M3 64262 五、新型說明： 【新型所屬之技術領域】 本創作是有關於一種電感元件，且特別是有關於 一種射出一體成型之電感元件。 . 【先前技術】 傳統之電感元件由鐵芯、線圈、膠合材質、軟磁性 I 金屬等所組成。線圈環繞於鐵芯之外圍，軟磁性金屬係 透過鑄模及高溫燒結而成。黏膠則混合設置於線圈及軟 磁性金屬之間用以黏結該軟磁性金屬。因其製造過程耗 費過多人工，且形狀不易微形化，不符電子裝置「輕、 薄、短、小」之需求，晚近有人提出一體成型之製造方 法，試圖以此方法進一步將電感元件的製造推入新的里 程。 綜觀前案，中華民國專利第1223288號提出一改良 • 發明，將線圈置於一磁導材料底座之上，將混有鐵合金 粉末之流態包覆體射出形成電感之包覆體（如第1圖所 示）。然此發明仍須先製備磁導材料底座，且此底座之 裝置須耗人工，等待包覆體凝結成型亦需時間。 中華民國專利第1234790號更進一步使用磁導材 ' 料蓋板，並使用塑膠射出料為包覆體材料（如第2圖所 ' 示）。此發明雖然需多製備蓋板，然使用塑膠射出料為 包覆材，不失為一省時之方法。 3 M364262 中華民國專利第1287810號提出了一體成型的電感 器製造方法，請見第3圖。該方法將導磁粉末佈滿於線 圈四週，利用成型模壓鑄成型，省時省工。但有下列之 缺陷： 一、 導磁粉末不易均勻散佈於模具底部； 二、 壓鑄過程中，易造成導線裂損，影響電感特 性；及 三、 成品易裂。 是故，有待改進之處尚多。 中華民國專利第1264740號另提出了一體成型的 電感器製造方法，如第4圖所示。該發明利用一預成型 之磁性座體，結合線圈後，加屢解構而後加熱成型。較 之1287810專利，本發明可解決第一與第二項問題。然 而重構成型之包覆層，強度還是不足，成品容易碎裂。 且此方法亦需後加工處理，費時費工。 中華民國專利第M308477號提出了新的包覆方 式，請見第5圖。其利用一磁心罩蓋，包覆一鐵心與線 圈，除易於結合製造外，各別元件之生產過程也相對簡 化。然，其磁心罩蓋下方開口處，為一導磁缺隙，影響 電感器的特性。 中華民國專利第M332922號利用混合軟磁性顆粒 之軟性膠質體，黏附於環繞於線圈的一工字型鐵芯側 邊，有效的解決導磁缺隙問題，請見第6圖。此發明之 優點為不需鑄模與燒結，此外亦不傷害線圈。然其尚需 4 M364262 加熱固化該膠質體，實乃美中不足之處。 中華民國專利第M317066號’如第7圖所示，提 • 供了一種無捲線圈數之大電流電感結構改良。利用一導 .線，貫穿一磁體，藉以滿足易於組裝的目的，亦可達成 電感陣列化之目的。然而，外露之導線減損了電感特 性’且會干擾鄰近電子元件。 因此，鑑於上述專利所無法解決的問題，創作人提 ' 出了一種新型電感元件。利用射出之混料形成包覆體， I 有效地提供該電感元件良好的電感特性與保護功效，製 作過程省時亦省工。 【新型内容】 由先前技術觀之，目前電感器具有以下之問題待改 進： —、不易滿足微形化之趨勢； φ 二、製造過程費工費時； 三、 本體易破裂； 四、 線圈部份因熱壓造成無法視察之破壞；及 五、 電感特性不良。 針對此欲解決的問題，本創作即在提供一種射出 ' 一體成型之電感元件。因其包覆體由軟磁性材料及塑 . 膠射出料混合組成，故可將形體縮小。製造簡便，亦 不傷其組件。除藉由塑料提供較佳之保護性外，亦可 5 M364262 按軟磁性材料_ 的目的。 鐵心，達到調整電感特性 本創作為一種射出—v > 出體成型之電感元件，包括· 一線圈部，包含至少一嬙固+ 匕括· 、線圈本體及至少二露出端；及 -射出包覆體，完全包覆該線圈本體 = ，㈣及塑膠射出料，其中該射出包覆體藉由射出人成 里’完全包覆該線圈本體。M3 64262 V. New description: [New technical field] The present invention relates to an inductive component, and in particular to an inductive component that is integrally formed by injection. [Prior Art] Conventional inductance components are composed of a core, a coil, a glued material, a soft magnetic I metal, and the like. The coil surrounds the periphery of the core, and the soft magnetic metal is sintered through a mold and high temperature. The glue is mixed between the coil and the soft magnetic metal to bond the soft magnetic metal. Because the manufacturing process is too labor-intensive and the shape is not easy to be micro-shaped, which is inconsistent with the demand for "light, thin, short, and small" electronic devices, a manufacturing method for integral molding has been proposed recently, in an attempt to further push the manufacture of the inductor component. Enter new miles. Looking at the previous case, the Republic of China Patent No. 1223288 proposes an improvement and invention. The coil is placed on a magnetically conductive material base, and the fluid-coated body mixed with the iron alloy powder is injected to form an inductor body (such as the first one). Figure shows). However, the invention still requires the preparation of a magnetically conductive material base, and the apparatus of the base is labor intensive, and it takes time to wait for the coating body to coagulate. Further, the Republic of China Patent No. 1234790 further uses a magnetic material material cover and uses a plastic injection material as a covering material (as shown in Fig. 2). Although the invention requires more preparation of the cover plate, the use of the plastic injection material as the cladding material is a time-saving method. 3 M364262 Republic of China Patent No. 1287810 proposes a method of manufacturing an integrally formed inductor, see Fig. 3. The method fills the circumference of the coil with the magnetic conductive powder, and is molded by a molding die, which saves time and labor. However, the following defects are involved: 1. The magnetic conductive powder is not easily dispersed evenly on the bottom of the mold; 2. During the die casting process, the wire is easily broken and affects the inductance; and 3. The finished product is easily cracked. Therefore, there are still many areas for improvement. The method of manufacturing an integrally formed inductor is also proposed in the Republic of China Patent No. 1264740, as shown in Fig. 4. The invention utilizes a preformed magnetic body that, after being combined with a coil, is repeatedly deconstructed and then heat formed. The present invention solves the first and second problems with respect to the 1287810 patent. However, the reconstituted coating layer is insufficient in strength and the finished product is easily broken. And this method also requires post-processing, which takes time and labor. The Republic of China Patent No. M308477 proposes a new coating method, see Figure 5. It utilizes a core cover to cover a core and a coil. In addition to being easy to combine, the production process of the individual components is relatively simple. However, the opening below the core cover is a magnetically conductive gap that affects the characteristics of the inductor. The Republic of China Patent No. M332922 utilizes a soft colloid of mixed soft magnetic particles to adhere to the side of an I-shaped core surrounding the coil to effectively solve the problem of magnetic flux gap, see Figure 6. The advantage of this invention is that it does not require molding and sintering, and does not damage the coil. However, it still needs 4 M364262 to heat and cure the colloid, which is a drawback. The Republic of China Patent No. M317066, as shown in Fig. 7, provides an improvement in the structure of a large current inductance of a coilless coil number. The use of a guide wire, through a magnet, for the purpose of easy assembly, can also achieve the purpose of inductor array. However, the exposed wires detract from the inductance characteristics and can interfere with adjacent electronic components. Therefore, in view of the problems that the above patents cannot solve, the author proposes a new type of inductance component. By using the injected mixture to form the cladding body, I effectively provides good inductance characteristics and protection effects of the inductance component, and the manufacturing process saves time and labor. [New content] From the prior art view, the current inductors have the following problems to be improved: -, it is not easy to meet the trend of micro-morphization; φ Second, the manufacturing process is labor-intensive; Third, the body is easy to break; Fourth, the coil part Damage that cannot be inspected due to hot pressing; and 5. Inductive characteristics are poor. In response to this problem, the present invention is providing an inductive component that is injection molded. Since the coating body is composed of a soft magnetic material and a plastic injection and discharge mixture, the shape can be reduced. It is easy to manufacture and does not damage its components. In addition to providing better protection by plastic, 5 M364262 can also be used for the purpose of soft magnetic materials. Core, to achieve the adjustment of the inductance characteristics of the present invention is an injection-v > out-of-body molding of the inductance component, including a coil portion, including at least one tamping + · ·, the coil body and at least two exposed ends; and - the injection package The covering body completely covers the coil body =, (4) and the plastic injection material, wherein the injection coating body completely covers the coil body by injecting a person into a body.
根據本案構想，進一步包含一 鐵芯 由一第二軟 磁性材料所製成，裝設於該線圈本體捲繞之空間中。 根據本案構想，其中該線圈部由一金屬線製成。 根據本案構想，其中該金屬線剖面為圓形、橢圓 形、多邊形或扁平形。 根據本案構想，其中該線圈部為多段金屬片端部 重疊連接製成。 ° 根據本案構想，其中該第一軟磁性材料為軟性鐵 軋體或合金系材料。 根據本案構想，其中該第二軟磁性材料為軟性鐵 氧體或合金系材料。 根據本案構想，其中該軟性鐵氧體為錳鋅鐵氧 體、鎳辞鐵氧體、鎳銅鋅鐵氧體、錳鎂鋅鐵氧體、錳 鎂鋁鐵氧體、錳銅鋅鐵氧體、鈷鐵氧體或前述物品之 混合物。 根據本案構想，其中該軟性鐵氧體為錳鋅鐵氧 體、錄鋅鐵氧體、錄銅鋅鐵氧體、猛鎂辞鐵氧體、般 6 M3 64262 鎂鋁鐵氧體、錳銅鋅鐵氧體、鈷鐵氧體或前述物品之 混合物。 根據本案構想’其中該熱固性塑料為環氧樹脂 (Epoxy Resin)、聚砜（Polysulfone,PSU)、聚醚颯 (Polyethersulfone, PES )、齡搭樹脂 (Phenol-Formaldehyde, PF)、聚矽樹脂（Silic〇nes， SI)、聚苯硫喊（Polyphenylenesulfide, PPS)或上述 材料之混合物。 根據本案構想，其中該熱塑性塑料為聚氨@旨 (Polyurethanes, PU )、聚對苯二甲酸丁酯 (Polybutylene Terephthalate，PBT )、聚對苯二曱酸乙 酯（Polyethylene Terephthalate，PET )、聚醯亞胺 (Polyhthalamide，PPA)、聚四氟乙烯 (Polytetrafluoroethene, PTFE )、聚醯胺（p〇iyamide )、 液晶（Liquid Crystal Polymer, LCP )或上述材料之混 合物。 根據本案構想，其中該第一軟磁性材料佔射出包 覆體的重量百分比為60%〜95%。 【實施方式】 本創作有三個實施例。參照圖式，第8圖至第1〇 圖為第一實施例之說明圖，第11圖為第二實施例之說 明圖，第12圖為第三實施例之說明圖。 第一實施例 7 M364262 請見第8圖，一種射出一體成型之電感元件之部分 組件如圖所示。由剖面圓形之銅線所繞製的一線圈部 10，具有二露出端102與線圈本體104。線圈本體104 中環繞一組鐵芯12。該鐵芯12為錳辞鐵氧體經燒結製 成，其可為加強電感品質因素（Quality Factor，簡稱Q 值）與提升電感值。其組成之半成品置於一射出成型模 20中（請見第9圖），藉由進料孔2〇2射入含有軟磁 性材料及塑膠射出料的混料，填滿射出成型模20的容 置空間。待約一分鐘的冷凝，即可脫模。一電感元件 3〇 (請見第10圖）即成型，其中包覆體302即為混料 冷凝所形成，並藉由二露出端102與電路板焊結。 此處混料所含之軟磁性材料，為鎳銅鋅鐵氧體； 塑膠射出料為熱塑性的聚醯胺（Polyamide)，軟磁性 材料所佔的重量百分比為95%。由於熱塑性塑膠具有 遇熱溶化的功效，因此具有可回收再利用之優點。此 外，5%的塑料亦提供包覆體足夠之韌性’使產品不因 些微碰撞而破裂。成型模2〇可為一模多穴（16穴以 上）’產品製作快速，經濟有效’亦不會於射出過程中， 損害線圈。 _第二實施例 請見第11圖，依照創作精神之第二實施例。由剖 面扁平形之銅線所繞製的一線圈部402 ’具有二露出端 4022與被包覆之線圈本體4024 ’包覆於含有軟磁性材 料及塑膠射出料的包覆體404中’形成電感元件40。 8 M364262 該二露出端4022可進一步彎折以利用表面黏著技術 (Surface Mounting Technology，SMT )，附著於電路板 上。 此處混料所含之軟磁性材料，為鐵鎳合金粉末；塑 膠射出料為熱固性的環氧樹脂（Ep0Xy Resin )，由於熱 固性塑膠具有遇熱固化的功效，因此可耐較高的工作溋 度（約280°C)。軟磁性材料所佔的重量百分比為70%。 _ 同時，因為射出料流動性佳，可將此例中的產品微形 化，滿足電子產品日益微形化的需求。 茗三實施例 請見第12圖’依照創作精神之第三實施例。由剖 面圓形之銅線所繞製的二個線圈部5〇2，具有四組露出 端5024與被包覆之二線圈本體5〇22，包覆於含有軟磁 性材料及塑膠射出料的包覆體5〇4中，形成電感元件 50。其中二個線圈部5〇2之線圈本體同軸串置， ® 形成了電感陣列。 此處混料所含之軟磁性材料，為鎳銅鋅鐵氧體；塑 膠射出料為熱固性的環氧樹脂（Epoxy Resin)，軟磁性 材料所佔的重量百分比為9〇%。由於線圈部5〇2的材 質與尺寸可依實際需求更改，故同一模具僅需修改固定 露出端5024的模片’即可達到不同陣列的設計需求， 卽省成本。 以上實施例所使用的材料，並非限定，須依實際的 電感特性需求，更換材料與配比。 9 M364262 雖然本創作已以實施例揭露如上，然其並非用以限 定本創作’任何所屬技術領域中具有通常知識者，在不 脫離本創作之精神和範圍内，當可作些許之更動與潤 飾，因此本創作之保護範圍當視後附之申請專利 界定者為準。 【圖式簡單說明】 _ 第1圖繪示一種電感器製造的先前技術； 第2圖繪示一種電感器塑膠射出黏合的先前技術； 第3圖緣示一種電感器一體成型製造的先前技術； 第4圖繪示一種電感器解構重製的先前技術； 第5圖繪示一種電感器組裝的先前技術； 第6圖繪示一種電感器固化製造的先前技術； 第7圖繪示一種電感器組裝的先前技術； 第8圖繪示本創作的電感元件之第一實施例組件； • 第9圖繪示本創作的電感元件之第一實施例鑄模情形； 第10圖繪示本創作的電感元件之第一實施例； 第Π圖繪示本創作的電感元件之第二實施例；及 第12圖繪示本創作的電感元件之第三實施例。 ' 【主要元件符號說明】 • 〔本創作〕 10 線圈部 104 線圈本體 102 露出端 12 鐵芯 M364262 20 射出成型模 202 進料孔 30 電感元件 302 包覆體 40 電感元件 402 線圈部 4022 露出端 4024 線圈本體 404 包覆體 50 電感元件 502 線圈部 5022 線圈本體 5024 露出端 504 包覆體According to the present invention, an iron core is further formed of a second soft magnetic material and is disposed in a space in which the coil body is wound. According to the present invention, the coil portion is made of a metal wire. According to the present invention, the wire has a circular, elliptical, polygonal or flat cross section. According to the present invention, the coil portion is formed by overlapping the ends of the plurality of metal sheets. ° According to the present invention, the first soft magnetic material is a soft iron rolled body or an alloy based material. According to the present invention, the second soft magnetic material is a soft ferrite or alloy-based material. According to the concept of the present invention, the soft ferrite is manganese zinc ferrite, nickel pyrite, nickel copper zinc ferrite, manganese magnesium zinc ferrite, manganese magnesium aluminum ferrite, manganese copper zinc ferrite , cobalt ferrite or a mixture of the foregoing. According to the concept of the present invention, the soft ferrite is manganese zinc ferrite, zinc-loaded ferrite, copper-zinc ferrite, ferro-magnesium ferrite, general 6 M3 64262 magnesium aluminum ferrite, manganese copper zinc Ferrite, cobalt ferrite or a mixture of the foregoing. According to the present invention, the thermosetting plastic is epoxy resin (Epoxy Resin), polysulfone (PSU), polyethersulfone (PES), Phenol-Formaldehyde (PF), and polydecene resin (Silic). 〇nes, SI), Polyphenylenesulfide (PPS) or a mixture of the above materials. According to the present invention, the thermoplastic is Polyurethanes (PU), Polybutylene Terephthalate (PBT), Polyethylene Terephthalate (PET), Polyfluorene. Polyhthalamide (PPA), polytetrafluoroethene (PTFE), p〇iyamide, liquid crystal polymer (LCP) or a mixture of the above materials. According to the present invention, the first soft magnetic material accounts for 60% to 95% by weight of the ejection envelope. [Embodiment] There are three embodiments of the creation. Referring to the drawings, Fig. 8 through Fig. 1 are explanatory views of the first embodiment, Fig. 11 is an explanatory view of the second embodiment, and Fig. 12 is an explanatory view of the third embodiment. First Embodiment 7 M364262 Referring to Fig. 8, a part of an integral component of an injection molded component is shown. A coil portion 10 wound by a copper wire having a circular cross section has two exposed ends 102 and a coil body 104. A coil core 12 is wound around the coil body 104. The iron core 12 is made of sintered manganese ferrite, which can strengthen the inductance factor (Q value) and increase the inductance value. The semi-finished product of the composition is placed in an injection molding die 20 (see Fig. 9), and the mixture containing the soft magnetic material and the plastic injection material is injected through the feeding hole 2〇2 to fill the capacity of the injection molding die 20. Set the space. After about one minute of condensation, the mold can be released. An inductive component 3〇 (see Fig. 10) is formed, wherein the cladding 302 is formed by the condensation of the mixture and is soldered to the circuit board by the two exposed ends 102. The soft magnetic material contained in the mixture here is nickel copper zinc ferrite; the plastic injection material is thermoplastic polyamide, and the soft magnetic material accounts for 95% by weight. Thermoplastics have the advantage of being recyclable because they have the effect of being melted by heat. In addition, 5% of the plastic also provides sufficient toughness of the cladding to prevent the product from rupturing due to micro-collisions. The molding die 2 can be made in a multi-hole (16 points or more) product quickly and cost-effectively, and will not damage the coil during the shooting process. _Second Embodiment Please refer to Fig. 11, in accordance with the second embodiment of the spirit of creation. A coil portion 402' wound by a flat-shaped copper wire has two exposed ends 4022 and a covered coil body 4024' wrapped in a covering body 404 containing a soft magnetic material and a plastic injection material. Element 40. 8 M364262 The two exposed ends 4022 can be further bent to adhere to the board using Surface Mounting Technology (SMT). The soft magnetic material contained in the mixture here is iron-nickel alloy powder; the plastic injection material is thermosetting epoxy resin (Ep0Xy Resin), and the thermosetting plastic has the effect of heat curing, so it can withstand high working temperature. (about 280 ° C). The soft magnetic material accounts for 70% by weight. _ At the same time, because of the good fluidity of the shot material, the products in this example can be micro-formed to meet the increasingly micro-formation requirements of electronic products. Third Embodiment Please refer to Fig. 12' in accordance with the third embodiment of the creative spirit. The two coil portions 5〇2 wound by the circular copper wire have four sets of exposed ends 5024 and the two coil bodies 5〇22 covered, and are wrapped in a package containing soft magnetic material and plastic injection material. In the cladding 5〇4, the inductance element 50 is formed. The coil bodies of the two coil portions 5〇2 are coaxially arranged, and the inductor array is formed. The soft magnetic material contained in the mixture here is nickel copper zinc ferrite; the plastic injection material is a thermosetting epoxy resin (Epoxy Resin), and the soft magnetic material accounts for 9% by weight. Since the material and size of the coil portion 5〇2 can be changed according to actual needs, the same mold only needs to modify the die s fixed to the exposed end 5024 to achieve the design requirements of different arrays, and the cost is saved. The materials used in the above embodiments are not limited, and the materials and ratios must be replaced according to the actual inductance characteristics. 9 M364262 Although the present invention has been disclosed in the above embodiments, it is not intended to limit the present invention to anyone having ordinary knowledge in the art, and may make some changes and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of this creation is subject to the definition of the patent application attached. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 illustrates a prior art of inductor manufacturing; FIG. 2 illustrates a prior art of inductor plastic injection bonding; and FIG. 3 illustrates a prior art in which an inductor is integrally formed; FIG. 4 illustrates a prior art of inductor destructuring reproduction; FIG. 5 illustrates a prior art of inductor assembly; FIG. 6 illustrates a prior art of inductor curing fabrication; and FIG. 7 illustrates an inductor Prior art of assembly; Fig. 8 is a view showing a first embodiment of the inductor element of the present invention; Fig. 9 is a view showing a molding of the first embodiment of the inventive inductor element; and Fig. 10 is a view showing the inductor of the present invention. A first embodiment of the component; a second embodiment of the inventive inductive component; and a second embodiment of the inventive inductive component. ' [Main component symbol description] • [This creation] 10 Coil part 104 Coil body 102 Exposed end 12 Iron core M364262 20 Injection molding die 202 Feed hole 30 Inductive component 302 Wrap body 40 Inductive component 402 Coil part 4022 Exposure end 4024 Coil body 404 wrap 50 inductive component 502 coil portion 5022 coil body 5024 exposed end 504 wrap
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