are separated into two intermediate connecting portions 212 and 222 via a cutting process. The intermediate connecting portions 212 and 222 can be designed to have a larger contact area with the conductive sheets 21 and 22, thereby further improving the electrical conductivity and the supporting force, and improving the inductance characteristics of the molded coil structure 2. The covering structure 23 includes a magnetic material, and the covering structure 23 covers the two conductive sheets 21 and 22 and the copper coil 20; wherein the second end points 211 and 221 of the two conductive sheets 21 and 22 expose the covering structure 23 In addition, they are electrically connected to an external circuit (not shown), This molded coil structure 2 performs an inductance function.

The above-mentioned die-cast coil structure 2 is connected to the conductive sheets 21 and 22 by using a bent structure on the ends 201 and 202, and is connected to the conductive sheets 21 and 22, and the curved structure further provides a supporting force to make the copper When the coil 20 and the two conductive sheets 21 and 22 are subjected to a welding process, deformation or displacement caused by the pressing can be avoided. In another embodiment, a more stable fixing effect can be provided by the positioning structure. By the design of the intermediate connecting portion, the two end points 201, 202 of the copper coil 20 can have the largest possible contact area with the intermediate connecting portion without being excessively close to each other, and after welding, cut from the middle. The cutting process can be cut, thereby greatly increasing the electrical conductivity and providing a strong supporting force when the covering structure 23 is formed, and is not susceptible to deformation or displacement.

In other embodiments, the two ends 201, 202 of the copper coil 20 can be extended or bent in different directions, and the pressing process is further performed. As shown in FIG. 4A, the two end points 201, 202 extend straight outward, or as shown in FIG. 4B, after a bending, a subsequent pressing process is performed. Different extension methods may be determined by different applications and are not limited by the above embodiments.

A second embodiment of the present invention is a plan view of a copper coil 50 and two conductive sheets 51, 52 according to a second embodiment of the present invention, as shown in Fig. 5A. In the present embodiment, only the embodiment of the copper coil 50 and the conductive sheets 51 and 52 is different from the previous embodiment. Therefore, the present embodiment will be described only for the copper coil 50 and the conductive sheets 51 and 52. The copper coil 50 includes two end points 501, 502. The two end points 501, 502 are respectively connected to an electrode sheet 503, 504 by a welding process. Among them, the welding process is achieved by a micro-resistance discharge bonding technique. Referring also to FIG. 5B, it is one of the copper coil 50 and the electrode sheets 503 and 504. Side view. In the embodiment, the electrode sheets 503 and 504 are each a flat plate, and the two end points 501 and 502 of the coil are pressed together with the electrode sheets to perform a welding process. In another embodiment, referring to Fig. 5C, the electrode sheets 503', 504' are each a flat plate, but further comprise a curled portion 505, 506 at the edge. The two end points 501 and 502 are riveted by the curling portions 505 and 506, and the welding process is performed.

The copper coil 50 and the conductive sheets 51, 52 are welded together by the electrode sheets 503, 504. The conductive sheets 51 and 52 respectively include first end points 510 and 520, second end points 511 and 521, and intermediate connecting portions 512 and 522. The intermediate connecting portions 512 and 522 are substantially integrated, and after the conductive sheets 51 and 52 are respectively welded to the electrode sheets 503 and 504, they are separated into two intermediate connecting portions 512 and 522 via a cutting process. The intermediate connecting portions 512 and 522 can be designed to have a larger contact area with the conductive sheets 51 and 52, and further improve the electrical conductivity and the supporting force.

The difference between this embodiment and the first embodiment is that the electrode sheets 503 and 504 are formed on both ends of the copper coil 50, and are overlapped by a micro-resistance discharge bonding technique by pressing or riveting. Better conductivity, and by the design of the intermediate connecting portions 512, 522, the electrode sheets 503, 504 can have as large a contact area as the intermediate connecting portions 512, 522 without being excessively close to each other, and After the welding, the cutting process can be cut from the cutting process, so that the conductivity is greatly increased.

In the practical application, the conductive sheet in the above two embodiments can be formed by a plurality of conductive members respectively corresponding to one copper coil as shown in FIG. FIG. 6 illustrates four conductive members 60, 61, 62, and 63. Taking the conductive member 60 as an example, the conductive member 60 includes two conductive sheets 600 and 601 and an intermediate connecting member 602. guide The first terminals 600a, 601a of the electrical sheets 600, 601 are connected to the intermediate connector 602, and the second terminals 600b, 601b are connected to the adjacent conductive members 61 by the side connectors 64, 65. After each of the conductive members is soldered to a copper coil, the side connecting portions 64, 65 are cut through the cutting process of the one side connecting portion to separate the conductive members.

A third embodiment of the present invention, as shown in FIG. 7, is a method of fabricating a molded coil structure, comprising the steps of: in step 701, providing a metal coil having two end points; and in step 702, at the second end Performing a press-bonding process to form a curved structure respectively; in step 703, performing a dip coating process on the two ends having the curved structure, dipping a metal onto the curved structure; and providing a conductive in step 704 The second conductive sheet has a first end point and a second end point, and the intermediate connecting portion is connected to the first end point of the two conductive sheets; in step 705, one The soldering process is respectively connected to the first end of the second conductive sheet having the curved end; and in step 706, the intermediate connecting portion is cut so that the two conductive sheets are electrically connected only by the metal coil.

A fourth embodiment of the present invention, as shown in FIG. 8, is a method of fabricating a molded coil structure comprising the steps of: in step 801, providing a metal coil having two endpoints; and in step 802, at the second endpoint And performing a soldering process, respectively soldering an electrode chip on the two end points; in step 803, providing a conductive member, comprising two conductive sheets and an intermediate connecting portion, wherein the two conductive sheets respectively have a first end point and a first a second end, the intermediate connecting portion is connected to the first end of the two conductive sheets; in step 804, the electrode sheets of the two end points of the metal coil are respectively connected to the first end of the two conductive sheets by a soldering process; Step 805, cutting the intermediate connecting portion, so that the two conductive sheets are only by the metal coil Phase electrical connection.

Although the present invention has been described above in terms of a preferred embodiment, it is not intended to limit the invention, and it is obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention. The scope of the invention is defined by the scope of the appended claims.

1‧‧‧Inductive components

10‧‧‧ coil

100, 101‧‧‧ endpoint

11, 12‧‧‧ conductive sheet

110, 120‧‧‧ first endpoint

13‧‧‧Covered structure

2‧‧·Molded coil structure

20‧‧‧Metal coil

201, 202‧‧‧ endpoint

21, 22‧‧‧ conductive sheet

210, 220‧‧‧ first endpoint

211, 221‧‧‧ second endpoint

212, 222‧‧‧Intermediate connection

23‧‧‧Covered structure

30, 31‧‧‧ Positioning structure

50‧‧‧Metal coil

501, 502‧‧‧ endpoint

51, 52‧‧‧ conductive sheet

503, 504, 503', 504'‧‧‧ electrodes

505, 506‧‧‧ curling department

510, 520‧‧‧ first endpoint

511, 521‧‧‧ second endpoint

512, 522‧‧‧Intermediate connection

60, 61, 62, 63‧‧‧ conductive parts

600, 601‧‧‧ conductive sheet

600a, 601a‧‧‧ first endpoint

600b, 601b‧‧‧ second endpoint

602‧‧‧Intermediate connectors

64, 65‧‧‧ Side connection

The above and other objects, features, advantages and embodiments of the present invention will become more <RTIgt; <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; 1B is a perspective view of a prior art inductive component; FIG. 2A is a perspective perspective view of a molded coil structure of a first embodiment of the present invention; FIG. 2B is a view of the present invention A top view of the copper coil and the two conductive sheets of the first embodiment; FIGS. 3A to 3C are respectively side views of the copper coil of the first embodiment of the present invention; FIGS. 4A and 4B are respectively FIG. 5A is a plan view of a copper coil and a second conductive sheet according to a second embodiment of the present invention; FIG. 5B is a second embodiment of the present invention; One side view of one of the copper coil and the two electrode sheet; 5C is a side view of a copper coil and a two-electrode piece according to another embodiment of the present invention; FIG. 6 is a schematic view showing the connection of a plurality of conductive members of the present invention; FIG. 7 is a view of the present invention A flow chart of a method of fabricating a molded coil structure in accordance with one of the third embodiments; and a flow chart of a method of manufacturing a molded coil structure in accordance with a fourth embodiment of the present invention.

20‧‧‧Metal coil

201, 202‧‧‧ endpoint

21, 22‧‧‧ conductive sheet

210, 220‧‧‧ first endpoint

211, 221‧‧‧ second endpoint

212, 222‧‧‧Intermediate connection

Claims (22)

A method of manufacturing a molded coil structure, comprising the steps of: providing a metal coil having two end points; performing a pressing process on the two end points, respectively forming a curved structure; and having the curved structure An immersion plating process is performed on the two ends, and a metal is immersed on the curved structure; a conductive member is provided, and two conductive sheets and an intermediate connection portion are provided, wherein the two conductive sheets respectively have a first end point and a second end point, the intermediate connection portion is connected to the first end of the two conductive sheets; and the two end points having the curved structure are respectively connected to the first end points of the two conductive sheets by a soldering process; The intermediate connecting portion is cut so that the two conductive sheets are electrically connected only by the metal coil. The method of claim 1, wherein the curved structure further comprises a positioning structure for fixing the metal coil and the two conductive sheets in the soldering process. The method of claim 1, wherein the curved structure has a flat wave shape or a cylindrical shape of a spiral sawtooth. The method of claim 1, wherein the immersion process is immersed in the curved structure. The method of claim 1, wherein the metal coil is formed of a copper material having a purity of at least 99.9%, and the copper material can withstand a temperature of 150-250 degrees. The method of claim 1, wherein the coil inductance of the metal coil is determined by a coil outer diameter, a coil center aperture, a coil height, and a coil number. The method of claim 1, wherein the second end points of the two conductive sheets are respectively connected to one side connecting portion, and are connected to two adjacent conductive members to cut the intermediate connection. After the step of the step, the step of cutting the side connecting portion is further included. The method of claim 1, further comprising the steps of: placing the connected metal coil and the two conductive sheets into a mold; and filling a magnetic material with a high pressure process to form a cladding structure, The two conductive sheets and the metal coil are covered by the covering structure to form the molded coil structure. A method for manufacturing a die-cast coil structure, comprising the steps of: providing a metal coil having two end points; performing a welding process on the two ends, and respectively welding an electrode sheet to Providing a conductive member, comprising two conductive sheets and an intermediate connecting portion, wherein the two conductive sheets respectively have a first end point and a second end point, wherein the intermediate connecting portion is connected to the two conductive sheets a first end point; the electrode sheet of the two end points of the metal coil is respectively connected to the first end of the two conductive sheets by a soldering process; and the intermediate connecting portion is cut, so that the two conductive sheets are only The metal coils are electrically connected to each other. The method of claim 9, wherein the fusing process is achieved by a micro-resistance discharge bonding technique. The method of claim 9, wherein each of the electrode sheets is a flat plate, and the two end points of the coil are pressed together with the electrode sheets, and the welding process is performed. The method of claim 9, wherein each of the electrode sheets is a flat plate, wherein the flat plate further comprises a curling portion, wherein the two ends of the coil are riveted to each of the electrode sheets by the curling portion. , 俾 perform the welding process. The method of claim 9, further comprising the steps of: placing the connected coil and the two conductive sheets into a mold; and filling a magnetic material with a high pressure process to form a cladding structure, The two conductive sheets and the coil are covered by the covering structure to form the molded coil structure. A die-cast coil structure comprising: a metal coil having two end points, wherein the two end points respectively have a curved structure, the curved structure further comprises a layer of immersion metal; and the two conductive sheets respectively comprise a first end a second end point and an intermediate connection portion, wherein the intermediate connection portion is connected to the two conductive sheets of the first end point, and is soldered to the two end points of the metal coil; and a covering structure comprising a magnetic The covering structure covers the two conductive sheets and the metal coil; wherein the second end of each of the two conductive sheets exposes the covering structure and is electrically connected to an external circuit. The molded coil structure of claim 14, wherein the curved structure further comprises a positioning structure to provide a fixing function when the metal coil and the two conductive sheets are subjected to a soldering process. The molded coil structure of claim 14, wherein the curved structure has a flat wave shape or a cylindrical shape of a spiral sawtooth. The molded coil structure of claim 14, wherein the immersion metal is tin. A molded coil structure as described in claim 14 of the patent application, The metal coil is formed of a copper material having a purity of at least 99.9%, and the copper material can withstand a temperature of 150-250 degrees. A die-cast coil structure comprising: a metal coil having two end points, wherein each of the two end points has an electrode sheet, and the two electrode sheets are formed on the two end points by a welding process; Each includes a first end point, a second end point, and an intermediate connection portion, wherein the intermediate connection portion connects the two conductive sheets of the first end point, and is soldered to the two electrode sheets; and a covering structure, The magnetic structure comprises a magnetic material, and the covering structure covers the two conductive sheets and the metal coil; wherein the second end of each of the two conductive sheets is exposed outside the covering structure, and is electrically connected to an external circuit. The molded coil structure according to claim 19, wherein the welding process is achieved by a micro-resistance discharge bonding technique. The molded coil structure according to claim 19, wherein each of the electrode sheets is a flat plate, and the two end points of the coil are pressed together with the electrode sheets, and the welding process is performed. The molded coil structure of claim 19, wherein each of the electrode sheets is a flat plate, wherein the flat plate further comprises a curling portion, wherein the two ends of the coil are formed by the curling portion and each of the electrodes The sheet is riveted and the splicing process is performed.