WO2013183183A1 - Compressed powder molded inductor member production device, production method for compressed powder molded inductor member, and compressed powder molded inductor member - Google Patents

Compressed powder molded inductor member production device, production method for compressed powder molded inductor member, and compressed powder molded inductor member Download PDF

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Publication number
WO2013183183A1
WO2013183183A1 PCT/JP2012/081287 JP2012081287W WO2013183183A1 WO 2013183183 A1 WO2013183183 A1 WO 2013183183A1 JP 2012081287 W JP2012081287 W JP 2012081287W WO 2013183183 A1 WO2013183183 A1 WO 2013183183A1
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WIPO (PCT)
Prior art keywords
coil
powder
groove
inductor member
molded
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PCT/JP2012/081287
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French (fr)
Japanese (ja)
Inventor
正治 長谷川
渚 神谷
高橋　大輔
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アイトリックス株式会社
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Publication of WO2013183183A1 publication Critical patent/WO2013183183A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F2017/048—Fixed inductances of the signal type  with magnetic core with encapsulating core, e.g. made of resin and magnetic powder

Definitions

  • the present invention relates to a dust-molded inductor member that encloses a coil and is compression-molded with powder, and more particularly to a manufacturing apparatus and a manufacturing method thereof.
  • Such a dust-molded inductor member can obtain a stable inductance by using a coil of a winding type, can flow a large current, and can seal the entire coil with magnetic metal powder. Thus, the leakage magnetic flux can be reduced, and the influence of magnetism on other components can be suppressed.
  • a coil is placed on a molded lower core, and then the lower core and the upper core are refilled with magnetic metal powder so as to fill the coil.
  • a method of manufacturing an integrated coil-filled green compact see, for example, Patent Document 1). According to this method, it is possible to increase the inductance without forming a gap between the lower core and the upper core and the coil.
  • the terminal portion of the coil is applied by applying an external force that moves the coil terminal portion toward the inner surface of the mold.
  • the outer surface is brought into contact with the inner surface of the mold, and then the mold is filled with magnetic metal powder and compression-molded (see, for example, Patent Document 2).
  • the coil terminal portion can be exposed on the surface and molded without shifting the arrangement position of the coil in the molding die.
  • JP 2001-267160 A (paragraph 0014, FIG. 1) JP 2005-294461 A (paragraphs 0057 to 0072, FIGS. 17 to 22)
  • Patent Document 1 after the lower core is molded, the end of the coil is sandwiched between the upper mold frame and the lower mold frame, and then refilled with magnetic metal powder, and then pressed with the upper and lower punches. For this reason, there is a risk of cutting, and a gap corresponding to the thickness of the end of the coil is formed between the upper mold frame and the lower mold frame. There is a problem that magnetic metal powder leaks. In particular, when the compacted inductor member is further downsized, the leakage of the magnetic metal powder becomes a more prominent problem.
  • the present invention has been made paying attention to such problems, and provides a compact molded inductor member manufacturing apparatus, a compact molded inductor member manufacturing method, and a compact molded inductor member that can be further miniaturized. With the goal.
  • the compacted inductor member manufacturing apparatus of the present invention is In a dust-molded inductor member manufacturing apparatus that manufactures a dust-molded inductor member that is compression-molded by enclosing a coil in powder, A mold part in which the shape at the time of compression molding is configured; and A supply unit for supplying the powder; A pressurizing unit that pressurizes the coil disposed in the mold part together with the powder supplied from the supply unit; Have The mold part is provided on the peripheral side of the hole part in which the coil is arranged and the powder is supplied by the supply part, and the end part of the coil is sandwiched between the end part of the coil.
  • the contact receiving portion includes a groove portion that receives an end portion of the coil, and a groove pressing portion that sandwiches the end portion of the coil received in the groove portion and fits into the groove portion.
  • the groove part and the groove pressing part can be formed by a concave part and a convex part.
  • the groove portion of the abutment receiving portion makes it easier to receive the end portion of the coil in the groove portion by making the width of the groove portion wider than the diameter of the end portion of the coil. With the same width, the groove portion and the groove holding portion can be properly fitted, and the groove portion where the coil end of the contact receiving portion abuts and the portions other than the groove holding portion are in contact with each other. You can keep in touch. As a result, it is possible to manufacture a dust-molded inductor member in which the end portion of the coil is extended to the outside from the compression-molded powder portion, and the compressed powder portion can be further downsized.
  • the groove includes an opening portion having a predetermined width for receiving an end portion of the coil and an arrangement portion for disposing an end portion of the coil that is narrower than the predetermined width of the opening portion.
  • the contact area between the end of the coil and the powder can be reduced, and the pressure applied to the end of the coil can be reduced.
  • the mold part including the groove part of the contact receiving part is hardly deteriorated. Even if the position of the end portion of the coil is slightly shifted and received from the opening portion, the width of the arrangement portion of the groove portion is narrow, so that it will be arranged at the same arrangement portion every time.
  • the product shape of the molded inductor member can be manufactured in the same shape for each product.
  • the pressurization is dispersed by providing a groove part having a different width between the opening part and the arrangement part. Will be.
  • the contact receiving portion sandwiches the end portion of the coil, and the portions other than the portion where the end portion of the coil is in contact with each other contact each other, so that the powder supplied from the supply portion is added by the pressurizing portion.
  • the predetermined width of the opening part is wider than the width of the arrangement part. This makes it easier to accept the end of the coil in the opening part, and the end of the coil is guided to the arrangement part narrower than the predetermined width so as to fit into the groove part properly.
  • the portions other than the portion where the end of the coil of the contact receiving portion is in contact can be in contact with each other. As a result, it is possible to manufacture a dust-molded inductor member in which the end portion of the coil is extended to the outside from the compression-molded powder portion, and the compressed powder portion can be further downsized.
  • At least one of the groove part and the groove pressing part includes an elastic member that is elastically deformed on the contact surface side of the end of the coil.
  • at least one of the groove portion and the groove pressing portion includes the elastic member that elastically deforms on the contact surface side when the end portion of the coil is sandwiched, so that the elastic member is the end portion of the coil. Therefore, when the powder supplied from the supply unit is pressurized by the pressurizing unit, the end of the coil is not crushed or cut when sandwiched.
  • the mold part has first mold means and second mold means that are divided and have contact surfaces that contact each other,
  • the first mold means comprises one of the groove part and the groove pressing part,
  • the second mold means includes the other of the groove part and the groove pressing part.
  • the first mold means and the second mold means which are divided are provided with a groove portion or a groove pressing portion, so that the end of the coil is received by one groove portion and the other groove pressing portion is received. The end portion of the coil received in the groove portion can be sandwiched and fitted into the groove portion.
  • the position of the contact surfaces (parts other than the groove part and the groove pressing part) of the first mold part means and the second mold part part that are separated from each other is, for example, compacted when formed. Since it can be set at a position above the top side (or below the bottom side) of the molded inductor member, the powder is formed on the abutting surfaces of the divided first mold means and second mold means. It becomes possible to eliminate the parting line (the boundary between the divided first molding die means and the second molding die means) of the dust molding inductor member caused by leakage.
  • a dust-molded inductor member manufacturing method for manufacturing a dust-molded inductor member that is compression-molded by enclosing a coil in powder In a dust-molded inductor member manufacturing method for manufacturing a dust-molded inductor member that is compression-molded by enclosing a coil in powder, A coil formed in a spiral shape is disposed in the hole portion of the mold part in which the shape at the time of compression molding is configured, The end of the coil is received and arranged from the groove provided on the peripheral side of the hole of the mold part, and the end of the coil is sandwiched by the groove pressing part fitted into the groove, Supplying the powder to the hole of the mold part, The coil arranged in the hole of the mold part is pressed together with the supplied powder.
  • the groove pressing portion is fitted into the groove portion, and the end portion of the coil is sandwiched between the groove pressing portion and the groove portion. Therefore, when the powder supplied from the supply portion is pressurized by the pressing portion. In the end side of the coil sandwiched between the groove pressing part and the groove part, it is possible to further prevent the powder from leaking and flowing, and by the powder leaking to the outside of the compacting inductor member Generation of burrs can be prevented.
  • the coil is received from an opening portion having a predetermined width of the groove, and is disposed in a portion where the groove is narrower than the predetermined width. Is sandwiched between the groove pressing portions.
  • the end portion of the coil is received from the opening portion having a predetermined width of the groove portion, and the arrangement portion is wider than the predetermined width of the opening portion.
  • the coil is placed in a certain position and can be sandwiched by the groove pressing part, and then the coil end part can be sandwiched. Thereafter, the powder is supplied to the hole part, and the coil is arranged in the hole part of the mold part. Can be pressurized together with the supplied powder.
  • the end of the coil By placing the end of the coil in the groove, the contact area between the end of the coil and the powder can be reduced, and the pressure applied to the end of the coil can be reduced.
  • the mold part including the groove part of the contact receiving part is hardly deteriorated.
  • the width of the arrangement portion of the groove portion is narrow, so that it will be arranged at the same arrangement portion every time.
  • the product shape of the molded inductor member can be manufactured in the same shape for each product. Further, when the coil arranged in the mold part is pressed together with the powder supplied from the supply unit by the pressurizing unit, the pressurization is dispersed by providing a groove part having a different width between the opening part and the arrangement part. Will be. When the powder supplied from the supply unit is pressurized by the pressurizing unit, the powder can be prevented from leaking and flowing to the end side of the sandwiched coil.
  • a dust-molded inductor member of the present invention In the method of manufacturing a dust-molded inductor member of the present invention, The end of the coil is sandwiched between elastic members that are elastically deformed and provided on the contact surface side of the end of the coil of at least one of the groove and the groove pressing portion. According to this feature, since the elastic member that elastically deforms at least one of the groove portion and the groove pressing portion is provided, when the end portion of the coil is sandwiched, the elastic member becomes the end portion of the coil.
  • the present invention is characterized by a powder-molded inductor member manufactured by the above-described method for manufacturing a powder-molded inductor member.
  • the dust-molded inductor member produced by the above-described method for producing a dust-molded inductor member can prevent the powder from leaking and flowing to the end side of the coil. Further, it is possible to prevent the generation of burrs due to the powder leaking to the outside of the compacted inductor member.
  • the dust-molded inductor member of the present invention In a compacted inductor member that is compression molded by enclosing a coil in powder, The compressed powder part that is compression-molded, and the coil enclosed in the compressed powder part, The coil includes a spiral portion in which a conducting wire is formed in a spiral shape, and an end portion of the conducting wire extending from the spiral portion, The spiral portion of the conducting wire is enclosed in the compressed powder portion, The outside of the compressed powder part does not have a parting line, The end portion of the conducting wire is not crushed by the compression molding. According to this feature, there is no parting line outside the compressed powder part, and the end of the conductor is not crushed by the compression molding, and the end of the coil is maintained as it is.
  • a compacted inductor member in a state can be provided. Moreover, it is good also as a powder-molded inductor member which suppressed generation
  • the dust-molded inductor member manufacturing apparatus of the present invention is In a dust-molded inductor member manufacturing apparatus that manufactures a dust-molded inductor member that is compression-molded by enclosing a coil in powder, A mold part in which the shape at the time of compression molding is configured; and A supply unit for supplying the powder; A pressurizing unit that pressurizes the coil disposed in the mold part together with the powder supplied from the supply unit; Have The mold part is provided on the peripheral side of the hole part in which the coil is arranged and the powder is supplied by the supply part, and the end part of the coil is sandwiched between the end part of the coil.
  • a contact receiving portion where the portions other than the contact are in contact with each other,
  • the contact receiving portion arranges an opening portion having a predetermined width for receiving the end portion of the coil when the end portion of the coil is sandwiched, and an end portion of the coil narrower than the predetermined width of the opening portion.
  • It has the groove part provided with an arrangement
  • the end of the coil is easily guided to the arrangement part of the groove, and the end of the coil is more appropriately arranged by fitting the end of the coil into the arrangement part of the groove.
  • the coil is placed in a certain position and can be sandwiched by the groove pressing part, and the end of the coil can be sandwiched, and then the powder is supplied to the hole and the coil placed in the hole of the mold part Can be pressurized together with the supplied powder.
  • the mold part including the groove part of the contact receiving part is hardly deteriorated. Even if the position of the end portion of the coil is slightly shifted and received from the opening portion, the width of the arrangement portion of the groove portion is narrow, so that it will be arranged at the same arrangement portion every time.
  • the product shape of the molded inductor member can be manufactured in the same shape for each product. Further, when the coil arranged in the mold part is pressed together with the powder supplied from the supply unit by the pressurizing unit, the pressurization is dispersed by providing a groove part having a different width between the opening part and the arrangement part. Will be.
  • the powder supplied from the supply unit When the powder supplied from the supply unit is pressurized by the pressurizing unit, the powder can be prevented from leaking and flowing to the end side of the sandwiched coil. Generation of burrs due to powder leakage to the outside of the inductor member can be prevented. As a result, it is possible to manufacture a dust-molded inductor member in which the end portion of the coil is extended to the outside from the compression-molded powder portion, and the compressed powder portion can be further downsized.
  • FIG. 7 is an external view (a) to (c) in the manufacturing process of the dust-molded inductor member in the first embodiment and the second embodiment. It is explanatory drawing (a)-(f) which shows the manufacturing process of the powder-molding inductor member in 1st Example. It is a partially expanded view (a) and (b) of the manufacturing process of the powder-molded inductor member in the first embodiment. It is explanatory drawing (a)-(f) which shows the manufacturing process of the powder-molded inductor member in 2nd Example. It is the elements on larger scale (a) and (b) of the manufacturing process of the powder-molded inductor member in 2nd Example.
  • a powder molded inductor member manufacturing apparatus a powder molded inductor member manufacturing method, and a mode for carrying out a powder molded inductor member according to the present invention will be described below based on examples.
  • a dust-molded inductor member manufacturing apparatus and method for manufacturing a dust-molded inductor member for compressing and molding a coil according to a first embodiment in powder will be described with reference to FIGS. .
  • FIG. 1 shows external views (a) to (c) in the manufacturing process of the dust-molded inductor member in the first embodiment.
  • FIG. 1 (a) shows a coil 2 enclosed inside a dust-molded inductor member
  • FIG. 1 (b) shows a core 11 that is a compacted powder portion that incorporates the coil 2 and is compacted.
  • FIG. 1C shows a dust-molded inductor member 13 provided with terminal electrode portions 12A and 12B on the outside of the dust-molded core 11.
  • FIG. 1 shows external views (a) to (c) in the manufacturing process of the dust-molded inductor member in the first embodiment.
  • FIG. 1 (a) shows a coil 2 enclosed inside a dust-molded inductor member
  • FIG. 1 (b) shows a core 11 that is a compacted powder portion that incorporates the coil 2 and is compacted.
  • FIG. 1C shows a dust-molded inductor member 13 provided with terminal electrode portions 12A and 12B on the outside of the dust-molded core 11.
  • the coil 2 includes a spiral portion 8C in which a conductive wire is formed in a spiral shape, and conductive wire ends 8A and 8B extending from the spiral portion 8C.
  • the number and size of turns of the spiral portion 8C, the line width and cross-sectional area of the conducting wire are determined according to the required inductance.
  • the surface of the coil conducting wire is covered with an insulating coating such as a resin or an inorganic insulating material.
  • the cross section of the conducting wire can be circular or rectangular, and a thin wire with high conductivity such as copper or aluminum whose longitudinal and horizontal lengths in the conducting wire cross section are approximately the same can be used. In the embodiment, it may not be a flat cross section.
  • the powder-molded inductor member 12 shown in FIG. 1B is manufactured by compressing powder by incorporating a coil 2 by a manufacturing method to be described later.
  • the ends 8A and 8B of the conducting wire are extended from the outside.
  • the compressed powder portion where the end portions 8A and 8B of the core 11 are extended can be maintained in a state compressed without any gaps by the powder.
  • the powder since the powder does not leak to the end portions 8A and 8B that extend outward, the powder can be prevented from adhering.
  • a mixture of magnetic metal powder, an insulating material, and a lubricant similar to the conventional ones can be used, and the size of the powder particles and the kind to be blended can be appropriately set according to the application.
  • magnétique metal powders examples include transition metals that exhibit soft magnetism such as iron, iron silicide, permalloy (Fe—Ni alloy), supermalloy (Fe—Ni—Mo), sendust, iron nitride, iron aluminum alloy, iron One type or two or more types can be selected and used from cobalt alloys, phosphorous iron, and the like.
  • transition metals that exhibit soft magnetism such as iron, iron silicide, permalloy (Fe—Ni alloy), supermalloy (Fe—Ni—Mo), sendust, iron nitride, iron aluminum alloy, iron
  • These metals and alloys have a suitable particle size by mechanical pulverization and thermal decomposition methods such as water atomization method, oil atomization method, gas atomization method, electrolysis method, rotating disk method, twin roll method, and rotating electrode method.
  • the insulating material functions as a binder for forming the core 11 and has a function of insulating between the magnetic metal powders.
  • the insulating material for example, an organic material such as water glass, phenol resin, acrylic resin, epoxy resin, silicon resin, polyamide resin, and polyimide resin can be used, and a thermosetting resin may be used.
  • the lubricant has a function of improving the lubricity of the powder and a function of improving the packing density of the core 11.
  • the lubricant for example, at least one selected from zinc stearate, aluminum stearate, magnesium stearate, calcium stearate, strontium stearate, barium stearate, Ca, Zn, Al, Mg and the like can be used.
  • the core 11 has a rectangular parallelepiped shape, but may be a cube or a columnar shape. Moreover, although the core 11 has shown the case where it is square in the planar view and the length of length and width is the same, rectangular shape may be sufficient and circular shape may be sufficient as it. Moreover, the core 11 by the manufacturing method in the first embodiment can be made to be 2 mm square or less, and the powder-molded inductor member 12 that can be further miniaturized can be formed.
  • the dust-molded inductor member 13 includes terminal electrode portions 14A and 14B on both sides of the dust-molded core 11, and in the first embodiment, an end portion 8A of the conducting wire.
  • -Since 8B is extended outside the compressed powder part, the terminal electrode part can be easily provided outside the compressed powder part, and the terminal electrode part can be reliably configured.
  • FIG. 2 shows manufacturing steps (a) to (f) of the dust-molded inductor member in the first embodiment.
  • the dust-molded inductor member manufacturing apparatus 1 in the first embodiment manufactures a dust-molded inductor member 12 as shown in FIG. 1 (b) or a dust-molded inductor member 13 as shown in FIG. 1 (c).
  • the upper molds 3A and 3B and the lower molds 4A and 4B, and the powder supply unit 10 serving as a supply unit for supplying the powder 9;
  • the upper punch 5A and the lower punch 5B of the pressurizing unit that pressurizes the coil 2 arranged in the lower molds 4A and 4B of the mold unit together with the powder 9 supplied from the powder supply unit 10 Have.
  • the upper molds 3A and 3B of the mold part are sandwiched between the end portions 8A and 8B of the coil 2, and the contact receiving portions where the portions other than the end portions 8A and 8B of the coil are in contact with each other are in contact with each other.
  • An elastic member 7 is provided.
  • the dust-molded inductor member manufacturing apparatus 1 may include a transfer unit that transfers the coil 2 and places it in the lower molds 4A and 4B.
  • the upper molds 3A and 3B and the lower molds 4A and 4B are a first mold unit and a second mold unit that are divided and have contact surfaces that contact each other. 3B and lower mold
  • die 4A * 4B are comprised by the contact shape with the same shape.
  • the upper molds 3A and 3B and the lower molds 4A and 4B of the mold part are respectively driven up and down by driving means (not shown).
  • the upper molds 3A and 3B and the lower molds 4A and 4B show the right side 3B and 4B and the left side 3A and 4A in the longitudinal section in FIG. 2, but the shape in plan view is rectangular, and the coil 2 are disposed, and the portion where the powder 9 is inserted to form the core 11 is formed with holes 6A and 6B.
  • the size of the cross-sectional area of the holes 6A and 6B corresponds to the size of the cross-sectional area of the core 11.
  • the core 11 (holes 6A and 6B) has a square shape in the plan view and the length and width are the same. However, the shape may be rectangular. It may be circular.
  • the powder supply unit 10 is a device for supplying the powder 9 described above, and can be moved in the horizontal direction by a driving means (not shown), and can be moved onto the hole 6A so as to form the core 11.
  • the powder 9 is supplied after the coil 2 is arranged.
  • the powder supply unit 10 is provided with a contact surface whose lower surface is in contact with the upper surfaces of the upper molds 3A and 3B and a supply hole at the center of the contact surface.
  • the powder 9 When moving to the outside, the powder 9 can be scraped off by sliding the upper surface of the powder 9.
  • the upper punch 5A is inserted into the hole 6A from above the upper molds 3A and 3B, and the lower punch 5B is inserted into the hole 6B from below the lower molds 4A and 4B.
  • the upper punch 5A and the lower punch 5B are driven up and down by driving means (not shown), and are pressed from above and below by the upper punch 5A and the lower punch 5B, thereby compressing the powder 9 and the coil 2.
  • the lower surface of the upper punch 5A has the same area as the upper surface of the core 11, and the upper surface of the lower punch 5B has the same area as the lower surface of the core 11.
  • the size of the outer periphery of the spiral portion 8C of the coil 2 is set to be approximately the same as or slightly smaller than the size of the holes 6A and 6B, so that the coil 2 fits into the holes 6A and 6B. can do.
  • the coil 2 having the spiral portion 8 ⁇ / b> C having a size substantially equal to the size of the core 11 can be obtained.
  • the contact receiving portion may be any member that sandwiches the end portions 8A and 8B of the coil 2 and is in contact with the portions other than the end portions 8A and 8B of the coil 2 that are in contact with each other.
  • the contact receiving portion includes an elastic member 7.
  • the elastic member 7 may be provided on any one of the contact surfaces of the upper molds 3A and 3B and the lower molds 4A and 4B.
  • FIG. 2 shows a case where the elastic members 7 are provided on the upper molds 3A and 3B. ing.
  • the elastic member 7 is made of a material that uses a material that is elastically deformed and restored when the end of the coil is sandwiched.
  • the elastic member 7 has a hardness smaller than the hardness of the conductive wire of the coil 2 and is sandwiched between the upper molds 3A and 3B and the lower molds 4A and 4B to press the powder 9 when the core 11 is molded. Strong enough to withstand.
  • a resin such as a silicone resin, or a rubber such as urethane, nitrile, chloroprene, ethylene, butyl, fluorine, or low elasticity can be used.
  • Rockwell hardness is about 200 to 50 M scale
  • Shore hardness A is about 95 to 30
  • Vickers hardness is about Hv 50 to 10
  • durometer is type D100 to 20 Set it to about.
  • the upper molds 3A and 3B and the lower molds 4A and 4B are driven and the upper mold 3A is driven.
  • a space is formed between 3B and the lower molds 4A and 4B, and the coil 2 is disposed at a predetermined position as shown in FIG.
  • the coil 2 may be connected in advance to a lead frame (not shown) so as to be easy to handle, and the coil 2 can be arranged at the center of the hole 6B by transferring the lead frame by a transfer unit (not shown). it can. Thereafter, as shown in FIG.
  • the upper molds 3A and 3B and the lower molds 4A and 4B are driven so as to sandwich the coil 2.
  • the upper molds 3A and 3B and the lower molds 4A and 4B are driven so that the vertical position of the coil 2 is not shifted.
  • the elastic member 7 of the contact receiving portion sandwiches the end portions 8A and 8B of the coil 2, and the portions other than the end portions 8A and 8B of the coil 2 are in contact with each other.
  • FIG. 3 shows partially enlarged views (a) and (b) of the manufacturing process of the dust-molded inductor member in the first embodiment.
  • 3A shows an enlarged view of a state in which a space is formed between the upper mold 3A and the lower mold 4A shown in FIG. 2A
  • FIG. 3B The enlarged view of the state which pinched
  • the elastic member 7 is elastic according to the shape of the end 8A of the coil 2. Deform.
  • the portions other than the end 8A of the coil 2 of the elastic member 7 are in contact with the contact surface of the lower mold 4A. Therefore, the elastic member 7 of the upper mold 3A and the lower mold 4A Can abut without gaps. That is, the contact surface of the elastic member 7 can contact the surface of the end 8A of the coil 2 without a gap and can also contact the contact surface of the lower mold 4A without a gap. For this reason, when the end portion 8A of the coil 2 is sandwiched between the upper mold 3A and the lower mold 4A, it is not crushed or cut.
  • the powder 9 supplied from the powder supply unit 10 is pressed by the upper punch 5A and the lower punch 5B, the powder 9 is placed on the end 8A side of the coil 2 sandwiched between the contact receiving portions. 9 can be prevented from leaking and flowing.
  • the elastic member 7 after the core 11 is molded, the upper mold 3A and the lower mold 4A are driven up and down, and a space is formed between the upper mold 3A and the lower mold 4A. It is desirable to form the coil 2 from a material that restores its shape when the end 8A of the coil 2 is separated from the elastic member 7. When the restoration is possible, it is not necessary to replace the elastic member 7, so that the next compacted inductor member can be continuously formed.
  • a groove corresponding to the size and length of the end 8 of the coil 2 is formed on the lower surface of the upper mold 3A and the upper surface of the lower mold 4A.
  • the end 8 of the coil 2 is fitted in the groove so that the lower surface of the upper mold 3A and the lower part of the portion other than the end 8 of the coil 2 are in contact with each other.
  • the contact surfaces of the upper surface of the mold 4A can be in contact with each other.
  • the contact receiving portion in the first embodiment is provided, and the end 8A of the coil 2 is sandwiched between the upper die 3A and the lower die 4A as shown in FIG. 2 (b).
  • the lower punch 5B is raised to an appropriate position corresponding to the size of the core 11, and the powder supply unit 10 is moved to a position on the spiral portion 8C of the coil 2 in the holes 6A and 6B.
  • a predetermined amount of powder 9 is supplied from the powder supply unit 10.
  • the lower punch 5B is provided with a sensor for measuring the supply amount of the powder supplied from the powder supply unit 10 by weight or the like so that the supply is stopped when a predetermined amount of the powder 9 is supplied. May be.
  • the powder supply unit 10 slides on the upper surface of the powder 9 when moving to the side after supplying the powder 9, so that the powder supply unit 10.
  • the powder 9 is scraped off on the lower surface of.
  • the powder 9 is supplied to the holes 6A and 6B so as to cover the entire surface of the spiral portion 8C of the coil 2.
  • the upper punch 5A is moved downward, and the upper punch 5A and the lower punch 5B are simultaneously pressed from above and below as shown in FIG. 2E to compress the powder 9 and the coil 2. .
  • the density of the powder 9 can be made uniform, and the arrangement position of the coil 2 is sealed without moving up and down.
  • the core 11 is formed by this compression. As shown in FIG.
  • the compression process is performed only once. Since the core 11 can be compression molded, the number of steps can be reduced and the core 11 can be easily manufactured. Further, since the end portions 8A and 8B of the coil 2 are sandwiched in the contact receiving portion of the mold part, and the portions other than the end portions 8A and 8B of the coil 2 are in contact with each other, the end portions of the coil 2 When 8 is sandwiched between the upper mold 3A and the lower mold 4A, it is not crushed or cut.
  • the end portions 8A and 8B of the coil 2 sandwiched between the contact receiving portions It is possible to prevent the powder 9 from leaking and flowing.
  • the dust-molded inductor member 12 can be manufactured in a state where the ends 8A and 8B of the coil 2 are extended outside and outside the compression-molded core 11. According to this manufacturing method, there is no possibility that the powder 9 leaks to the end portions 8A and 8B during compression, and the same size as the molds of the upper molds 3A and 3B and the lower molds 4A and 4B.
  • the size of the core 11 can be further reduced, and the size of the dust-molded inductor member 12 can be further reduced.
  • the elastic member 7 when the elastic member 7 is provided, the elastic member is deformed in accordance with the shape of the end portion of the coil, and therefore, the end portion of the coil is not crushed or cut when sandwiched. .
  • a conductive wire of the coil 2 can be used as a thin conductive wire having a circular or square cross section.
  • the upper molds 3A and 3B are provided with the elastic member 7, grooves corresponding to the size and length of the end 8 of the coil 2 are further provided on the upper surfaces of the lower molds 4A and 4B. May be.
  • the arrangement positions of the elastic member 7 and the groove may be any of the upper molds 3A and 3 and the lower molds 4A and 4B. Further, since the end portions 8A and 8B of the conducting wire are extended to the outside of the core 11, the terminal electrode portions 14A and 14B can be easily connected to the end portions 8A and 8B of the conducting wire. The terminal electrode portions 14A and 14B that are securely connected can be configured. For this reason, since the contact failure by end part 8A and 8B and terminal electrode part 14A * 14B can be reduced, a yield can be improved.
  • the dust-molded inductor member 12 and the dust-molded inductor member 13 can be further reduced in size, it is possible to save space when arranged. Moreover, since the dust-molded inductor member 12 and the dust-molded inductor member 13 are closed magnetic circuit types and the spiral portion 8C of the coil 2 is covered with a magnetic material, leakage magnetic flux can be reduced, and other adjacent components can be reduced. The influence of magnetism can be reduced. Since the dust-molded inductor member 13 externally attaches the terminal electrode portion to the outside of the core 11, the diameter of the spiral portion 8 ⁇ / b> C can be increased to the size of the core 11.
  • the dust-molded inductor member 13 has an effect that the inductance can be increased, the heat generation becomes difficult, and the heat dissipation becomes easy.
  • the core 9 is molded simultaneously with the encapsulation of the coil 2, so that the powder 9 that seals the coil 2 becomes the core 11.
  • the powder 9 can pass through the entire surface of the coil 2 without a gap, and the core 11 can be formed. Since there is no gap between the coil 2 and the core 11, a decrease in inductance can be prevented.
  • the density of the powder 9 can be made uniform, the quality can be improved.
  • the dust-molded inductor member 12 and the dust-molded inductor member 13 according to the first embodiment are used for, for example, a power choke used in a power supply circuit, an inductor for impedance matching in a high-frequency circuit, a filter for noise countermeasures, and the like. can do.
  • the dust-molded inductor member 12 and the dust-molded inductor member 13 have a coil of a winding type spiral shape, so that the rated current can be increased, the resistance can be lowered, and the loss can be reduced. Can do.
  • FIGS. 4 to 9 a dust-molded inductor member manufacturing apparatus and a manufacturing method thereof for manufacturing a dust-molded inductor member that is compression-molded by enclosing the coil according to the second embodiment in powder will be described with reference to FIGS. 4 to 9. I will explain.
  • the ends 8A and 8B of the coil 2 are received when the ends 8A and 8B of the coil 2 are sandwiched.
  • the elastic member 7 is provided as a contact receiving portion to prevent the powder from leaking and flowing to the end portion side of the coil.
  • the groove portion and the groove pressing portion are provided with shapes to be fitted, and can be set in various shapes as will be described later. It can be set as a shape which does not produce a gap when the portions 8A and 8B are sandwiched.
  • the groove portion may be formed in a groove shape having a V-shaped cross section
  • the groove pressing portion may be formed in a protruding shape having a V-shaped cross section so as to sandwich the end portion of the coil.
  • the groove part may be a recessed part for receiving the coil end parts 8A and 8B, or the groove holding part. May be in the shape of a convex part sandwiching the end parts 8A and 8B of the coil received in the concave part.
  • the same reference numerals are used to indicate the same configuration as in the first embodiment.
  • the external views (a) to (c) of the dust-molded inductor member shown in FIG. 1 are the same for the dust-molded inductor member produced by the manufacturing process in the second embodiment, and its material and configuration The same applies to unless otherwise specified.
  • FIG. 4 shows manufacturing steps (a) to (f) of the dust-molded inductor member in the second embodiment.
  • 5A and 5B are partially enlarged views of the left side in FIGS. 4A and 4B of the manufacturing process.
  • FIG. 5A shows an enlarged view of a state in which a space is formed between the upper mold 3A and the lower mold 4A shown in FIG. 4A
  • FIG. 5A shows an enlarged view of a state in which a space is formed between the upper mold 3A and the lower mold 4A shown in FIG. 4A
  • a compact molded inductor member manufacturing apparatus 1A according to the second embodiment shown in FIG. 4 is a compact molded inductor member 12 as shown in FIG. 1B or a compact molded inductor member 13 as shown in FIG. And a powder supply as a supply unit for supplying the powder 9 and the upper molds 3A and 3B and the lower molds 4A and 4B in which the shape at the time of compression molding is formed
  • the upper die 3A of the mold part is sandwiched between the end portion 8A of the coil 2 and portions other than the end portion 8A of the coil in contact with each other.
  • An abutment receiving portion that abuts, and the abutment receiving portion receives an end portion 8A of the coil 2 when the end portion 8A of the coil 2 is sandwiched between the opening portions 26A (the abutment receiving portion on the end portion 8B side) having a predetermined width L.
  • an arrangement portion 27A (the contact receiving portion on the end portion 8B side is also not shown) in which the end portion 8A of the coil narrower than the predetermined width L of the opening portion 26A is disposed.
  • the opening portion 26 is an opening portion of the groove portion 21 formed to receive the end portion 8A of the coil 2
  • the arrangement portion 27 is connected to the opening portion 26 and is located on the bottom surface side of the groove portion 21. It is a part to be provided.
  • the width of the opening portion 26 and the arrangement portion 27 is the width in the short direction of the groove portion 21, and the width of the arrangement portion 27 is the width of the bottom surface when the end portion 8 of the coil 2 is disposed, or from the bottom surface to the coil.
  • the height of the groove portions 21A and 21B and the groove pressing portions 22A and 22B can be made larger than the diameter of the end portion 8A of the coil.
  • the upper molds 3A and 3B and the lower molds 4A and 4B are a first mold unit and a second mold unit that are divided and have contact surfaces that contact each other.
  • 3B and lower molds 4A and 4B have substantially the same abutment surface, and lower molds 4A and 4B are provided with groove portions 21A and 21B, respectively, and upper molds 3A and 3B have grooves.
  • the holding parts 22A and 22B are provided.
  • the groove parts 21A and 21B of the lower molds 4A and 4B and the groove pressing parts 22A and 22B of the upper molds 3A and 3B may be integrally formed of the same material as the mold,
  • the members of the groove portions 21A, 21B and the groove pressing portions 22A, 22B are made of a material different from that of the upper molds 3A, 3B and the lower molds 4A, 4B of the mold part, and the upper molds 3A, 3B and You may make it the structure which can be attached to the lower metal mold
  • the members of the groove portions 21A and 21B and the groove pressing portions 22A and 22B may be configured by the elastic member 7 in the first embodiment described above.
  • the groove portions 21A and 21B and the groove pressing portions 22A and 22B may be configured by the elastic member 7.
  • the groove pressing portions 22 ⁇ / b> A and 22 ⁇ / b> B of the upper molds 3 ⁇ / b> A and 3 ⁇ / b> B are configured by the elastic member 7.
  • the elastic member 7 is made of a material that uses a material that is elastically deformed and restored when the end of the coil is sandwiched.
  • the elastic member 7 has a hardness smaller than the hardness of the conductive wire of the coil 2 and is sandwiched between the upper molds 3A and 3B and the lower molds 4A and 4B to press the powder 9 when the core 11 is molded. Strong enough to withstand. With this configuration, the elastic members 7 of the groove pressing portions 22A and 22B are in contact with the surface of the end portion 8A of the coil 2 without gaps, and are in contact with the groove portions 21A and 21B of the lower mold 4A without gaps. Can do. For this reason, when the end portion 8A of the coil 2 is sandwiched between the upper mold 3A and the lower mold 4A, it is not crushed or cut.
  • the powder 9 supplied from the powder supply unit 10 is pressed by the upper punch 5A and the lower punch 5B, the powder 9 is placed on the end 8A side of the coil 2 sandwiched between the contact receiving portions. 9 can be prevented from leaking and flowing.
  • the elastic member 7 after the core 11 is molded, the upper mold 3A and the lower mold 4A are driven up and down, and a space is formed between the upper mold 3A and the lower mold 4A. It is desirable to form the coil 2 from a material that restores its shape when the end 8A of the coil 2 is separated from the elastic member 7. When the restoration is possible, it is not necessary to replace the elastic member 7, so that the next compacted inductor member can be continuously formed.
  • the elastic member 7 of the groove pressing portions 22A and 22B of the upper mold 3A is detachably attachable, it can be replaced with a new one when the elastic member is deteriorated.
  • the powder supply unit 10 is a device for supplying the powder 9 described above, and can be moved in the horizontal direction by a driving means (not shown), and can be moved onto the hole 6A so as to form the core 11.
  • the powder 9 is supplied after the coil 2 is arranged.
  • the powder supply unit 10 is provided with a contact surface whose lower surface is in contact with the upper surfaces of the upper molds 3A and 3B and a supply hole at the center of the contact surface. When moving to the outside, the powder 9 can be scraped off by sliding the upper surface of the powder 9.
  • the upper punch 5A is inserted into the hole 6A from above the upper molds 3A and 3B, and the lower punch 5B is inserted into the hole 6B from below the lower molds 4A and 4B.
  • the upper punch 5A and the lower punch 5B are driven up and down by driving means (not shown), and are pressed from above and below by the upper punch 5A and the lower punch 5B, thereby compressing the powder 9 and the coil 2.
  • the lower surface of the upper punch 5A has the same area as the upper surface of the core 11, and the upper surface of the lower punch 5B has the same area as the lower surface of the core 11.
  • the size of the outer periphery of the spiral portion 8C of the coil 2 is set to be approximately the same as or slightly smaller than the size of the holes 6A and 6B, so that the coil 2 fits into the holes 6A and 6B. can do.
  • the coil 2 having the spiral portion 8 ⁇ / b> C having a size substantially equal to the size of the core 11 can be obtained.
  • the upper molds 3A and 3B and the lower molds 4A and 4B are driven, and the upper mold 3A is driven.
  • a space is formed between 3B and the lower molds 4A and 4B, and the coil 2 is disposed at a predetermined position as shown in FIG.
  • the coil 2 may be connected in advance to a lead frame (not shown) so as to be easy to handle, and the coil 2 can be arranged at the center of the hole 6B by transferring the lead frame by a transfer unit (not shown). it can. Thereafter, as shown in FIG.
  • the upper molds 3A and 3B and the lower molds 4A and 4B are driven so as to sandwich the coil 2.
  • the upper molds 3A and 3B and the lower molds 4A and 4B are driven so that the vertical position of the coil 2 is not shifted.
  • the groove portions 21A and 21B and the groove pressing portions 22A and 22B of the contact receiving portion sandwich the end portions 8A and 8B of the coil 2, and the groove portions 21A and 21B and the end portions 8A and 8B of the coil 2 are in contact with each other.
  • the portions of the contact receiving portions other than the groove pressing portions 22A and 22B contact each other.
  • a groove 21A is formed in the lower mold 4A.
  • the groove 21A has an opening portion 26A having a predetermined width L for receiving the end portion 8A of the coil 2 and an opening portion 26A.
  • an arrangement portion 27A in which end portions 8A and 8B of a coil having a width M narrower than a predetermined width L are arranged.
  • the width M of the arrangement portion 27A is set to a width corresponding to the size of the diameter of the end portion 8A of the coil 2, and the predetermined width L of the opening portion 26A is set to this arrangement portion.
  • the lower mold 4A has a vertical cross section (same cross section as the vertical cross section of the coil end portion 8A when the coil end portion 8A is sandwiched) having a V-shape, which is wider than the width M of 27A.
  • the end portion 8A of the coil 2 can be easily received in the opening portion 26A, and the end portion 8A of the coil 2 is guided to the arrangement portion 27A side narrower than the predetermined width L, and is appropriately fitted in the arrangement portion 27A of the groove portion 21A. You can get stuck.
  • the upper mold 3A is provided with a protruding groove holding portion 22A having a V-shaped cross section, and when fitted into the groove portion 21A, the end portions 8A and 8B of the coil 2 are sandwiched from above.
  • the height (depth) of the groove 21D is preferably deeper than half the height of the core 11 completed as a product.
  • the contact receiving portions other than the groove portion 21A and the groove pressing portion 22A with which the end portion 8A of the coil 2 of the contact receiving portion is in contact can be in contact with each other. As a result, it is possible to manufacture a dust-molded inductor member in which the end portion 8A of the coil 2 is extended to the outside from the compressed powder portion that has been compression-molded, and to further reduce the size of the compressed powder portion. it can.
  • the groove 21A has an opening part 26A having a predetermined width L and an arrangement part 27A having a width M narrower than the predetermined width L, and a groove pressing part 22A corresponding to the shape
  • the cross section V You may make it shapes, such as U shape other than character shape.
  • the end 8A of the coil 2 is arranged in the arrangement portion 27A of the groove 21A.
  • the end portion 8A of the coil 2 can be sandwiched by the groove pressing portion 22A from above.
  • the upper mold 3A comes into contact with the contact surface of the lower mold 4A at portions other than the groove 21A and the groove pressing section 22A with which the end 8A of the coil 2 is in contact.
  • the mold 4A is in contact with no gap, and the end portion 8A of the coil 2 can be sandwiched between the groove portion 21A and the groove pressing portion 22A without any gap.
  • the powder 9 supplied from the powder supply unit 10 is pressurized by the upper punch 5A and the lower punch 5B, the powder 9 is placed on the end 8A side of the coil 2 sandwiched by the contact receiving unit. It is possible to prevent the body 9 from leaking and flowing.
  • the contact receiving portion in the second embodiment as described above is provided, and as shown in FIG. 4B, the end portion 8A of the coil 2 is sandwiched between the upper die 3A and the lower die 4A.
  • the lower punch 5B is raised to an appropriate position corresponding to the size of the core 11, and the powder supply unit 10 is moved to a position on the spiral portion 8C of the coil 2 in the holes 6A and 6B.
  • a predetermined amount of the powder 9 is supplied from the powder supply unit 10.
  • the lower punch 5B is provided with a sensor for measuring the supply amount of the powder supplied from the powder supply unit 10 by weight or the like so that the supply is stopped when a predetermined amount of the powder 9 is supplied. May be.
  • the powder supply unit 10 slides on the upper surface of the powder 9 when moving to the side after supplying the powder 9, so that the powder supply unit 10.
  • the powder 9 is scraped off on the lower surface of.
  • the powder 9 is supplied to the holes 6A and 6B so as to cover the entire surface of the spiral portion 8C of the coil 2.
  • the upper punch 5A is moved downward, and the upper punch 5A and the lower punch 5B are simultaneously pressed from above and below as shown in FIG. 4E to compress the powder 9 and the coil 2. .
  • the density of the powder 9 can be made uniform, and the arrangement position of the coil 2 is sealed without moving up and down.
  • the core 11 is formed by this compression. As shown in FIG.
  • the positions of the contact surfaces (portions other than the groove 21 and the groove pressing portion 22) of the divided upper molds 3A and 3B and the lower molds 4A and 4B are as follows. Since it is possible to set the position of the upper side of the core 11 when it is molded, the powder 9 leaks out at the contact surfaces of the divided upper molds 3A and 3B and lower molds 4A and 4B. It is possible to eliminate the parting line of the dust-molded inductor member generated in step (b).
  • FIGS. 6 to 9 show longitudinal sections of the upper mold 3A and the lower mold 4A.
  • FIG. 6 shows the configuration of the groove portion 21C and the groove pressing portion 22C as another configuration of the second embodiment.
  • the groove portion 21C has such a width that the width M of the arrangement portion 27C where the end portion 8A of the coil 2 is arranged corresponds to the diameter of the end portion 8A of the coil 2, and the shape of the bottom surface of the arrangement portion 27C is The coil 2 has a rounded shape along the lower periphery of the end 8 ⁇ / b> A of the coil 2. Further, the predetermined width L of the opening portion 26C is made wider than the width M of the arrangement portion 27C, and the groove portion 21C is formed in a groove shape having a substantially V-shaped cross section.
  • the portion 8A can be easily received, and the end portion 8A of the coil 2 can be guided to the arrangement portion 27C narrower than the predetermined width L, and can be appropriately fitted into the arrangement portion 27C of the groove portion 21C.
  • the upper mold 3A has a protruding shape with a substantially V-shaped cross section, and the protruding tip portion corresponds to the size of the diameter of the end portion 8A of the coil 2, and the end portion of the coil 2
  • a groove pressing portion 22C having a shape that is cut by a rounded semicircular shape along the periphery of 8A is formed. As shown in FIG.
  • FIG. 7 shows the configuration of the groove 21D and the configuration of the upper mold 3A as another configuration of the second embodiment.
  • FIG. 7 shows an example in which the upper mold 3A is not provided with a groove pressing portion.
  • the groove portion 21D has a width such that the width M of the arrangement portion 27D corresponds to the size of the diameter of the end portion 8A of the coil 2, and the shape of the arrangement portion 27D extends along the periphery of the end portion 8A of the coil 2. It has a rounded shape. Further, by forming a predetermined width L of the opening portion 26D larger than the width M of the arrangement portion 27D and forming a groove having a substantially U-shaped cross section, the end portion 8A of the coil 2 is formed in the opening portion 26D.
  • the end portion 8A of the coil 2 is guided to the arrangement portion 27D narrower than the predetermined width L, and can be appropriately fitted into the arrangement portion 27D of the groove portion 21D.
  • the cross-sectional area of the groove portion of the groove portion 21D is made substantially equal to the cross-sectional area of the coil end portion 8A, and the height (depth) of the groove portion 21D is smaller than the diameter of the coil end portion 8A.
  • it is set to a portion corresponding to the radius of the end portion 8A of the coil.
  • the height of the groove 21D is smaller than the diameter of the coil end 8A by sandwiching the end 8A of the coil 2 disposed in the groove 21D with the upper mold 3A from above.
  • the shape of the groove 21D may be a U-shape other than the U-shaped cross section. According to the example shown in FIG. 7, since the upper mold 3A does not include the groove pressing portion, the mold is hardly deteriorated.
  • FIG. 8 shows the configuration of the groove 21E and the groove pressing portion 22E as another configuration of the second embodiment.
  • the groove portion 21E and the groove pressing portion 22E have a U-shaped uneven shape in the longitudinal section.
  • the opening part of the predetermined width of the groove 21E and the width of the arrangement part are set to the same width, and the width of the protruding part of the groove pressing part 22E is also substantially the same.
  • the width L of the opening part 26E and the width M of the arrangement part 27E are larger than the diameter of the end 8A of the coil 2.
  • the upper mold 3A is formed with a U-shaped protruding groove pressing portion 22E corresponding to the groove portion 21E.
  • the groove pressing portion 22E fits into the groove 21E as shown in FIG. 8B.
  • a gap is created.
  • the end portion 8A of the coil 2 is sandwiched from above, the end portion 8A of the coil 2 is crushed by the groove pressing portion 22E and fitted into the groove portion 21E, and the inside of the groove portion 21E is buried in the end portion 8A of the coil 2.
  • the end portion of the coil 2 8A can be made easier to accept. Further, by sandwiching the groove portion 21E and the groove pressing portion 22E between the concave and convex portions, the position of the end portion 8A of the coil 2 can be fixed and sandwiched, the pressing force is dispersed, and the core 11 in the groove portion 21E and the groove pressing portion 22E is dispersed.
  • the parting line (upper and lower boundaries) can be eliminated.
  • FIG. 9 shows the configuration of the groove portion 21F and the groove pressing portion 22F as another configuration of the second embodiment.
  • FIG. 9 illustrates an example in which the protruding tip portion of the groove pressing portion 22 is configured by the elastic member 7 in the configuration illustrated in FIG. 5.
  • the groove portion 21F has the same shape as the groove portion 21C shown in FIG. 6, and the width M of the arrangement portion 27F where the end portion 8A of the coil 2 is disposed corresponds to the size of the diameter of the end portion 8A of the coil 2. Further, the bottom surface of the arrangement portion 27F is rounded so as to be along the lower periphery of the end portion 8A of the coil 2.
  • the predetermined width L of the opening portion 26F is made wider than the width M of the arrangement portion 27F and the groove portion 21F is formed in a groove shape having a substantially V-shaped cross section, so that the end of the coil 2 is formed in the opening portion 26F.
  • the portion 8A can be easily received, and the end portion 8A of the coil 2 can be guided to the arrangement portion 27F narrower than the predetermined width L, and can be appropriately fitted into the arrangement portion 27F of the groove portion 21F.
  • the upper mold 3A has a protruding shape having a substantially V-shaped cross section, and the protruding tip end portion is constituted by the elastic member 7, and is elastically deformed along the periphery of the end portion 8A of the coil 2.
  • the groove pressing portion 22F is formed.
  • the elastic member 7 of the groove pressing portion 22F contacts the surface of the end portion 8A of the coil 2 without a gap, It is possible to contact the groove portion 21A of the lower mold 4A without a gap. For this reason, when the end portion 8A of the coil 2 is sandwiched between the upper mold 3A and the lower mold 4A, it is not crushed or cut.
  • the protruding tip portion of the groove pressing portion 22F is elastically deformed so that the bottom surface portion of the groove portion 21F conforms to the shape of the end portion 8A of the coil 2.
  • the elastic member 7 of the groove pressing portion 22 is configured to be detachable so that it can be replaced with a new one when the elastic member 7 deteriorates.
  • the compression process is performed only once. Since the core 11 can be compression molded, the number of steps can be reduced and the core 11 can be easily manufactured. Further, in the groove portion 21 of the contact receiving portion of the molding die portion, the end portion 8 of the coil 2 is received from the opening portion 26 having the predetermined width L of the groove portion 21, and the arrangement portion 27 is wider than the predetermined width L of the opening portion 26.
  • the end portion 8 of the coil 2 is easily guided to the arrangement portion 27 of the groove portion 21, and the end portion 8 of the coil 2 is fitted into the arrangement portion 27 of the groove portion 21.
  • the end of the coil can be more appropriately arranged at a certain position as the arrangement site.
  • the groove 21 is formed in the lower molds 4A and 4B of the molding die and the end 8 of the coil 2 is fitted thereto, thereby reducing the contact area with the powder 9 and reducing the pressure applied to the elastic member 7. it can. Further, since the end portion 8 of the coil 2 is arranged at the same arrangement site every time, the elastic member 7 is hardly deteriorated.
  • the groove portion 21 is formed in a V shape, so that it is arranged at the same arrangement portion 27 every time.
  • the product shape of the compacted molded inductor member can be manufactured in the same shape for each product. Even if pressing is performed between the upper and lower molds, the provision of the V-shaped groove 21 disperses the pressing force and eliminates the parting line (upper and lower boundaries) of the core 11 in the groove 21. it can.
  • the position of the contact surfaces of the divided upper molds 3A and 3B and the lower molds 4A and 4B that are in contact with each other can be set to the position of the upper side of the core 11 when molded.
  • the groove portion 21 of the contact receiving portion has a predetermined width L of the opening portion 26.
  • the end part 8 of the coil 2 can be easily received in the opening part 26, and the end part 8 of the coil 2 is arranged in the arrangement part of the width M narrower than the predetermined width L.
  • the dust-molded inductor member in a state in which the end 8 of the coil 2 is extended to the outside from the compression-molded core 11 can be manufactured, and the core 11 can be further downsized.
  • This also makes it possible to manufacture the dust-molded inductor member 12 in the state where the ends 8A and 8B of the coil 2 are extended outside the compression-molded core 11 and outside.
  • this manufacturing method there is no possibility that the powder 9 leaks to the end portions 8A and 8B during compression, and the same size as the molds of the upper molds 3A and 3B and the lower molds 4A and 4B. Therefore, the size of the core 11 can be further reduced, and the size of the dust-molded inductor member 12 can be further reduced.
  • the contact receiving portion has the groove pressing portion 22 that fits into the groove portion 21 and sandwiches the end portion 8 of the coil 2
  • the groove pressing portion 22 fits into the groove portion 21, and the groove pressing portion 22 and the groove portion. 21
  • the end portion 8 of the coil 2 is sandwiched between the end portions of the coil 2, so that the end portion of the coil can be pressed by the groove pressing portion to fix the position of the coil end portion, and the powder 9 supplied from the powder supply portion 10 can be added.
  • the pressure part it is possible to further prevent the powder 9 from leaking and flowing to the end 8 side of the coil sandwiched between the groove pressing part 22 and the groove part 21.
  • the powder 9 does not leak out of the core 11, no burrs are generated due to the leakage of the powder 9, and the end 8 of the coil 2 is It is possible to provide a dust-molded inductor member that is not crushed by the mold 3A and the lower mold 4A but maintains the end 8 of the coil 2 as it is.
  • the contact receiving portion may have a concave portion that receives the end portion 8A of the coil 2 and a convex portion that sandwiches the end portion 8A of the coil 2 that is received in the concave portion.
  • the coil end is received by the concave part and the coil end received by the convex part is sandwiched between the concave part and the convex part of the coil.
  • the portion other than the concave portion and the convex portion with which the end portion of the coil is in contact with each other comes into contact with each other, so that the powder 9 supplied from the powder supply portion 10 is fed by the upper punch 5A and the lower punch 5B.
  • the concave portion of the contact receiving portion can easily receive the end portion of the coil in the concave portion, and the convex portion is the same as the concave portion. It is possible to fit the concave portion and the convex portion appropriately, and the portions other than the concave portion and the convex portion where the end portion 8A of the coil 2 of the contact receiving portion is in contact with each other are in contact with each other. You can leave. Thereby, the dust-molded inductor member in a state in which the end portion 8A of the coil 2 is extended outside the compression-molded core 11 can be manufactured, and the core 11 can be further downsized.
  • the compacted inductor member 12 and the compacted inductor member 13 according to the second embodiment can be further reduced in size, it is possible to save space when arranged.
  • the dust-molded inductor member 12 and the dust-molded inductor member 13 are closed magnetic circuit types and the spiral portion 8C of the coil 2 is covered with a magnetic material, leakage magnetic flux can be reduced, and other adjacent components can be reduced. The influence of magnetism can be reduced. Since the dust-molded inductor member 13 externally attaches the terminal electrode portion to the outside of the core 11, the diameter of the spiral portion 8 ⁇ / b> C can be increased to the size of the core 11.
  • the dust-molded inductor member 13 has an effect that the inductance can be increased, the heat generation becomes difficult, and the heat dissipation becomes easy.
  • the core 9 is molded simultaneously with the encapsulation of the coil 2, so that the powder 9 that seals the coil 2 becomes the core 11.
  • the powder 9 can pass through the entire surface of the coil 2 without a gap, and the core 11 can be formed. Since there is no gap between the coil 2 and the core 11, a decrease in inductance can be prevented.
  • the density of the powder 9 can be made uniform, the quality can be improved.
  • the dust-molded inductor member 12 and the dust-molded inductor member 13 according to the second embodiment are used for, for example, a power choke used in a power supply circuit, an inductor for impedance matching in a high-frequency circuit, a filter for noise countermeasures, and the like. can do.
  • the dust-molded inductor member 12 and the dust-molded inductor member 13 have a coil of a winding type spiral shape, so that the rated current can be increased, the resistance can be lowered, and the loss can be reduced. Can do.
  • a plurality of powder compacted inductor members 12 may be manufactured at the same time by providing a plurality of these in parallel.
  • it can be configured by including a plurality of molding parts including at least the upper molds 3A and 3B and the lower molds 4A and 4B, the powder supply unit 10, the upper punch 5A, and the lower punch 5B.
  • the lead frame is transferred by the transfer unit, so that the coil 2 is in the hole 6B of each molding unit. Can be placed in the center of
  • the structure of the groove part 21 and the groove pressing part 22 in 2nd Example should just be provided with the shape of the part which the edge part 8A of the coil 2 contacts as mentioned above, and the upper metal mold
  • the groove pressing portion 22 may be shaped to fit into the upper mold 3 ⁇ / b> A.
  • the groove portion 21 may be a member having a groove shape and may be shaped to fit into the lower mold 4A.
  • groove portion 21 and the groove pressing portion 22 in the second embodiment may be provided in either the upper or lower mold.
  • the groove part 21 may be provided in the upper molds 3A and 3B, and the groove pressing part 22 may be provided in the lower molds 4A and 4B.
  • the material of the groove portion 21 and the groove pressing portion 22 may be a mold.
  • the elastic member 7 may be used as appropriate in addition to the material.
  • the combination of the groove portion 21 and the groove pressing portion 22 is not limited to the combination shown in each drawing, but may be combined with the groove portion 21 shown in FIGS. 5 to 9 and the groove pressing portion 22 in other drawings. .

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Abstract

Provided are a compressed powder molded inductor member production device capable of being more compact, a production method for a compressed powder molded inductor member, and the compressed powder molded inductor member. The compressed powder molded inductor member production device has at least: upper dies (3A, 3B) and lower dies (4A, 4B) in a molding section having the shape for compression molding; a powder supply section (10) as a supply section for supplying powder (9); and an upper punch (5A) and a lower punch (5B) in a pressurizing section that pressurizes a coil (2) arranged inside the lower dies (4A, 4B) in the molding section and also pressurizes the powder (9) supplied by the powder supply section (10). The upper dies (3A, 3B) in the molding section comprise: groove sections (21A, 21B) comprising an opening site (26A) of a prescribed width that receives end sections (8A, 8B) of the coil (2), when the end sections (8A, 8B) of the coil (2) are inserted into the upper dies, and an arrangement site (27A) having a narrower width than the opening site (26A); and groove pressing sections (22A, 22B) that sandwich the end sections (8A, 8B) of the coil (2) that have been received in the groove sections (21).

Description

圧粉成型インダクタ部材製造装置、圧粉成型インダクタ部材の製造方法および圧粉成型インダクタ部材Powder molding inductor member manufacturing apparatus, powder molding inductor member manufacturing method, and powder molding inductor member
　本発明は、コイルを封入して粉体で圧縮成型する圧粉成型インダクタ部材に係り、特に、その製造装置および製造方法に関する。 The present invention relates to a dust-molded inductor member that encloses a coil and is compression-molded with powder, and more particularly to a manufacturing apparatus and a manufacturing method thereof.
　近年、小型化されたインダクタなどの電子部品として、巻線タイプのコイルを磁性金属粉末の内部に封入し成型した圧粉成型インダクタ部材が用いられている。 Recently, as an electronic component such as a miniaturized inductor, a powder-molded inductor member in which a winding type coil is encapsulated and molded in a magnetic metal powder is used.
　このような圧粉成型インダクタ部材は、巻線タイプのコイルを利用することで、安定したインダクタンスを得られるとともに、大電流を流すことができ、また、磁性金属粉末でコイルの全体を密封することで、漏れ磁束を少なくすることができ、他の部品への磁気による影響を押さえることができる。 Such a dust-molded inductor member can obtain a stable inductance by using a coil of a winding type, can flow a large current, and can seal the entire coil with magnetic metal powder. Thus, the leakage magnetic flux can be reduced, and the influence of magnetism on other components can be suppressed.
　このような圧粉成型インダクタ部材の製造方法としては、成型された下部コア上にコイルを載置した後、このコイルを埋めるように磁性金属粉末を再充填することで下部コアと上部コアとが一体となったコイル封入圧粉成型体を製造する方法がある（例えば、特許文献１参照）。この方法によれば、下部コアおよび上部コアと、コイルとの間に隙間が形成されずに、インダクタンスを大きくすることができる。 As a method of manufacturing such a dust-molded inductor member, a coil is placed on a molded lower core, and then the lower core and the upper core are refilled with magnetic metal powder so as to fill the coil. There is a method of manufacturing an integrated coil-filled green compact (see, for example, Patent Document 1). According to this method, it is possible to increase the inductance without forming a gap between the lower core and the upper core and the coil.
　また、螺旋状のコイルの端子部を下方に屈曲させてから成型型内に載置した後に、コイルの端子部が成型型内の内側面方向へ移動する外力を与えることで、コイルの端子部の外側面を、成型型内の内側面に当接させてから、成型型内に磁性金属粉末を充填し圧縮成型しているものがある（例えば、特許文献２参照）。この方法によれば、磁性金属粉末を充填する際に、成型型内にあるコイルの配置位置がずれることなく、コイルの端子部を表面に露出させて成型することができる。 In addition, after the terminal portion of the spiral coil is bent downward and placed in the mold, the terminal portion of the coil is applied by applying an external force that moves the coil terminal portion toward the inner surface of the mold. In some cases, the outer surface is brought into contact with the inner surface of the mold, and then the mold is filled with magnetic metal powder and compression-molded (see, for example, Patent Document 2). According to this method, when the magnetic metal powder is filled, the coil terminal portion can be exposed on the surface and molded without shifting the arrangement position of the coil in the molding die.
特開２００１－２６７１６０号公報（段落００１４、図１）JP 2001-267160 A (paragraph 0014, FIG. 1) 特開２００５－２９４４６１号公報（段落００５７～００７２、図１７～図２２）JP 2005-294461 A (paragraphs 0057 to 0072, FIGS. 17 to 22)
　しかしながら、特許文献１にあっては、下部コアの成型後にコイルの端部を、上部型枠と下部型枠との間に挟み込んだ後に磁性金属粉末を再充填してから上下のパンチで加圧するため、切断してしまう恐れがあり、また、上部型枠と下部型枠との間にコイルの端部の厚さ分の隙間ができてしまうため、磁性金属粉末の加圧時に、この隙間から磁性金属粉末が漏れてしまうという問題がある。特に、圧粉成型インダクタ部材をより小型化する場合には、この磁性金属粉末の漏れは、より顕著な問題となる。また、特許文献２においては、コイルの端子部を折り曲げて金型の外壁に接触させておくことで、圧縮成型体の表面にコイルの端子部を露出させているものの、コイルの端子部を金型の内部に配置するため、小型化を図るのが難しいという問題がある。 However, in Patent Document 1, after the lower core is molded, the end of the coil is sandwiched between the upper mold frame and the lower mold frame, and then refilled with magnetic metal powder, and then pressed with the upper and lower punches. For this reason, there is a risk of cutting, and a gap corresponding to the thickness of the end of the coil is formed between the upper mold frame and the lower mold frame. There is a problem that magnetic metal powder leaks. In particular, when the compacted inductor member is further downsized, the leakage of the magnetic metal powder becomes a more prominent problem. Moreover, in patent document 2, although the terminal part of a coil is bent and it is made to contact the outer wall of a metal mold | die, the terminal part of a coil is exposed to the surface of a compression molding body, but the terminal part of a coil is made into a metal mold | die. Since it is arranged inside the mold, there is a problem that it is difficult to reduce the size.
　本発明は、このような問題点に着目してなされたもので、より小型化が可能な圧粉成型インダクタ部材製造装置、圧粉成型インダクタ部材の製造方法および圧粉成型インダクタ部材を提供することを目的とする。 The present invention has been made paying attention to such problems, and provides a compact molded inductor member manufacturing apparatus, a compact molded inductor member manufacturing method, and a compact molded inductor member that can be further miniaturized. With the goal.
　前記課題を解決するために、本発明の圧粉成型インダクタ部材製造装置は、
　コイルを粉体内に封入して圧縮成型された圧粉成型インダクタ部材を製造する圧粉成型インダクタ部材製造装置において、
　前記圧縮成型する際の形状が構成された成形型部と、
　前記粉体を供給する供給部と、
　前記成形型部内に配置された前記コイルを、前記供給部より供給された粉体とともに加圧する加圧部と、
　を有し、
　前記成形型部は、前記コイルが配置され、前記供給部により粉体が供給される孔部と、当該孔部の周囲側に設けられ、前記コイルの端部を挟み込み、当該コイルの端部が当接している以外の部分が互いに当接する当接受け部と、を備え、
　前記当接受け部は、前記コイルの端部を受け入れる溝部と、当該溝部に受け入れられた前記コイルの端部を挟み込んで前記溝部に嵌まり込む溝押さえ部とを有することを特徴としている。
　この特徴によれば、成形型部の当接受け部において、溝部でコイルの端部を受け入れて、溝押さえ部で溝部に受け入れられた前記コイルの端部を挟み込んで溝部に嵌まり込むことで、当接受け部の溝部と溝押さえ部とでコイルの端部を挟み込み、当該コイルの端部が当接している溝部と溝押さえ部以外の部分が互いに当接するため、前記供給部より供給された粉体が加圧部により加圧されたときに、当接受け部により挟み込まれているコイルの端部側には、粉体が漏れて流れていくのを防ぐことができ、圧粉成型インダクタ部材の外側に粉体が漏れることによるバリの発生を防ぐことができる。例えば、溝部と溝押さえ部とは、凹部と凸部とにより形成することができる。当接受け部の溝部は、例えば、溝部の幅を、コイルの端部の径の大きさより広くしておくことで、溝部においてコイルの端部を受け入れやすくなり、また、溝部と溝押さえ部とを同じ幅としておくことで適切に溝部と溝押さえ部とで嵌まり込むようにでき、また、当接受け部のコイルの端部が当接している溝部と溝押さえ部以外の部分は互いに当接しておくようにできる。これにより、圧縮成型された圧縮粉体部より外部にコイルの端部が延出された状態の圧粉成型インダクタ部材を製造することができ、圧縮粉体部をより小型化することができる。 In order to solve the above problems, the compacted inductor member manufacturing apparatus of the present invention is
In a dust-molded inductor member manufacturing apparatus that manufactures a dust-molded inductor member that is compression-molded by enclosing a coil in powder,
A mold part in which the shape at the time of compression molding is configured; and
A supply unit for supplying the powder;
A pressurizing unit that pressurizes the coil disposed in the mold part together with the powder supplied from the supply unit;
Have
The mold part is provided on the peripheral side of the hole part in which the coil is arranged and the powder is supplied by the supply part, and the end part of the coil is sandwiched between the end part of the coil. A contact receiving portion where the portions other than the contact are in contact with each other,
The contact receiving portion includes a groove portion that receives an end portion of the coil, and a groove pressing portion that sandwiches the end portion of the coil received in the groove portion and fits into the groove portion.
According to this feature, in the contact receiving part of the mold part, the end of the coil is received by the groove, and the end of the coil received by the groove is sandwiched by the groove holding part and fitted into the groove. The end portion of the coil is sandwiched between the groove portion and the groove holding portion of the contact receiving portion, and the groove portion that is in contact with the end portion of the coil and the portion other than the groove holding portion are in contact with each other. When the pressed powder is pressed by the pressing part, it can be prevented that the powder leaks and flows to the end of the coil sandwiched by the contact receiving part. Generation of burrs due to powder leakage to the outside of the inductor member can be prevented. For example, the groove part and the groove pressing part can be formed by a concave part and a convex part. The groove portion of the abutment receiving portion, for example, makes it easier to receive the end portion of the coil in the groove portion by making the width of the groove portion wider than the diameter of the end portion of the coil. With the same width, the groove portion and the groove holding portion can be properly fitted, and the groove portion where the coil end of the contact receiving portion abuts and the portions other than the groove holding portion are in contact with each other. You can keep in touch. As a result, it is possible to manufacture a dust-molded inductor member in which the end portion of the coil is extended to the outside from the compression-molded powder portion, and the compressed powder portion can be further downsized.
　本発明の圧粉成型インダクタ部材製造装置において、
　前記溝部は、前記コイルの端部を受け入れる所定幅の開口部位と、当該開口部位の前記所定幅より幅狭な前記コイルの端部を配置する配置部位とを備えることを特徴としている。
　この特徴によれば、成形型部の当接受け部の溝部において、溝部の所定幅の開口部位よりコイルの端部を受け入れて、配置部位が、当該開口部位の前記所定幅より幅狭に設定されていることで、溝部の配置部位にコイルの端部が導かれやすくなり、溝部の配置部位にコイルの端部を嵌まり込ませて、より適切にコイルの端部を配置部位である一定の位置に配置させることができる。溝部にコイルの端部をはめこんで配置し、溝押さえ部で挟み込むことで、コイルの端部と粉体との接触面積が減り、また、コイルの端部にかかる圧力を軽減することができる。また、毎回同じ配置部位の位置にコイルの端部が配置されるため、当接受け部の溝部を含む成形型部が劣化しにくくなる。コイルの端部の位置が多少ずれて開口部位より受け入れても、溝部の配置部位の幅が狭く形成されているため、毎回同じ配置部位の位置に配置されることになるため、完成した圧粉成型インダクタ部材の製品の形状を、製品ごとに同じ形状で製造させることができる。また、加圧部で成形型部内に配置されたコイルを供給部より供給された粉体とともに加圧する場合に、開口部位と配置部位との幅が異なる溝部を設けることによって、加圧が分散されることになる。また、当接受け部は、コイルの端部を挟み込み、当該コイルの端部が当接している部分以外の部分が互いに当接するため、前記供給部より供給された粉体が加圧部により加圧されたときに、当接受け部により挟み込まれているコイルの端部側には、粉体が漏れて流れていくのを防ぐことができ、圧粉成型インダクタ部材の外側に粉体が漏れることによるバリの発生を防ぐことができる。当接受け部の溝部は、例えば、配置部位の幅を、コイルの端部の径の大きさに相当するような幅とする場合には、開口部位の所定幅をこの配置部位の幅より広くしておくことで、開口部位においてはコイルの端部を受け入れやすくなり、また、所定幅より幅狭な配置部位にコイルの端部が導かれて適切に溝部に嵌まり込むようにでき、また、当接受け部のコイルの端部が当接している部分以外の部分は互いに当接しておくようにできる。これにより、圧縮成型された圧縮粉体部より外部にコイルの端部が延出された状態の圧粉成型インダクタ部材を製造することができ、圧縮粉体部をより小型化することができる。 In the powder molded inductor member manufacturing apparatus of the present invention,
The groove includes an opening portion having a predetermined width for receiving an end portion of the coil and an arrangement portion for disposing an end portion of the coil that is narrower than the predetermined width of the opening portion.
According to this feature, in the groove part of the contact receiving part of the mold part, the end of the coil is received from the opening part having a predetermined width of the groove part, and the arrangement part is set to be narrower than the predetermined width of the opening part. As a result, the end of the coil is easily guided to the arrangement part of the groove, the end of the coil is fitted into the arrangement part of the groove, and the end of the coil is more appropriately the arrangement part. It can be arranged at the position. By placing the end of the coil in the groove and sandwiching it with the groove pressing part, the contact area between the end of the coil and the powder can be reduced, and the pressure applied to the end of the coil can be reduced. . In addition, since the end of the coil is arranged at the same arrangement site every time, the mold part including the groove part of the contact receiving part is hardly deteriorated. Even if the position of the end portion of the coil is slightly shifted and received from the opening portion, the width of the arrangement portion of the groove portion is narrow, so that it will be arranged at the same arrangement portion every time. The product shape of the molded inductor member can be manufactured in the same shape for each product. Further, when the coil arranged in the mold part is pressed together with the powder supplied from the supply unit by the pressurizing unit, the pressurization is dispersed by providing a groove part having a different width between the opening part and the arrangement part. Will be. The contact receiving portion sandwiches the end portion of the coil, and the portions other than the portion where the end portion of the coil is in contact with each other contact each other, so that the powder supplied from the supply portion is added by the pressurizing portion. When pressed, it is possible to prevent the powder from leaking and flowing to the end portion side of the coil sandwiched by the contact receiving portion, and the powder leaks to the outside of the compacted inductor member. It is possible to prevent the occurrence of burrs. For example, when the width of the arrangement part is set to a width corresponding to the diameter of the end of the coil, the predetermined width of the opening part is wider than the width of the arrangement part. This makes it easier to accept the end of the coil in the opening part, and the end of the coil is guided to the arrangement part narrower than the predetermined width so as to fit into the groove part properly. The portions other than the portion where the end of the coil of the contact receiving portion is in contact can be in contact with each other. As a result, it is possible to manufacture a dust-molded inductor member in which the end portion of the coil is extended to the outside from the compression-molded powder portion, and the compressed powder portion can be further downsized.
　本発明の圧粉成型インダクタ部材製造装置において、
　前記溝部と前記溝押さえ部とのうち少なくとも一方は、前記コイルの端部の当接面側に、弾性変形する弾性部材を備えることを特徴としている。
　この特徴によれば、溝部と溝押さえ部とのうち少なくとも一方は、コイルの端部を挟み込んだ際の当接面側に弾性変形する弾性部材を備えているため、弾性部材がコイルの端部の形状に合わせて変形するため、挟み込まれたときにコイルの端部が潰されることや切断されることがなく、供給部より供給された粉体が加圧部により加圧されたときに、当接受け部により挟み込まれているコイルの端部側には、粉体が漏れて流れていくのを防ぐことができ、圧粉成型インダクタ部材の外側に粉体が漏れることによるバリの発生を防ぐことができる。これにより、圧縮成型された圧縮粉体部より外部にコイルの端部が延出された状態の圧粉成型インダクタ部材を製造することができ、圧縮粉体部をより小型化することができる。 In the powder molded inductor member manufacturing apparatus of the present invention,
At least one of the groove part and the groove pressing part includes an elastic member that is elastically deformed on the contact surface side of the end of the coil.
According to this feature, at least one of the groove portion and the groove pressing portion includes the elastic member that elastically deforms on the contact surface side when the end portion of the coil is sandwiched, so that the elastic member is the end portion of the coil. Therefore, when the powder supplied from the supply unit is pressurized by the pressurizing unit, the end of the coil is not crushed or cut when sandwiched. It is possible to prevent the powder from leaking and flowing to the end side of the coil sandwiched between the contact receiving portions, and to generate burrs due to the powder leaking to the outside of the compacted inductor member. Can be prevented. As a result, it is possible to manufacture a dust-molded inductor member in which the end portion of the coil is extended to the outside from the compression-molded powder portion, and the compressed powder portion can be further downsized.
　本発明の圧粉成型インダクタ部材製造装置において、
　前記成形型部は、分割されて、互いに当接する当接面を備える第一成形型手段および第二成形型手段を有し、
　前記第一成形型手段は、前記溝部と前記溝押さえ部とのうち一方を備え、
　前記第二成形型手段は、前記溝部と前記溝押さえ部とのうち他方を備えることを特徴としている。
　この特徴によれば、分割されている第一成形型手段と第二成形型手段とで、溝部または溝押さえ部を備えることで、一方の溝部でコイルの端部を受け入れて、他方の溝押さえ部で溝部に受け入れられた前記コイルの端部を挟み込んで溝部に嵌まり込むことができる。このため、分割されている第一成形型手段と第二成形型手段との互いに当接する当接面（溝部と前記溝押さえ部以外の部分）の位置を、例えば、成形された際の圧粉成型インダクタ部材の上辺以上（または底辺以下）の位置に設定することが可能となるので、分割されている第一成形型手段と第二成形型手段との互いに当接する当接面において粉体が漏れ出ることで生じる圧粉成型インダクタ部材のパーティングライン（分割されている第一成形型手段と第二成形型手段との境目）を無くすことが可能となる。 In the powder molded inductor member manufacturing apparatus of the present invention,
The mold part has first mold means and second mold means that are divided and have contact surfaces that contact each other,
The first mold means comprises one of the groove part and the groove pressing part,
The second mold means includes the other of the groove part and the groove pressing part.
According to this feature, the first mold means and the second mold means which are divided are provided with a groove portion or a groove pressing portion, so that the end of the coil is received by one groove portion and the other groove pressing portion is received. The end portion of the coil received in the groove portion can be sandwiched and fitted into the groove portion. For this reason, the position of the contact surfaces (parts other than the groove part and the groove pressing part) of the first mold part means and the second mold part part that are separated from each other is, for example, compacted when formed. Since it can be set at a position above the top side (or below the bottom side) of the molded inductor member, the powder is formed on the abutting surfaces of the divided first mold means and second mold means. It becomes possible to eliminate the parting line (the boundary between the divided first molding die means and the second molding die means) of the dust molding inductor member caused by leakage.
　本発明の圧粉成型インダクタ部材製造方法において、
　コイルを粉体内に封入して圧縮成型された圧粉成型インダクタ部材を製造する圧粉成型インダクタ部材製造方法において、
　コイルを粉体内に封入して圧縮成型された圧粉成型インダクタ部材を製造する圧粉成型インダクタ部材製造方法において、
　前記圧縮成型する際の形状が構成された成形型部の孔部に、螺旋状に形成されたコイルを配置し、
　当該コイルの端部を、前記成形型部の前記孔部の周囲側に設けられる溝部より受け入れて配置するとともに、前記溝部に嵌まり込む溝押さえ部により当該コイルの端部を挟み込み、
　前記成形型部の前記孔部に前記粉体を供給し、
　前記成形型部の前記孔部に配置された前記コイルを、供給された粉体とともに加圧することを特徴としている。
　この特徴によれば、溝押さえ部が溝部に嵌まり込み、溝押さえ部と溝部とでコイルの端部を挟み込むため、供給部より供給された粉体が加圧部により加圧されたときに、溝押さえ部と溝部とにより挟み込まれているコイルの端部側には、粉体が漏れて流れていくのをより防ぐことができ、圧粉成型インダクタ部材の外側に粉体が漏れることによるバリの発生を防ぐことができる。 In the method of manufacturing a dust-molded inductor member of the present invention,
In a dust-molded inductor member manufacturing method for manufacturing a dust-molded inductor member that is compression-molded by enclosing a coil in powder,
In a dust-molded inductor member manufacturing method for manufacturing a dust-molded inductor member that is compression-molded by enclosing a coil in powder,
A coil formed in a spiral shape is disposed in the hole portion of the mold part in which the shape at the time of compression molding is configured,
The end of the coil is received and arranged from the groove provided on the peripheral side of the hole of the mold part, and the end of the coil is sandwiched by the groove pressing part fitted into the groove,
Supplying the powder to the hole of the mold part,
The coil arranged in the hole of the mold part is pressed together with the supplied powder.
According to this feature, the groove pressing portion is fitted into the groove portion, and the end portion of the coil is sandwiched between the groove pressing portion and the groove portion. Therefore, when the powder supplied from the supply portion is pressurized by the pressing portion. In the end side of the coil sandwiched between the groove pressing part and the groove part, it is possible to further prevent the powder from leaking and flowing, and by the powder leaking to the outside of the compacting inductor member Generation of burrs can be prevented.
　本発明の圧粉成型インダクタ部材製造方法において、
　前記コイルの端部を、前記溝部に受け入れる際に、当該溝部の所定幅の開口部位より受け入れるとともに、当該開口部位の前記所定幅より幅狭な溝部の配置部位に配置し、当該コイルの端部を前記溝押さえ部により挟み込むことを特徴としている。
　この特徴によれば、成形型部の孔部の周囲側に設けられる溝部において、溝部の所定幅の開口部位よりコイルの端部を受け入れて、配置部位が、当該開口部位の前記所定幅より幅狭に設定されていることで、溝部の配置部位にコイルの端部が導かれやすくなり、溝部の配置部位にコイルの端部を嵌まり込ませて、より適切にコイルの端部を配置部位である一定の位置に配置させ、溝押さえ部で挟み込んだ状態で、コイルの端部を挟み込むことができ、その後、孔部に粉体を供給し、成形型部の孔部に配置されたコイルを、供給された粉体とともに加圧することができる。溝部にコイルの端部をはめこんで配置することで、コイルの端部と粉体との接触面積が減り、また、コイルの端部にかかる圧力を軽減することができる。また、毎回同じ配置部位の位置にコイルの端部が配置されるため、当接受け部の溝部を含む成形型部が劣化しにくくなる。コイルの端部の位置が多少ずれて開口部位より受け入れても、溝部の配置部位の幅が狭く形成されているため、毎回同じ配置部位の位置に配置されることになるため、完成した圧粉成型インダクタ部材の製品の形状を、製品ごとに同じ形状で製造させることができる。また、加圧部で成形型部内に配置されたコイルを供給部より供給された粉体とともに加圧する場合に、開口部位と配置部位との幅が異なる溝部を設けることによって、加圧が分散されることになる。供給部より供給された粉体が加圧部により加圧されたときに、挟み込まれているコイルの端部側には、粉体が漏れて流れていくのを防ぐことができ、圧粉成型インダクタ部材の外側に粉体が漏れることによるバリの発生を防ぐことができる。これにより、圧縮成型された圧縮粉体部より外部にコイルの端部が延出された状態の圧粉成型インダクタ部材を製造することができ、圧縮粉体部をより小型化することができる。 In the method of manufacturing a dust-molded inductor member of the present invention,
When the end of the coil is received in the groove, the coil is received from an opening portion having a predetermined width of the groove, and is disposed in a portion where the groove is narrower than the predetermined width. Is sandwiched between the groove pressing portions.
According to this feature, in the groove portion provided on the peripheral side of the hole portion of the mold portion, the end portion of the coil is received from the opening portion having a predetermined width of the groove portion, and the arrangement portion is wider than the predetermined width of the opening portion. By being set narrowly, the end of the coil is easily guided to the arrangement part of the groove, and the end of the coil is more appropriately arranged by fitting the end of the coil into the arrangement part of the groove. The coil is placed in a certain position and can be sandwiched by the groove pressing part, and then the coil end part can be sandwiched. Thereafter, the powder is supplied to the hole part, and the coil is arranged in the hole part of the mold part. Can be pressurized together with the supplied powder. By placing the end of the coil in the groove, the contact area between the end of the coil and the powder can be reduced, and the pressure applied to the end of the coil can be reduced. In addition, since the end of the coil is arranged at the same arrangement site every time, the mold part including the groove part of the contact receiving part is hardly deteriorated. Even if the position of the end portion of the coil is slightly shifted and received from the opening portion, the width of the arrangement portion of the groove portion is narrow, so that it will be arranged at the same arrangement portion every time. The product shape of the molded inductor member can be manufactured in the same shape for each product. Further, when the coil arranged in the mold part is pressed together with the powder supplied from the supply unit by the pressurizing unit, the pressurization is dispersed by providing a groove part having a different width between the opening part and the arrangement part. Will be. When the powder supplied from the supply unit is pressurized by the pressurizing unit, the powder can be prevented from leaking and flowing to the end side of the sandwiched coil. Generation of burrs due to powder leakage to the outside of the inductor member can be prevented. As a result, it is possible to manufacture a dust-molded inductor member in which the end portion of the coil is extended to the outside from the compression-molded powder portion, and the compressed powder portion can be further downsized.
　本発明の圧粉成型インダクタ部材製造方法において、
　前記溝部と前記溝押さえ部とのうち少なくともいずれか一方の前記コイルの端部の当接面側に備える弾性変形する弾性部材により前記コイルの端部を挟み込むことを特徴としている。
　この特徴によれば、溝部と溝押さえ部とのうち少なくとも一方の当接面側に弾性変形する弾性部材を備えているため、コイルの端部を挟み込んだ際、弾性部材がコイルの端部の形状に合わせて変形するため、挟み込まれたときにコイルの端部が潰されることや切断されることがなく、供給部より供給された粉体が加圧部により加圧されたときに、当接受け部により挟み込まれているコイルの端部側には、粉体が漏れて流れていくのを防ぐことができ、圧粉成型インダクタ部材の外側に粉体が漏れることによるバリの発生を防ぐことができる。これにより、圧縮成型された圧縮粉体部より外部にコイルの端部が延出された状態の圧粉成型インダクタ部材を製造することができ、圧縮粉体部をより小型化することができる。 In the method of manufacturing a dust-molded inductor member of the present invention,
The end of the coil is sandwiched between elastic members that are elastically deformed and provided on the contact surface side of the end of the coil of at least one of the groove and the groove pressing portion.
According to this feature, since the elastic member that elastically deforms at least one of the groove portion and the groove pressing portion is provided, when the end portion of the coil is sandwiched, the elastic member becomes the end portion of the coil. Because it deforms according to the shape, the end of the coil is not crushed or cut when sandwiched, and when the powder supplied from the supply unit is pressurized by the pressurization unit, Powder can be prevented from leaking and flowing to the end side of the coil sandwiched between the contact parts, and burrs can be prevented from occurring due to the powder leaking outside of the compacted inductor member. be able to. As a result, it is possible to manufacture a dust-molded inductor member in which the end portion of the coil is extended to the outside from the compression-molded powder portion, and the compressed powder portion can be further downsized.
　本発明は、上述した圧粉成型インダクタ部材の製造方法により製造された圧粉成型インダクタ部材を特徴としている。
　この特徴によれば、上述した圧粉成型インダクタ部材の製造方法により製造された圧粉成型インダクタ部材は、コイルの端部側には、粉体が漏れて流れていくことを防ぐことができるので、圧粉成型インダクタ部材の外側に粉体が漏れることによるバリの発生を防ぐことができる。 The present invention is characterized by a powder-molded inductor member manufactured by the above-described method for manufacturing a powder-molded inductor member.
According to this feature, the dust-molded inductor member produced by the above-described method for producing a dust-molded inductor member can prevent the powder from leaking and flowing to the end side of the coil. Further, it is possible to prevent the generation of burrs due to the powder leaking to the outside of the compacted inductor member.
　本発明の圧粉成型インダクタ部材において、
　コイルを粉体内に封入して圧縮成型された圧粉成型インダクタ部材において、
　前記圧縮成型された圧縮粉体部と、前記圧縮粉体部に封入された前記コイルとを有し、
　前記コイルは、導線を螺旋状に形成した螺旋部と、前記螺旋部から延びる導線の端部とを備え、
　前記導線の前記螺旋部は、前記圧縮粉体部に封入され、
　前記圧縮粉体部の外側には、パーティングラインを備えておらず、
　前記導線の前記端部は、前記圧縮成型により押し潰されていないことを特徴としている。
　この特徴によれば、圧縮粉体部の外側にはパーティングラインを備えておらず、また、導線の前記端部は、前記圧縮成型により押し潰されてなく、コイルの端部をそのまま維持した状態の圧粉成型インダクタ部材を提供できる。また、粉体が漏れることによるバリの発生も抑えた圧粉成型インダクタ部材としてもよい。 In the dust-molded inductor member of the present invention,
In a compacted inductor member that is compression molded by enclosing a coil in powder,
The compressed powder part that is compression-molded, and the coil enclosed in the compressed powder part,
The coil includes a spiral portion in which a conducting wire is formed in a spiral shape, and an end portion of the conducting wire extending from the spiral portion,
The spiral portion of the conducting wire is enclosed in the compressed powder portion,
The outside of the compressed powder part does not have a parting line,
The end portion of the conducting wire is not crushed by the compression molding.
According to this feature, there is no parting line outside the compressed powder part, and the end of the conductor is not crushed by the compression molding, and the end of the coil is maintained as it is. A compacted inductor member in a state can be provided. Moreover, it is good also as a powder-molded inductor member which suppressed generation | occurrence | production of the burr | flash by powder leaking.
　本発明の圧粉成型インダクタ部材製造装置は、
　コイルを粉体内に封入して圧縮成型された圧粉成型インダクタ部材を製造する圧粉成型インダクタ部材製造装置において、
　前記圧縮成型する際の形状が構成された成形型部と、
　前記粉体を供給する供給部と、
　前記成形型部内に配置された前記コイルを、前記供給部より供給された粉体とともに加圧する加圧部と、
　を有し、
　前記成形型部は、前記コイルが配置され、前記供給部により粉体が供給される孔部と、当該孔部の周囲側に設けられ、前記コイルの端部を挟み込み、当該コイルの端部が当接している以外の部分が互いに当接する当接受け部と、を備え、
　前記当接受け部は、前記コイルの端部を挟み込むときに、前記コイルの端部を受け入れる所定幅の開口部位と、当該開口部位の前記所定幅より幅狭な前記コイルの端部を配置する配置部位とを備える溝部を有することを特徴としている。
　この特徴によれば、成形型部の孔部の周囲側に設けられる溝部において、溝部の所定幅の開口部位よりコイルの端部を受け入れて、配置部位が、当該開口部位の前記所定幅より幅狭に設定されていることで、溝部の配置部位にコイルの端部が導かれやすくなり、溝部の配置部位にコイルの端部を嵌まり込ませて、より適切にコイルの端部を配置部位である一定の位置に配置させ、溝押さえ部で挟み込んだ状態で、コイルの端部を挟み込むことができ、その後、孔部に粉体を供給し、成形型部の孔部に配置されたコイルを、供給された粉体とともに加圧することができる。溝部にコイルの端部をはめこんで配置することで、コイルの端部と粉体との接触面積が減り、また、コイルの端部にかかる圧力を軽減することができる。また、毎回同じ配置部位の位置にコイルの端部が配置されるため、当接受け部の溝部を含む成形型部が劣化しにくくなる。コイルの端部の位置が多少ずれて開口部位より受け入れても、溝部の配置部位の幅が狭く形成されているため、毎回同じ配置部位の位置に配置されることになるため、完成した圧粉成型インダクタ部材の製品の形状を、製品ごとに同じ形状で製造させることができる。また、加圧部で成形型部内に配置されたコイルを供給部より供給された粉体とともに加圧する場合に、開口部位と配置部位との幅が異なる溝部を設けることによって、加圧が分散されることになる。供給部より供給された粉体が加圧部により加圧されたときに、挟み込まれているコイルの端部側には、粉体が漏れて流れていくのを防ぐことができ、圧粉成型インダクタ部材の外側に粉体が漏れることによるバリの発生を防ぐことができる。これにより、圧縮成型された圧縮粉体部より外部にコイルの端部が延出された状態の圧粉成型インダクタ部材を製造することができ、圧縮粉体部をより小型化することができる。 The dust-molded inductor member manufacturing apparatus of the present invention is
In a dust-molded inductor member manufacturing apparatus that manufactures a dust-molded inductor member that is compression-molded by enclosing a coil in powder,
A mold part in which the shape at the time of compression molding is configured; and
A supply unit for supplying the powder;
A pressurizing unit that pressurizes the coil disposed in the mold part together with the powder supplied from the supply unit;
Have
The mold part is provided on the peripheral side of the hole part in which the coil is arranged and the powder is supplied by the supply part, and the end part of the coil is sandwiched between the end part of the coil. A contact receiving portion where the portions other than the contact are in contact with each other,
The contact receiving portion arranges an opening portion having a predetermined width for receiving the end portion of the coil when the end portion of the coil is sandwiched, and an end portion of the coil narrower than the predetermined width of the opening portion. It has the groove part provided with an arrangement | positioning site | part, It is characterized by the above-mentioned.
According to this feature, in the groove portion provided on the peripheral side of the hole portion of the mold portion, the end portion of the coil is received from the opening portion having a predetermined width of the groove portion, and the arrangement portion is wider than the predetermined width of the opening portion. By being set narrowly, the end of the coil is easily guided to the arrangement part of the groove, and the end of the coil is more appropriately arranged by fitting the end of the coil into the arrangement part of the groove. The coil is placed in a certain position and can be sandwiched by the groove pressing part, and the end of the coil can be sandwiched, and then the powder is supplied to the hole and the coil placed in the hole of the mold part Can be pressurized together with the supplied powder. By placing the end of the coil in the groove, the contact area between the end of the coil and the powder can be reduced, and the pressure applied to the end of the coil can be reduced. In addition, since the end of the coil is arranged at the same arrangement site every time, the mold part including the groove part of the contact receiving part is hardly deteriorated. Even if the position of the end portion of the coil is slightly shifted and received from the opening portion, the width of the arrangement portion of the groove portion is narrow, so that it will be arranged at the same arrangement portion every time. The product shape of the molded inductor member can be manufactured in the same shape for each product. Further, when the coil arranged in the mold part is pressed together with the powder supplied from the supply unit by the pressurizing unit, the pressurization is dispersed by providing a groove part having a different width between the opening part and the arrangement part. Will be. When the powder supplied from the supply unit is pressurized by the pressurizing unit, the powder can be prevented from leaking and flowing to the end side of the sandwiched coil. Generation of burrs due to powder leakage to the outside of the inductor member can be prevented. As a result, it is possible to manufacture a dust-molded inductor member in which the end portion of the coil is extended to the outside from the compression-molded powder portion, and the compressed powder portion can be further downsized.
第１実施例、第２実施例における圧粉成型インダクタ部材の製造工程における外観図（ａ）～（ｃ）である。FIG. 7 is an external view (a) to (c) in the manufacturing process of the dust-molded inductor member in the first embodiment and the second embodiment. 第１実施例における圧粉成型インダクタ部材の製造工程を示す説明図（ａ）～（ｆ）である。It is explanatory drawing (a)-(f) which shows the manufacturing process of the powder-molding inductor member in 1st Example. 第１実施例における圧粉成型インダクタ部材の製造工程の一部拡大図（ａ）および（ｂ）である。It is a partially expanded view (a) and (b) of the manufacturing process of the powder-molded inductor member in the first embodiment. 第２実施例における圧粉成型インダクタ部材の製造工程を示す説明図（ａ）～（ｆ）である。It is explanatory drawing (a)-(f) which shows the manufacturing process of the powder-molded inductor member in 2nd Example. 第２実施例における圧粉成型インダクタ部材の製造工程の一部拡大図（ａ）および（ｂ）である。It is the elements on larger scale (a) and (b) of the manufacturing process of the powder-molded inductor member in 2nd Example. 第２実施例の他の構成における圧粉成型インダクタ部材の製造工程の一部拡大図（ａ）および（ｂ）である。It is the elements on larger scale (a) and (b) of the manufacturing process of the powder-molding inductor member in other composition of the 2nd example. 第２実施例の他の構成における圧粉成型インダクタ部材の製造工程の一部拡大図（ａ）および（ｂ）である。It is the elements on larger scale (a) and (b) of the manufacturing process of the powder-molding inductor member in other composition of the 2nd example. 第２実施例の他の構成における圧粉成型インダクタ部材の製造工程の一部拡大図（ａ）および（ｂ）である。It is the elements on larger scale (a) and (b) of the manufacturing process of the powder-molding inductor member in other composition of the 2nd example. 第２実施例の他の構成における圧粉成型インダクタ部材の製造工程の一部拡大図（ａ）および（ｂ）である。It is the elements on larger scale (a) and (b) of the manufacturing process of the powder-molding inductor member in other composition of the 2nd example.
　本発明に係る圧粉成型インダクタ部材製造装置、圧粉成型インダクタ部材の製造方法および圧粉成型インダクタ部材を実施するための形態を実施例に基づいて以下に説明する。 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A powder molded inductor member manufacturing apparatus, a powder molded inductor member manufacturing method, and a mode for carrying out a powder molded inductor member according to the present invention will be described below based on examples.
第１実施例First embodiment
　第１実施例に係るコイルを粉体内に封入して圧縮成型された圧粉成型インダクタ部材を製造する圧粉成型インダクタ部材製造装置とその製造方法につき、図１から図３を参照して説明する。 A dust-molded inductor member manufacturing apparatus and method for manufacturing a dust-molded inductor member for compressing and molding a coil according to a first embodiment in powder will be described with reference to FIGS. .
　図１は、第１実施例における圧粉成型インダクタ部材の製造工程における外観図（ａ）～（ｃ）を示している。図１（ａ）は、圧粉成型インダクタ部材の内部に封入されるコイル２を示し、図１（ｂ）は、コイル２を内蔵し、圧粉成型された圧縮粉体部であるコア１１を備える圧粉成型インダクタ部材１２を示し、図１（ｃ）は、圧粉成型されたコア１１の外側に端子電極部１２Ａ・１２Ｂを備えた圧粉成型インダクタ部材１３を示している。 FIG. 1 shows external views (a) to (c) in the manufacturing process of the dust-molded inductor member in the first embodiment. FIG. 1 (a) shows a coil 2 enclosed inside a dust-molded inductor member, and FIG. 1 (b) shows a core 11 that is a compacted powder portion that incorporates the coil 2 and is compacted. FIG. 1C shows a dust-molded inductor member 13 provided with terminal electrode portions 12A and 12B on the outside of the dust-molded core 11. FIG.
　図１（ａ）において、コイル２は、導線を螺旋状に形成した螺旋部８Ｃと、螺旋部８Ｃから延びる導線の端部８Ａ・８Ｂとを備えている。螺旋部８Ｃの巻き数や大きさ、導線の線幅や断面積は、要求されるインダクタンスに応じて定められる。コイルの導線の表面は、樹脂や無機絶縁材などにより絶縁被膜されている。導線の断面は、円状または方形としておくことができ、導線の断面における縦長と横長とがほぼ同じぐらいの細線の銅やアルミなどの導電率の高い線材を利用することができ、本第１実施例においては、扁平断面でなくてもよい。上述した先行技術文献１においては、本第１実施例に示す当接受け部を備えていないため、導線を扁平断面にしても粉体が端部側に漏れて流れていく可能性があったが、本第１実施例によれば、このような導線の形状の制約はなくなる。 1 (a), the coil 2 includes a spiral portion 8C in which a conductive wire is formed in a spiral shape, and conductive wire ends 8A and 8B extending from the spiral portion 8C. The number and size of turns of the spiral portion 8C, the line width and cross-sectional area of the conducting wire are determined according to the required inductance. The surface of the coil conducting wire is covered with an insulating coating such as a resin or an inorganic insulating material. The cross section of the conducting wire can be circular or rectangular, and a thin wire with high conductivity such as copper or aluminum whose longitudinal and horizontal lengths in the conducting wire cross section are approximately the same can be used. In the embodiment, it may not be a flat cross section. In the above-mentioned prior art document 1, since the contact receiving portion shown in the first embodiment is not provided, there is a possibility that the powder leaks and flows to the end side even if the conducting wire has a flat cross section. However, according to the first embodiment, such a restriction on the shape of the conducting wire is eliminated.
　図１（ｂ）に示す圧粉成型インダクタ部材１２は、後述する製造方法によりコイル２を内蔵させて粉体を圧縮することで製造され、圧粉成型された圧縮粉体部のコア１１の両外側から導線の端部８Ａ・８Ｂを延出させている。本第１実施例においては、コア１１の端部８Ａ・８Ｂが延出される部分の圧縮粉体部分は、粉体により隙間なく圧縮した状態を維持できる。また、外側に延出された端部８Ａ・８Ｂ部分には、圧縮する際に粉体が漏れ出ることがないため、粉体が付着しないように構成できる。粉体としては、従来と同様の磁性金属粉末、絶縁材、潤滑剤を混合したもの利用することができ、用途に応じて粉末粒子の大きさや配合する種類を適宜設定することができる。例えば、磁性金属粉末としては、鉄などの軟磁性を示す遷移金属、ケイ化鉄、パーマロイ（Ｆｅ－Ｎｉ合金）、スーパーマロイ（Ｆｅ－Ｎｉ－Ｍｏ）、センダスト、窒化鉄、鉄アルミ合金、鉄コバルト合金、リン鉄等から、１種または２種以上を選択して用いることができる。これらの金属や合金を、水アトマイズ法、油アトマイズ法、ガスアトマイズ法、電解法、回転円板法、双ロール法、回転電極法などの機械的な粉砕や熱分解による方法によって適当な粒径を備える粉末にする。絶縁材は、コア１１を形成するためのバインダーとしての機能し、また、磁性金属粉末間の絶縁を図る機能を備えている。絶縁材としては、例えば、水ガラス、フェノール樹脂、アクリル樹脂、エポキシ樹脂、シリコン樹脂、ポリアミド樹脂、ポリイミド樹脂などの有機材料を使用でき、また、熱硬化性樹脂を使用してもよい。潤滑剤は、粉体の潤滑性を向上させる機能を備え、コア１１の充填密度を向上させる機能を備える。潤滑剤としては、例えば、ステアリン酸亜鉛、ステアリン酸アルミニウム、ステアリン酸マグネシウム、ステアリン酸カルシウム、ステアリン酸ストロンチウム、ステアリン酸バリウム、Ｃａ、Ｚｎ、Ａｌ、Ｍｇなどから少なくとも１種を使用できる。これらの磁性金属粉末、絶縁材、潤滑剤を、用途に応じた適切な比率で混合させて図２における粉体９として利用する。本第１実施例においては、コア１１の形状は、直方体の形状を示しているが立方体や円柱状の形状であってもよい。また、コア１１は、平面視において方形で縦と横の長さが同一である場合を示しているが、長方形状であってもよいし円状であってもよい。また、本第１実施例における製造方法によるコア１１は、２ｍｍ角以下とすることができ、より小型化を図ることができる圧粉成型インダクタ部材１２を形成できる。 The powder-molded inductor member 12 shown in FIG. 1B is manufactured by compressing powder by incorporating a coil 2 by a manufacturing method to be described later. The ends 8A and 8B of the conducting wire are extended from the outside. In the first embodiment, the compressed powder portion where the end portions 8A and 8B of the core 11 are extended can be maintained in a state compressed without any gaps by the powder. In addition, since the powder does not leak to the end portions 8A and 8B that extend outward, the powder can be prevented from adhering. As the powder, a mixture of magnetic metal powder, an insulating material, and a lubricant similar to the conventional ones can be used, and the size of the powder particles and the kind to be blended can be appropriately set according to the application. Examples of magnetic metal powders include transition metals that exhibit soft magnetism such as iron, iron silicide, permalloy (Fe—Ni alloy), supermalloy (Fe—Ni—Mo), sendust, iron nitride, iron aluminum alloy, iron One type or two or more types can be selected and used from cobalt alloys, phosphorous iron, and the like. These metals and alloys have a suitable particle size by mechanical pulverization and thermal decomposition methods such as water atomization method, oil atomization method, gas atomization method, electrolysis method, rotating disk method, twin roll method, and rotating electrode method. Prepare powder. The insulating material functions as a binder for forming the core 11 and has a function of insulating between the magnetic metal powders. As the insulating material, for example, an organic material such as water glass, phenol resin, acrylic resin, epoxy resin, silicon resin, polyamide resin, and polyimide resin can be used, and a thermosetting resin may be used. The lubricant has a function of improving the lubricity of the powder and a function of improving the packing density of the core 11. As the lubricant, for example, at least one selected from zinc stearate, aluminum stearate, magnesium stearate, calcium stearate, strontium stearate, barium stearate, Ca, Zn, Al, Mg and the like can be used. These magnetic metal powders, insulating materials, and lubricants are mixed at an appropriate ratio according to the application and used as the powder 9 in FIG. In the first embodiment, the core 11 has a rectangular parallelepiped shape, but may be a cube or a columnar shape. Moreover, although the core 11 has shown the case where it is square in the planar view and the length of length and width is the same, rectangular shape may be sufficient and circular shape may be sufficient as it. Moreover, the core 11 by the manufacturing method in the first embodiment can be made to be 2 mm square or less, and the powder-molded inductor member 12 that can be further miniaturized can be formed.
　図１（ｃ）において、圧粉成型インダクタ部材１３は、圧粉成型されたコア１１の両側部に端子電極部１４Ａ・１４Ｂを備えており、本第１実施例においては、導線の端部８Ａ・８Ｂは、圧縮粉体部の外側に延出されているため、端子電極部を、圧縮粉体部の外側に設けやすくすることができ、確実に端子電極部を構成できる。 In FIG. 1 (c), the dust-molded inductor member 13 includes terminal electrode portions 14A and 14B on both sides of the dust-molded core 11, and in the first embodiment, an end portion 8A of the conducting wire. -Since 8B is extended outside the compressed powder part, the terminal electrode part can be easily provided outside the compressed powder part, and the terminal electrode part can be reliably configured.
　つぎに、第１実施例における圧粉成型インダクタ部材の製造工程を説明する。図２に、第１実施例における圧粉成型インダクタ部材の製造工程（ａ）～（ｆ）を示す。 Next, the manufacturing process of the dust-molded inductor member in the first embodiment will be described. FIG. 2 shows manufacturing steps (a) to (f) of the dust-molded inductor member in the first embodiment.
　本第１実施例における圧粉成型インダクタ部材製造装置１は、図１（ｂ）に示すような圧粉成型インダクタ部材１２または図１（ｃ）に示すような圧粉成型インダクタ部材１３を製造するものであって、圧縮成型する際の形状が構成された成形型部の上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂと、粉体９を供給する供給部としての粉体供給部１０と、成形型部の下金型４Ａ・４Ｂ内に配置されたコイル２を、粉体供給部１０より供給された粉体９とともに加圧する加圧部の上パンチ５Ａおよび下パンチ５Ｂと、を少なくとも有している。また、成形型部の上金型３Ａ・３Ｂには、コイル２の端部８Ａおよび８Ｂを挟み込み、コイルの端部８Ａおよび８Ｂが当接している以外の部分が互いに当接する当接受け部の弾性部材７を備える。また、圧粉成型インダクタ部材製造装置１は、コイル２を移送して下金型４Ａ・４Ｂ内に配置する移送部を備えてもよい。 The dust-molded inductor member manufacturing apparatus 1 in the first embodiment manufactures a dust-molded inductor member 12 as shown in FIG. 1 (b) or a dust-molded inductor member 13 as shown in FIG. 1 (c). The upper molds 3A and 3B and the lower molds 4A and 4B, and the powder supply unit 10 serving as a supply unit for supplying the powder 9; The upper punch 5A and the lower punch 5B of the pressurizing unit that pressurizes the coil 2 arranged in the lower molds 4A and 4B of the mold unit together with the powder 9 supplied from the powder supply unit 10 Have. Further, the upper molds 3A and 3B of the mold part are sandwiched between the end portions 8A and 8B of the coil 2, and the contact receiving portions where the portions other than the end portions 8A and 8B of the coil are in contact with each other are in contact with each other. An elastic member 7 is provided. Moreover, the dust-molded inductor member manufacturing apparatus 1 may include a transfer unit that transfers the coil 2 and places it in the lower molds 4A and 4B.
　成形型部の上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂは、分割されて、互いに当接する当接面を備える第一成形型手段および第二成形型手段であり、上金型３Ａ・３Ｂと、下金型４Ａ・４Ｂとは、当接面が同一形状で構成されている。成形型部の上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂは、図示しない駆動手段によりそれぞれ上下に駆動される。上金型３Ａ・３Ｂと、下金型４Ａ・４Ｂとは、図２においては縦断面における右側３Ｂ・４Ｂと左側３Ａ・４Ａとを示しているが、平面視の形状は矩形であり、コイル２が配置され粉体９が挿入されてコア１１が形成される部分は孔部６Ａ・６Ｂが形成されている。この孔部６Ａ・６Ｂの断面積の大きさがコア１１の断面積の大きさに相当する。本第１実施例においては、コア１１（孔部６Ａ・６Ｂ）の形状は平面視において方形で縦と横の長さが同一である場合を示しているが、長方形状であってもよいし円状であってもよい。粉体供給部１０は、上述した粉体９を供給する装置であって、図示しない駆動手段により水平方向に移動でき、孔部６Ａ上に移動して、コア１１を形成するのに必要な分量の粉体９をコイル２の配置後に供給する。粉体供給部１０は、下面が上金型３Ａ・３Ｂの上面に当接するような当接面と、この当接面の中央に供給孔とを備えておくことで、粉体９の供給後に外部に移動する際に、粉体９の上面をスライドすることで、粉体９を擦切るようにできる。上パンチ５Ａは、上金型３Ａ・３Ｂの上方から孔部６Ａ内に挿入され、下パンチ５Ｂは、下金型４Ａ・４Ｂの下方から孔部６Ｂ内に挿入される。上パンチ５Ａおよび下パンチ５Ｂは、図示しない駆動手段によりそれぞれ上下に駆動され、上パンチ５Ａおよび下パンチ５Ｂにより、上下からそれぞれ押圧することで、粉体９およびコイル２を圧縮する。上パンチ５Ａの下面はコア１１の上面と同一面積で、下パンチ５Ｂの上面はコア１１の下面と同一面積となる。コイル２の螺旋部８Ｃの外周の大きさは、孔部６Ａ・６Ｂの大きさとほぼ同一もしくは若干小さめの大きさとなるようにしておくことで、孔部６Ａ・６Ｂ内に嵌まり込むように配置することができる。この場合、端子電極を、コア１１内には設けないので、コア１１の大きさにほぼ等しい大きさの螺旋部８Ｃを有するコイル２とすることができる。 The upper molds 3A and 3B and the lower molds 4A and 4B are a first mold unit and a second mold unit that are divided and have contact surfaces that contact each other. 3B and lower mold | die 4A * 4B are comprised by the contact shape with the same shape. The upper molds 3A and 3B and the lower molds 4A and 4B of the mold part are respectively driven up and down by driving means (not shown). The upper molds 3A and 3B and the lower molds 4A and 4B show the right side 3B and 4B and the left side 3A and 4A in the longitudinal section in FIG. 2, but the shape in plan view is rectangular, and the coil 2 are disposed, and the portion where the powder 9 is inserted to form the core 11 is formed with holes 6A and 6B. The size of the cross-sectional area of the holes 6A and 6B corresponds to the size of the cross-sectional area of the core 11. In the first embodiment, the core 11 ( holes 6A and 6B) has a square shape in the plan view and the length and width are the same. However, the shape may be rectangular. It may be circular. The powder supply unit 10 is a device for supplying the powder 9 described above, and can be moved in the horizontal direction by a driving means (not shown), and can be moved onto the hole 6A so as to form the core 11. The powder 9 is supplied after the coil 2 is arranged. The powder supply unit 10 is provided with a contact surface whose lower surface is in contact with the upper surfaces of the upper molds 3A and 3B and a supply hole at the center of the contact surface. When moving to the outside, the powder 9 can be scraped off by sliding the upper surface of the powder 9. The upper punch 5A is inserted into the hole 6A from above the upper molds 3A and 3B, and the lower punch 5B is inserted into the hole 6B from below the lower molds 4A and 4B. The upper punch 5A and the lower punch 5B are driven up and down by driving means (not shown), and are pressed from above and below by the upper punch 5A and the lower punch 5B, thereby compressing the powder 9 and the coil 2. The lower surface of the upper punch 5A has the same area as the upper surface of the core 11, and the upper surface of the lower punch 5B has the same area as the lower surface of the core 11. The size of the outer periphery of the spiral portion 8C of the coil 2 is set to be approximately the same as or slightly smaller than the size of the holes 6A and 6B, so that the coil 2 fits into the holes 6A and 6B. can do. In this case, since the terminal electrode is not provided in the core 11, the coil 2 having the spiral portion 8 </ b> C having a size substantially equal to the size of the core 11 can be obtained.
　当接受け部は、コイル２の端部８Ａ・８Ｂを挟み込み、コイル２の端部８Ａ・８Ｂが当接している以外の部分が互いに当接するものであればよく、粉体供給部１０より供給された粉体９が上パンチ５Ａおよび下パンチ５Ｂにより加圧されたときに、当接受け部により挟み込まれているコイル２の端部８Ａ・８Ｂ側には、粉体９が漏れて流れていくことがないように構成されている。この点については、後述する。本第１実施例においては、当接受け部は、弾性部材７を備える。弾性部材７は、上金型３Ａ・３Ｂと、下金型４Ａ・４Ｂとのうちいずれかの当接面に備えればよく、図２においては、上金型３Ａ・３Ｂに備える場合を示している。弾性部材７としては、コイルの端部を挟み込んだ際に弾性変形して復元する素材を利用する素材により構成される。弾性部材７は、その硬さがコイル２の導線の硬さより小さく、上金型３Ａ・３Ｂと下金型４Ａ・４Ｂとにより挟み込まれて、コア１１を成形する際の粉体９の押圧力に耐えうるような強度を持つ。弾性部材７としては、例えば、シリコン樹脂などの樹脂や、ウレタン、ニトリル、クロロプレン、エチレン、プチル、フッ素、低弾性などのゴムを利用することができる。この場合、弾性部材７の硬度としては、例えば、ロックウェル硬度としては、Ｍスケール２００～５０ぐらい、ショア硬度Ａ９５～３０ぐらい、ビッカース硬度としてはＨｖ５０～１０ぐらい、デュロメータとしては、タイプＤ１００～２０ぐらいに設定しておけばよい。 The contact receiving portion may be any member that sandwiches the end portions 8A and 8B of the coil 2 and is in contact with the portions other than the end portions 8A and 8B of the coil 2 that are in contact with each other. When the powder 9 is pressed by the upper punch 5A and the lower punch 5B, the powder 9 leaks and flows to the ends 8A and 8B of the coil 2 sandwiched between the contact receiving portions. It is configured not to go. This point will be described later. In the first embodiment, the contact receiving portion includes an elastic member 7. The elastic member 7 may be provided on any one of the contact surfaces of the upper molds 3A and 3B and the lower molds 4A and 4B. FIG. 2 shows a case where the elastic members 7 are provided on the upper molds 3A and 3B. ing. The elastic member 7 is made of a material that uses a material that is elastically deformed and restored when the end of the coil is sandwiched. The elastic member 7 has a hardness smaller than the hardness of the conductive wire of the coil 2 and is sandwiched between the upper molds 3A and 3B and the lower molds 4A and 4B to press the powder 9 when the core 11 is molded. Strong enough to withstand. As the elastic member 7, for example, a resin such as a silicone resin, or a rubber such as urethane, nitrile, chloroprene, ethylene, butyl, fluorine, or low elasticity can be used. In this case, as the hardness of the elastic member 7, for example, Rockwell hardness is about 200 to 50 M scale, Shore hardness A is about 95 to 30, Vickers hardness is about Hv 50 to 10, and durometer is type D100 to 20 Set it to about.
　このような構成の圧粉成型インダクタ部材製造装置１で、圧粉成型インダクタ部材の製造を行う場合、まず、上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂが駆動されて、上金型３Ａ・３Ｂと下金型４Ａ・４Ｂとの間に空間が形成され、図２（ａ）に示すように所定の位置にコイル２を配置する。コイル２は、扱いやすいように図示しないリードフレームに予め接続しておくようにしてもよく、リードフレームを図示しない移送部により移送することで、コイル２を孔部６Ｂの中央に配置することができる。その後、図２（ｂ）に示すように、上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂが、コイル２を挟み込むように駆動される。その際に、コイル２の上下位置はズラさないように上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂが駆動される。その際に、当接受け部の弾性部材７は、コイル２の端部８Ａ・８Ｂを挟み込み、コイル２の端部８Ａ・８Ｂが当接している以外の部分が互いに当接する。 When producing a dust-molded inductor member with the dust-molded inductor member manufacturing apparatus 1 having such a configuration, first, the upper molds 3A and 3B and the lower molds 4A and 4B are driven and the upper mold 3A is driven. A space is formed between 3B and the lower molds 4A and 4B, and the coil 2 is disposed at a predetermined position as shown in FIG. The coil 2 may be connected in advance to a lead frame (not shown) so as to be easy to handle, and the coil 2 can be arranged at the center of the hole 6B by transferring the lead frame by a transfer unit (not shown). it can. Thereafter, as shown in FIG. 2B, the upper molds 3A and 3B and the lower molds 4A and 4B are driven so as to sandwich the coil 2. At that time, the upper molds 3A and 3B and the lower molds 4A and 4B are driven so that the vertical position of the coil 2 is not shifted. At that time, the elastic member 7 of the contact receiving portion sandwiches the end portions 8A and 8B of the coil 2, and the portions other than the end portions 8A and 8B of the coil 2 are in contact with each other.
　この点について、図３を参照してさらに説明する。図３においては、第１実施例における圧粉成型インダクタ部材の製造工程の一部拡大図（ａ）および（ｂ）を示している。図３（ａ）においては、図２（ａ）に示す上金型３Ａと下金型４Ａとの間に空間が形成された状態の拡大図を示し、図３（ｂ）においては、図２（ｂ）に示す上金型３Ａと下金型４Ａとでコイル２の端部８Ａを挟み込んだ状態の拡大図を示している。図３（ｂ）に示すように、上金型３Ａと下金型４Ａとでコイル２の端部８Ａを挟み込んだ状態においては、コイル２の端部８Ａの形状に応じて弾性部材７が弾性変形する。これにより、弾性部材７のコイル２の端部８Ａが当接している以外の部分は、下金型４Ａの当接面に当接するため、上金型３Ａの弾性部材７と下金型４Ａとが隙間なく当接することができる。すなわち、弾性部材７の当接面は、コイル２の端部８Ａの表面に隙間なく接触するとともに、下金型４Ａの当接面にも隙間なく接触することができる。このため、コイル２の端部８Ａが、上金型３Ａと下金型４Ａとにより挟み込まれたときに、潰されることや切断されることがない。また、粉体供給部１０より供給された粉体９が上パンチ５Ａおよび下パンチ５Ｂにより加圧されたときに、当接受け部により挟み込まれているコイル２の端部８Ａ側に、粉体９が漏れて流れていくのを防ぐことができる。弾性部材７は、コア１１の成形後、上金型３Ａと下金型４Ａとが上下に駆動されて、上金型３Ａと下金型４Ａとの間に空間が形成された状態になり、コイル２の端部８Ａが弾性部材７から分離されると、その形状が復元するような材料で形成するのが望ましい。復元可能な場合には、弾性部材７を取り換える必要がないので、つぎの圧粉成型インダクタ部材を連続して成形することができる。また、当接受け部としては、弾性部材７を設ける代わりに、コイル２の端部８の径の大きさと長さに応じた溝を、上金型３Ａの下面と下金型４Ａの上面とのうちの少なくとも一方に設けておき、コイル２の端部８が溝に嵌まり込むようにしておくことで、コイル２の端部８が当接している以外の部分の上金型３Ａの下面と下金型４Ａの上面の当接面が互いに当接しておくようにできる。 This point will be further described with reference to FIG. FIG. 3 shows partially enlarged views (a) and (b) of the manufacturing process of the dust-molded inductor member in the first embodiment. 3A shows an enlarged view of a state in which a space is formed between the upper mold 3A and the lower mold 4A shown in FIG. 2A, and FIG. The enlarged view of the state which pinched | interposed the edge part 8A of the coil 2 with the upper metal mold | die 3A and the lower metal mold | die 4A shown to (b) is shown. As shown in FIG. 3B, in a state where the end 8A of the coil 2 is sandwiched between the upper mold 3A and the lower mold 4A, the elastic member 7 is elastic according to the shape of the end 8A of the coil 2. Deform. As a result, the portions other than the end 8A of the coil 2 of the elastic member 7 are in contact with the contact surface of the lower mold 4A. Therefore, the elastic member 7 of the upper mold 3A and the lower mold 4A Can abut without gaps. That is, the contact surface of the elastic member 7 can contact the surface of the end 8A of the coil 2 without a gap and can also contact the contact surface of the lower mold 4A without a gap. For this reason, when the end portion 8A of the coil 2 is sandwiched between the upper mold 3A and the lower mold 4A, it is not crushed or cut. Further, when the powder 9 supplied from the powder supply unit 10 is pressed by the upper punch 5A and the lower punch 5B, the powder 9 is placed on the end 8A side of the coil 2 sandwiched between the contact receiving portions. 9 can be prevented from leaking and flowing. In the elastic member 7, after the core 11 is molded, the upper mold 3A and the lower mold 4A are driven up and down, and a space is formed between the upper mold 3A and the lower mold 4A. It is desirable to form the coil 2 from a material that restores its shape when the end 8A of the coil 2 is separated from the elastic member 7. When the restoration is possible, it is not necessary to replace the elastic member 7, so that the next compacted inductor member can be continuously formed. Further, as the contact receiving portion, instead of providing the elastic member 7, a groove corresponding to the size and length of the end 8 of the coil 2 is formed on the lower surface of the upper mold 3A and the upper surface of the lower mold 4A. The end 8 of the coil 2 is fitted in the groove so that the lower surface of the upper mold 3A and the lower part of the portion other than the end 8 of the coil 2 are in contact with each other. The contact surfaces of the upper surface of the mold 4A can be in contact with each other.
　上述したように本第１実施例における当接受け部を設けておき、図２（ｂ）に示すように、コイル２の端部８Ａが、上金型３Ａと下金型４Ａとにより挟み込まれた状態で、下パンチ５Ｂをコア１１の大きさに対応するような適切な位置まで上昇させるとともに、粉体供給部１０を孔部６Ａ・６Ｂにあるコイル２の螺旋部８Ｃ上の位置まで移動させる。その後、図２（ｃ）に示すように、粉体供給部１０から粉体９を所定量供給する。下パンチ５Ｂには、粉体供給部１０から供給される粉体の供給量を重量などにより測量するセンサを設けておき、粉体９が所定量供給された際に、供給を停止させるようにしてもよい。つぎに、図２（ｄ）に示すように、粉体供給部１０は、粉体９の供給後に側部に移動する際に、粉体９の上面をスライドすることで、粉体供給部１０の下面で粉体９を擦切るようにしている。粉体９は、コイル２の螺旋部８Ｃの表面を全て覆うように孔部６Ａ・６Ｂに供給される。そして、上パンチ５Ａを下側方向に移動させて、上パンチ５Ａおよび下パンチ５Ｂにより、図２（ｅ）に示すように、上下からそれぞれ同時に加圧して、粉体９およびコイル２を圧縮する。上下からそれぞれ同時に加圧することで、粉体９の密度を均一にすることができ、また、コイル２の配置位置が上下に移動することなく密封される。この圧縮により、コア１１が形成される。図２（ｆ）に示すように、上パンチ５Ａおよび下パンチ５Ｂと、上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂとをそれぞれ移動させることで開放することで、図１（ｂ）に示すような圧粉成型インダクタ部材１２の製造が完成する。その後、コア１１の両側部に端子電極部１４Ａ・１４Ｂを装着し、端子電極部１４Ａ・１４Ｂを導線の端部８Ａ・８Ｂに導通するように接続させる。これにより、図１（ｃ）に示すような圧粉成型インダクタ部材１３の製造が完成する。 As described above, the contact receiving portion in the first embodiment is provided, and the end 8A of the coil 2 is sandwiched between the upper die 3A and the lower die 4A as shown in FIG. 2 (b). In this state, the lower punch 5B is raised to an appropriate position corresponding to the size of the core 11, and the powder supply unit 10 is moved to a position on the spiral portion 8C of the coil 2 in the holes 6A and 6B. Let Thereafter, as shown in FIG. 2 (c), a predetermined amount of powder 9 is supplied from the powder supply unit 10. The lower punch 5B is provided with a sensor for measuring the supply amount of the powder supplied from the powder supply unit 10 by weight or the like so that the supply is stopped when a predetermined amount of the powder 9 is supplied. May be. Next, as shown in FIG. 2 (d), the powder supply unit 10 slides on the upper surface of the powder 9 when moving to the side after supplying the powder 9, so that the powder supply unit 10. The powder 9 is scraped off on the lower surface of. The powder 9 is supplied to the holes 6A and 6B so as to cover the entire surface of the spiral portion 8C of the coil 2. Then, the upper punch 5A is moved downward, and the upper punch 5A and the lower punch 5B are simultaneously pressed from above and below as shown in FIG. 2E to compress the powder 9 and the coil 2. . By simultaneously pressing from above and below, the density of the powder 9 can be made uniform, and the arrangement position of the coil 2 is sealed without moving up and down. The core 11 is formed by this compression. As shown in FIG. 2 (f), the upper punch 5A and the lower punch 5B and the upper molds 3A and 3B and the lower molds 4A and 4B are opened by moving them, respectively, so that FIG. The production of the compacted inductor member 12 as shown is completed. Thereafter, terminal electrode portions 14A and 14B are mounted on both sides of the core 11, and the terminal electrode portions 14A and 14B are connected to the conductive wire ends 8A and 8B so as to be conducted. Thereby, manufacture of the compacting inductor member 13 as shown in FIG.1 (c) is completed.
　以上、本第１実施例における圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３の製造方法によれば、コイル２の螺旋部８Ｃに粉体９を充填後、圧縮工程を１度行うだけで、コア１１を圧縮成型できるため、工程数を少なくでき、容易に製造することができる。また、成形型部の当接受け部において、コイル２の端部８Ａおよび８Ｂを挟み込み、コイル２の端部８Ａおよび８Ｂが当接している以外の部分が互いに当接するため、コイル２の端部８が、上金型３Ａと下金型４Ａとにより挟み込まれたときに、潰されることや切断されることがない。また、粉体供給部１０より供給された粉体９が上パンチ５Ａおよび下パンチ５Ｂにより加圧されたときに、当接受け部により挟み込まれているコイル２の端部８Ａおよび８Ｂ側に、粉体９が漏れて流れていくのを防ぐことができる。これにより、圧縮成型されたコア１１より外部であって外側にコイル２の端部８Ａ・８Ｂが延出された状態の圧粉成型インダクタ部材１２を製造することができる。この製造方法によれば、圧縮の際に、粉体９が端部８Ａおよび８Ｂ側に漏れてしまう恐れがなく、上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂの成形型と同じ大きさのコア１１を作成することができるため、コア１１の大きさをより小型化することができ、圧粉成型インダクタ部材１２の大きさをより小型化することができる。また、弾性部材７を備える場合には、弾性部材がコイルの端部の形状に合わせて変形するため、挟み込まれたときにコイルの端部が潰されることや切断されることがないのでより好ましい。また、コイルの端部が潰されることや切断されることがないので、コイル２の導線を、通常利用する断面が円状または方形の細い導線を利用できる。また、上金型３Ａ・３Ｂに弾性部材７を備える場合に、さらに、下金型４Ａ・４Ｂの上面に、コイル２の端部８の径の大きさと長さに応じた溝を設けておいてもよい。これらの弾性部材７と溝との配置位置は、上金型３Ａ・３と下金型４Ａ・４Ｂとのうちどちらでもよい。また、導線の端部８Ａおよび８Ｂが、コア１１の外側に延出されているため、端子電極部１４Ａ・１４Ｂを導線の端部８Ａおよび８Ｂに接続しやすくなるため、端子電極部１４Ａ・１４Ｂを設けやすくすることができ、確実に接続された端子電極部１４Ａ・１４Ｂを構成できる。このため、端部８Ａおよび８Ｂと端子電極部１４Ａ・１４Ｂとによる接触不良を減少させることができるので、歩留りを向上させることができる。 As described above, according to the method for manufacturing the dust-molded inductor member 12 and the dust-molded inductor member 13 in the first embodiment, after the powder 9 is filled in the spiral portion 8C of the coil 2, the compression process is performed only once. Since the core 11 can be compression molded, the number of steps can be reduced and the core 11 can be easily manufactured. Further, since the end portions 8A and 8B of the coil 2 are sandwiched in the contact receiving portion of the mold part, and the portions other than the end portions 8A and 8B of the coil 2 are in contact with each other, the end portions of the coil 2 When 8 is sandwiched between the upper mold 3A and the lower mold 4A, it is not crushed or cut. Further, when the powder 9 supplied from the powder supply unit 10 is pressurized by the upper punch 5A and the lower punch 5B, the end portions 8A and 8B of the coil 2 sandwiched between the contact receiving portions It is possible to prevent the powder 9 from leaking and flowing. As a result, the dust-molded inductor member 12 can be manufactured in a state where the ends 8A and 8B of the coil 2 are extended outside and outside the compression-molded core 11. According to this manufacturing method, there is no possibility that the powder 9 leaks to the end portions 8A and 8B during compression, and the same size as the molds of the upper molds 3A and 3B and the lower molds 4A and 4B. Therefore, the size of the core 11 can be further reduced, and the size of the dust-molded inductor member 12 can be further reduced. Further, when the elastic member 7 is provided, the elastic member is deformed in accordance with the shape of the end portion of the coil, and therefore, the end portion of the coil is not crushed or cut when sandwiched. . In addition, since the end portion of the coil is not crushed or cut, a conductive wire of the coil 2 can be used as a thin conductive wire having a circular or square cross section. In addition, when the upper molds 3A and 3B are provided with the elastic member 7, grooves corresponding to the size and length of the end 8 of the coil 2 are further provided on the upper surfaces of the lower molds 4A and 4B. May be. The arrangement positions of the elastic member 7 and the groove may be any of the upper molds 3A and 3 and the lower molds 4A and 4B. Further, since the end portions 8A and 8B of the conducting wire are extended to the outside of the core 11, the terminal electrode portions 14A and 14B can be easily connected to the end portions 8A and 8B of the conducting wire. The terminal electrode portions 14A and 14B that are securely connected can be configured. For this reason, since the contact failure by end part 8A and 8B and terminal electrode part 14A * 14B can be reduced, a yield can be improved.
　また、圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３は、より小型化が図れるため、配置した場合に省スペース化が可能となる。また、圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３は、閉磁路タイプで、コイル２の螺旋部８Ｃを磁性材で覆うため、漏れ磁束を少なくすることができ、他の隣接部品への磁気による影響を少なくすることができる。圧粉成型インダクタ部材１３は、端子電極部をコア１１の外側に外付けするため、コア１１の寸法ギリギリまで螺旋部８Ｃの直径を大きくすることができる。これにより、圧粉成型インダクタ部材１３は、インダクタンスを大きくすることができ、発熱しにくくなり、放熱しやすくなるという効果がある。圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３は、コイル２の封入と同時にコアを成形することで、コイル２を密封させる粉体９がコア１１になる。これにより粉体９がコイル２の全面に隙間無くいきわたり、コア１１を成形することができる。コイル２とコア１１の間に隙間が生じないため、インダクタンスの低下を防止することができる。また、粉体９の密度を均一にすることができるため、品質を向上させることができる。 Further, since the dust-molded inductor member 12 and the dust-molded inductor member 13 can be further reduced in size, it is possible to save space when arranged. Moreover, since the dust-molded inductor member 12 and the dust-molded inductor member 13 are closed magnetic circuit types and the spiral portion 8C of the coil 2 is covered with a magnetic material, leakage magnetic flux can be reduced, and other adjacent components can be reduced. The influence of magnetism can be reduced. Since the dust-molded inductor member 13 externally attaches the terminal electrode portion to the outside of the core 11, the diameter of the spiral portion 8 </ b> C can be increased to the size of the core 11. Thereby, the dust-molded inductor member 13 has an effect that the inductance can be increased, the heat generation becomes difficult, and the heat dissipation becomes easy. In the powder-molded inductor member 12 and the powder-molded inductor member 13, the core 9 is molded simultaneously with the encapsulation of the coil 2, so that the powder 9 that seals the coil 2 becomes the core 11. As a result, the powder 9 can pass through the entire surface of the coil 2 without a gap, and the core 11 can be formed. Since there is no gap between the coil 2 and the core 11, a decrease in inductance can be prevented. Moreover, since the density of the powder 9 can be made uniform, the quality can be improved.
　本第１実施例による圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３は、例えば、電源回路に用いられるパワーチョーク、高周波回路におけるインピーダンス整合のためのインダクタ、ノイズ対策のためのフィルタ等に利用することができる。特に、圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３は、コイルを巻線タイプの螺旋状にしているため、定格電流を大きくすることができ、抵抗をより低くでき、損失を少なくすることができる。 The dust-molded inductor member 12 and the dust-molded inductor member 13 according to the first embodiment are used for, for example, a power choke used in a power supply circuit, an inductor for impedance matching in a high-frequency circuit, a filter for noise countermeasures, and the like. can do. In particular, the dust-molded inductor member 12 and the dust-molded inductor member 13 have a coil of a winding type spiral shape, so that the rated current can be increased, the resistance can be lowered, and the loss can be reduced. Can do.
第２実施例Second embodiment
　つぎに、第２実施例に係るコイルを粉体内に封入して圧縮成型された圧粉成型インダクタ部材を製造する圧粉成型インダクタ部材製造装置とその製造方法につき、図４から図９を参照して説明する。 Next, with reference to FIGS. 4 to 9, a dust-molded inductor member manufacturing apparatus and a manufacturing method thereof for manufacturing a dust-molded inductor member that is compression-molded by enclosing the coil according to the second embodiment in powder will be described with reference to FIGS. 4 to 9. I will explain.
　第２実施例においては、上記第１実施例における当接受け部として、弾性部材７を設ける代わりに、コイル２の端部８Ａ・８Ｂを挟み込むときに、コイル２の端部８Ａ・８Ｂを受け入れる所定幅の開口部位と、当該開口部位の前記所定幅より幅狭な前記コイルの端部８Ａ・８Ｂを配置する配置部位とを備える溝部と、この溝部に嵌まり込み、コイル２の端部８Ａ・８Ｂを挟み込む溝押さえ部とを有する場合を例にする。上記第１実施例においては、当接受け部として弾性部材７を設けておくことで、コイルの端部側には、粉体が漏れて流れていくのを防いでいるが、第２実施例においては、当接受け部として溝部と溝押さえ部とでコイル２の端部８Ａ・８Ｂを挟み込むことで、粉体が漏れて流れていくのを防ぐことができる。本実施例において、溝部と溝押さえ部とは、嵌合するような形状を備えており、後述するように様々な形状に設定しておくことができ、溝部および溝押さえ部で、コイルの端部８Ａ・８Ｂを挟み込んだときに隙間が生じないような形状としておくことができる。例えば、本実施例において、溝部を断面V字形状とした溝状に形成し、溝押さえ部を断面V字形状とした突状に形成しておきコイルの端部を挟み込むようにしてもよいし、また、溝部の所定幅の開口部位と、配置部位の幅とを同じ幅に設定した場合には、溝部はコイルの端部８Ａ・８Ｂを受け入れる凹部にしてもよいし、また、溝押さえ部は当該凹部に受け入れられたコイルの端部８Ａ・８Ｂを挟み込む凸部の形状にしてもよい。 In the second embodiment, instead of providing the elastic member 7 as the contact receiving portion in the first embodiment, the ends 8A and 8B of the coil 2 are received when the ends 8A and 8B of the coil 2 are sandwiched. A groove portion including an opening portion having a predetermined width and an arrangement portion where the end portions 8A and 8B of the coil narrower than the predetermined width of the opening portion are disposed, and the end portion 8A of the coil 2 is fitted into the groove portion. -Take as an example a case having a groove pressing part for sandwiching 8B. In the first embodiment, the elastic member 7 is provided as a contact receiving portion to prevent the powder from leaking and flowing to the end portion side of the coil. In this case, it is possible to prevent the powder from leaking and flowing by sandwiching the end portions 8A and 8B of the coil 2 between the groove portion and the groove pressing portion as the contact receiving portion. In this embodiment, the groove portion and the groove pressing portion are provided with shapes to be fitted, and can be set in various shapes as will be described later. It can be set as a shape which does not produce a gap when the portions 8A and 8B are sandwiched. For example, in this embodiment, the groove portion may be formed in a groove shape having a V-shaped cross section, and the groove pressing portion may be formed in a protruding shape having a V-shaped cross section so as to sandwich the end portion of the coil. In addition, when the opening part of the predetermined width of the groove part and the width of the arrangement part are set to the same width, the groove part may be a recessed part for receiving the coil end parts 8A and 8B, or the groove holding part. May be in the shape of a convex part sandwiching the end parts 8A and 8B of the coil received in the concave part.
　なお、第２実施例において、第１実施例と同一の構成を備える場合には同一の符号により示している。また、図１に示す圧粉成型インダクタ部材の外観図（ａ）～（ｃ）は、第２の実施例における製造工程により作成される圧粉成型インダクタ部材においても同様であり、その材料や構成についても特に記載しない限り同様である。 In the second embodiment, the same reference numerals are used to indicate the same configuration as in the first embodiment. Further, the external views (a) to (c) of the dust-molded inductor member shown in FIG. 1 are the same for the dust-molded inductor member produced by the manufacturing process in the second embodiment, and its material and configuration The same applies to unless otherwise specified.
　つぎに、第２実施例における圧粉成型インダクタ部材の製造工程を説明する。図４に、第２実施例における圧粉成型インダクタ部材の製造工程（ａ）～（ｆ）を示す。また、製造工程の図４（ａ）、（ｂ）における左側一部拡大図を図５（ａ）、（ｂ）に示している。図５（ａ）においては、図４（ａ）に示す上金型３Ａと下金型４Ａとの間に空間が形成された状態の拡大図を示し、図５（ｂ）においては、図４（ｂ）に示す上金型３Ａと下金型４Ａとでコイル２の端部８Ａを挟み込んだ状態の拡大図を示している。 Next, the manufacturing process of the dust-molded inductor member in the second embodiment will be described. FIG. 4 shows manufacturing steps (a) to (f) of the dust-molded inductor member in the second embodiment. 5A and 5B are partially enlarged views of the left side in FIGS. 4A and 4B of the manufacturing process. FIG. 5A shows an enlarged view of a state in which a space is formed between the upper mold 3A and the lower mold 4A shown in FIG. 4A, and FIG. The enlarged view of the state which pinched | interposed the edge part 8A of the coil 2 with the upper metal mold | die 3A and the lower metal mold | die 4A shown to (b) is shown.
　図４に示す第２実施例における圧粉成型インダクタ部材製造装置１Ａは、図１（ｂ）に示すような圧粉成型インダクタ部材１２または図１（ｃ）に示すような圧粉成型インダクタ部材１３を製造するものであって、圧縮成型する際の形状が構成された成形型部の上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂと、粉体９を供給する供給部としての粉体供給部１０と、成形型部の下金型４Ａ・４Ｂ内に配置されたコイル２を、粉体供給部１０より供給された粉体９とともに加圧する加圧部の上パンチ５Ａおよび下パンチ５Ｂと、を少なくとも有している。また、図５（ａ）に拡大して示すように、成形型部の上金型３Ａには、コイル２の端部８Ａを挟み込み、コイルの端部８Ａが当接している以外の部分が互いに当接する当接受け部を備え、当接受け部は、コイル２の端部８Ａを挟み込むときに、コイル２の端部８Ａを受け入れる所定幅Ｌの開口部位２６Ａ（端部８Ｂ側の当接受け部も図示しないが同様）と、開口部位２６Ａの所定幅Ｌより幅狭なコイルの端部８Ａを配置する配置部位２７Ａ（端部８Ｂ側の当接受け部も図示しないが同様）とを備える溝部２１Ａ、２１Ｂと、この溝部２１Ａ、２１Ｂにそれぞれ嵌まり込み、コイル２の端部８Ａ・８Ｂを挟み込む溝押さえ部２２Ａ、２２Ｂとを有する。ここで、開口部位２６は、コイル２の端部８Ａを受け入れるために形成された溝部２１の開口している部分であり、配置部位２７は、開口部位２６に接続されて溝部２１の底面側に設けられる部分である。また、開口部位２６と配置部位２７の幅は、溝部２１の短手方向の幅であり、配置部位２７の幅はコイル２の端部８を配置した場合の底面の幅、または、底面からコイル２の端部の半径分上側の水平方向の幅をいう。また、溝部２１Ａ、２１Ｂと、溝押さえ部２２Ａ、２２Ｂとの高さは、コイルの端部８Ａの直径よりも大きくすることができる。 A compact molded inductor member manufacturing apparatus 1A according to the second embodiment shown in FIG. 4 is a compact molded inductor member 12 as shown in FIG. 1B or a compact molded inductor member 13 as shown in FIG. And a powder supply as a supply unit for supplying the powder 9 and the upper molds 3A and 3B and the lower molds 4A and 4B in which the shape at the time of compression molding is formed An upper punch 5A and a lower punch 5B for pressing the portion 10 and the coil 2 arranged in the lower molds 4A and 4B of the mold portion together with the powder 9 supplied from the powder supply unit 10; , At least. Further, as shown in an enlarged view in FIG. 5A, the upper die 3A of the mold part is sandwiched between the end portion 8A of the coil 2 and portions other than the end portion 8A of the coil in contact with each other. An abutment receiving portion that abuts, and the abutment receiving portion receives an end portion 8A of the coil 2 when the end portion 8A of the coil 2 is sandwiched between the opening portions 26A (the abutment receiving portion on the end portion 8B side) having a predetermined width L. And an arrangement portion 27A (the contact receiving portion on the end portion 8B side is also not shown) in which the end portion 8A of the coil narrower than the predetermined width L of the opening portion 26A is disposed. There are groove portions 21A and 21B, and groove pressing portions 22A and 22B that fit into the groove portions 21A and 21B and sandwich the end portions 8A and 8B of the coil 2, respectively. Here, the opening portion 26 is an opening portion of the groove portion 21 formed to receive the end portion 8A of the coil 2, and the arrangement portion 27 is connected to the opening portion 26 and is located on the bottom surface side of the groove portion 21. It is a part to be provided. Further, the width of the opening portion 26 and the arrangement portion 27 is the width in the short direction of the groove portion 21, and the width of the arrangement portion 27 is the width of the bottom surface when the end portion 8 of the coil 2 is disposed, or from the bottom surface to the coil. The width in the horizontal direction above the radius of the end of 2. Further, the height of the groove portions 21A and 21B and the groove pressing portions 22A and 22B can be made larger than the diameter of the end portion 8A of the coil.
　成形型部の上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂは、分割されて、互いに当接する当接面を備える第一成形型手段および第二成形型手段であり、上金型３Ａ・３Ｂと、下金型４Ａ・４Ｂとは、当接面がほぼ同一形状で構成され、下金型４Ａ・４Ｂには、溝部２１Ａ、２１Ｂをそれぞれ備え、上金型３Ａ・３Ｂには、溝押さえ部２２Ａ、２２Ｂをそれぞれ備える。下金型４Ａ・４Ｂの溝部２１Ａ、２１Ｂと、また、上金型３Ａ・３Ｂの溝押さえ部２２Ａ、２２Ｂとは、それぞれ金型と同一の材質により一体に形成しておいてもよいし、溝部２１Ａ、２１Ｂと溝押さえ部２２Ａ、２２Ｂとの部材は、成形型部の上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂとは異なる材質で、成形型部の上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂに装着して取り外しが可能な構成にしてもよい。例えば、溝部２１Ａ、２１Ｂと溝押さえ部２２Ａ、２２Ｂとの部材を、上述した第１実施例における弾性部材７により構成してもよい。この場合、溝部２１Ａ、２１Ｂと溝押さえ部２２Ａ、２２Ｂとのうち少なくとも一方を弾性部材７で構成するようにしてもよい。図４および図５に示す例においては、上金型３Ａ・３Ｂの溝押さえ部２２Ａ、２２Ｂを弾性部材７で構成している場合を示している。弾性部材７としては、第１実施例と同様に、コイルの端部を挟み込んだ際に弾性変形して復元する素材を利用する素材により構成される。弾性部材７は、その硬さがコイル２の導線の硬さより小さく、上金型３Ａ・３Ｂと下金型４Ａ・４Ｂとにより挟み込まれて、コア１１を成形する際の粉体９の押圧力に耐えうるような強度を持つ。このように構成することで、溝押さえ部２２Ａ、２２Ｂの弾性部材７が、コイル２の端部８Ａの表面に隙間なく接触するとともに、下金型４Ａの溝部２１Ａ、２１Ｂに隙間なく接触することができる。このため、コイル２の端部８Ａが、上金型３Ａと下金型４Ａとにより挟み込まれたときに、潰されることや切断されることがない。また、粉体供給部１０より供給された粉体９が上パンチ５Ａおよび下パンチ５Ｂにより加圧されたときに、当接受け部により挟み込まれているコイル２の端部８Ａ側に、粉体９が漏れて流れていくのを防ぐことができる。弾性部材７は、コア１１の成形後、上金型３Ａと下金型４Ａとが上下に駆動されて、上金型３Ａと下金型４Ａとの間に空間が形成された状態になり、コイル２の端部８Ａが弾性部材７から分離されると、その形状が復元するような材料で形成するのが望ましい。復元可能な場合には、弾性部材７を取り換える必要がないので、つぎの圧粉成型インダクタ部材を連続して成形することができる。また、上金型３Ａの溝押さえ部２２Ａ、２２Ｂの弾性部材７を取り換え可能に着脱できる構成としておけば、弾性部材が劣化した際に新しいものに取り換えることができる。 The upper molds 3A and 3B and the lower molds 4A and 4B are a first mold unit and a second mold unit that are divided and have contact surfaces that contact each other. 3B and lower molds 4A and 4B have substantially the same abutment surface, and lower molds 4A and 4B are provided with groove portions 21A and 21B, respectively, and upper molds 3A and 3B have grooves. The holding parts 22A and 22B are provided. The groove parts 21A and 21B of the lower molds 4A and 4B and the groove pressing parts 22A and 22B of the upper molds 3A and 3B may be integrally formed of the same material as the mold, The members of the groove portions 21A, 21B and the groove pressing portions 22A, 22B are made of a material different from that of the upper molds 3A, 3B and the lower molds 4A, 4B of the mold part, and the upper molds 3A, 3B and You may make it the structure which can be attached to the lower metal mold | die 4A * 4B and can be removed. For example, the members of the groove portions 21A and 21B and the groove pressing portions 22A and 22B may be configured by the elastic member 7 in the first embodiment described above. In this case, at least one of the groove portions 21A and 21B and the groove pressing portions 22A and 22B may be configured by the elastic member 7. In the example shown in FIGS. 4 and 5, the groove pressing portions 22 </ b> A and 22 </ b> B of the upper molds 3 </ b> A and 3 </ b> B are configured by the elastic member 7. As in the first embodiment, the elastic member 7 is made of a material that uses a material that is elastically deformed and restored when the end of the coil is sandwiched. The elastic member 7 has a hardness smaller than the hardness of the conductive wire of the coil 2 and is sandwiched between the upper molds 3A and 3B and the lower molds 4A and 4B to press the powder 9 when the core 11 is molded. Strong enough to withstand. With this configuration, the elastic members 7 of the groove pressing portions 22A and 22B are in contact with the surface of the end portion 8A of the coil 2 without gaps, and are in contact with the groove portions 21A and 21B of the lower mold 4A without gaps. Can do. For this reason, when the end portion 8A of the coil 2 is sandwiched between the upper mold 3A and the lower mold 4A, it is not crushed or cut. Further, when the powder 9 supplied from the powder supply unit 10 is pressed by the upper punch 5A and the lower punch 5B, the powder 9 is placed on the end 8A side of the coil 2 sandwiched between the contact receiving portions. 9 can be prevented from leaking and flowing. In the elastic member 7, after the core 11 is molded, the upper mold 3A and the lower mold 4A are driven up and down, and a space is formed between the upper mold 3A and the lower mold 4A. It is desirable to form the coil 2 from a material that restores its shape when the end 8A of the coil 2 is separated from the elastic member 7. When the restoration is possible, it is not necessary to replace the elastic member 7, so that the next compacted inductor member can be continuously formed. Moreover, if the elastic member 7 of the groove pressing portions 22A and 22B of the upper mold 3A is detachably attachable, it can be replaced with a new one when the elastic member is deteriorated.
　図４において、成形型部の上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂは、図示しない駆動手段によりそれぞれ上下に駆動される。粉体供給部１０は、上述した粉体９を供給する装置であって、図示しない駆動手段により水平方向に移動でき、孔部６Ａ上に移動して、コア１１を形成するのに必要な分量の粉体９をコイル２の配置後に供給する。粉体供給部１０は、下面が上金型３Ａ・３Ｂの上面に当接するような当接面と、この当接面の中央に供給孔とを備えておくことで、粉体９の供給後に外部に移動する際に、粉体９の上面をスライドすることで、粉体９を擦切るようにできる。上パンチ５Ａは、上金型３Ａ・３Ｂの上方から孔部６Ａ内に挿入され、下パンチ５Ｂは、下金型４Ａ・４Ｂの下方から孔部６Ｂ内に挿入される。上パンチ５Ａおよび下パンチ５Ｂは、図示しない駆動手段によりそれぞれ上下に駆動され、上パンチ５Ａおよび下パンチ５Ｂにより、上下からそれぞれ押圧することで、粉体９およびコイル２を圧縮する。上パンチ５Ａの下面はコア１１の上面と同一面積で、下パンチ５Ｂの上面はコア１１の下面と同一面積となる。コイル２の螺旋部８Ｃの外周の大きさは、孔部６Ａ・６Ｂの大きさとほぼ同一もしくは若干小さめの大きさとなるようにしておくことで、孔部６Ａ・６Ｂ内に嵌まり込むように配置することができる。この場合、端子電極を、コア１１内には設けないので、コア１１の大きさにほぼ等しい大きさの螺旋部８Ｃを有するコイル２とすることができる。 In FIG. 4, the upper molds 3A and 3B and the lower molds 4A and 4B of the mold part are driven up and down by driving means (not shown). The powder supply unit 10 is a device for supplying the powder 9 described above, and can be moved in the horizontal direction by a driving means (not shown), and can be moved onto the hole 6A so as to form the core 11. The powder 9 is supplied after the coil 2 is arranged. The powder supply unit 10 is provided with a contact surface whose lower surface is in contact with the upper surfaces of the upper molds 3A and 3B and a supply hole at the center of the contact surface. When moving to the outside, the powder 9 can be scraped off by sliding the upper surface of the powder 9. The upper punch 5A is inserted into the hole 6A from above the upper molds 3A and 3B, and the lower punch 5B is inserted into the hole 6B from below the lower molds 4A and 4B. The upper punch 5A and the lower punch 5B are driven up and down by driving means (not shown), and are pressed from above and below by the upper punch 5A and the lower punch 5B, thereby compressing the powder 9 and the coil 2. The lower surface of the upper punch 5A has the same area as the upper surface of the core 11, and the upper surface of the lower punch 5B has the same area as the lower surface of the core 11. The size of the outer periphery of the spiral portion 8C of the coil 2 is set to be approximately the same as or slightly smaller than the size of the holes 6A and 6B, so that the coil 2 fits into the holes 6A and 6B. can do. In this case, since the terminal electrode is not provided in the core 11, the coil 2 having the spiral portion 8 </ b> C having a size substantially equal to the size of the core 11 can be obtained.
　このような構成の圧粉成型インダクタ部材製造装置１Ａで、圧粉成型インダクタ部材の製造を行う場合、まず、上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂが駆動されて、上金型３Ａ・３Ｂと下金型４Ａ・４Ｂとの間に空間が形成され、図４（ａ）に示すように所定の位置にコイル２を配置する。コイル２は、扱いやすいように図示しないリードフレームに予め接続しておくようにしてもよく、リードフレームを図示しない移送部により移送することで、コイル２を孔部６Ｂの中央に配置することができる。その後、図４（ｂ）に示すように、上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂが、コイル２を挟み込むように駆動される。その際に、コイル２の上下位置はズラさないように上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂが駆動される。この場合、当接受け部の溝部２１Ａ、２１Ｂおよび溝押さえ部２２Ａ、２２Ｂは、コイル２の端部８Ａ・８Ｂを挟み込み、コイル２の端部８Ａ・８Ｂが当接している溝部２１Ａ、２１Ｂおよび溝押さえ部２２Ａ、２２Ｂ以外の当接受け部の部分が互いに当接する。 When producing a dust-molded inductor member with the dust-molded inductor member manufacturing apparatus 1A having such a configuration, first, the upper molds 3A and 3B and the lower molds 4A and 4B are driven, and the upper mold 3A is driven. A space is formed between 3B and the lower molds 4A and 4B, and the coil 2 is disposed at a predetermined position as shown in FIG. The coil 2 may be connected in advance to a lead frame (not shown) so as to be easy to handle, and the coil 2 can be arranged at the center of the hole 6B by transferring the lead frame by a transfer unit (not shown). it can. Thereafter, as shown in FIG. 4B, the upper molds 3A and 3B and the lower molds 4A and 4B are driven so as to sandwich the coil 2. At that time, the upper molds 3A and 3B and the lower molds 4A and 4B are driven so that the vertical position of the coil 2 is not shifted. In this case, the groove portions 21A and 21B and the groove pressing portions 22A and 22B of the contact receiving portion sandwich the end portions 8A and 8B of the coil 2, and the groove portions 21A and 21B and the end portions 8A and 8B of the coil 2 are in contact with each other. The portions of the contact receiving portions other than the groove pressing portions 22A and 22B contact each other.
　この点について、図５を参照してさらに説明する。図５（ａ）に示すように、下金型４Ａには、溝部２１Ａが構成されており、溝部２１Ａは、コイル２の端部８Ａを受け入れる所定幅Ｌの開口部位２６Ａと、開口部位２６Ａに接続されて形成され、所定幅Ｌより幅狭な幅Ｍのコイルの端部８Ａ・８Ｂを配置する配置部位２７Ａとを備えている。図５（ａ）に示す例においては、配置部位２７Ａの幅Ｍが、コイル２の端部８Ａの径の大きさに相当するような幅としており、開口部位２６Ａの所定幅Ｌをこの配置部位２７Ａの幅Ｍより広くして下金型４Ａの垂直断面（コイル端部８Ａを挟み込んだ際のコイル端部８Ａの垂直断面と同一断面）をV字形状とした溝状に形成しておくことで、開口部位２６Ａにおいてはコイル２の端部８Ａを受け入れやすくなり、所定幅Ｌより幅狭な配置部位２７Ａ側にコイル２の端部８Ａが導かれて適切に溝部２１Ａの配置部位２７Ａに嵌まり込むようにできる。また、上金型３Ａには、断面V字形状とした突状の溝押さえ部２２Ａを形成しておき、溝部２１Ａに嵌まり込んだ際に、コイル２の端部８Ａ・８Ｂを上側から挟み込み、コイル２の端部８Ａ・８Ｂに接触して弾性部材７が変形することで、上金型３Ａと下金型４Ａとの隙間から粉体９の漏れが生じるのを防止することができる。また、溝部２１Ｄの高さ（深さ）は、製品として完成したコア１１の高さの半分より深い方が望ましい。当接受け部のコイル２の端部８Ａが当接している溝部２１Ａおよび溝押さえ部２２Ａ以外の部分の当接受け部は互いに当接しておくようにできる。これにより、圧縮成型された圧縮粉体部より外部にコイル２の端部８Ａが延出された状態の圧粉成型インダクタ部材を製造することができ、圧縮粉体部をより小型化することができる。この場合、溝部２１Ａが所定幅Ｌの開口部位２６Ａと所定幅Ｌより幅狭な幅Ｍの配置部位２７Ａとを備え、その形状に対応するような溝押さえ部２２Ａを備えていれば、断面Ｖ字形状以外のＵ字形状などの形状にしてもよい。 This point will be further described with reference to FIG. As shown in FIG. 5A, a groove 21A is formed in the lower mold 4A. The groove 21A has an opening portion 26A having a predetermined width L for receiving the end portion 8A of the coil 2 and an opening portion 26A. And an arrangement portion 27A in which end portions 8A and 8B of a coil having a width M narrower than a predetermined width L are arranged. In the example shown in FIG. 5A, the width M of the arrangement portion 27A is set to a width corresponding to the size of the diameter of the end portion 8A of the coil 2, and the predetermined width L of the opening portion 26A is set to this arrangement portion. The lower mold 4A has a vertical cross section (same cross section as the vertical cross section of the coil end portion 8A when the coil end portion 8A is sandwiched) having a V-shape, which is wider than the width M of 27A. Thus, the end portion 8A of the coil 2 can be easily received in the opening portion 26A, and the end portion 8A of the coil 2 is guided to the arrangement portion 27A side narrower than the predetermined width L, and is appropriately fitted in the arrangement portion 27A of the groove portion 21A. You can get stuck. The upper mold 3A is provided with a protruding groove holding portion 22A having a V-shaped cross section, and when fitted into the groove portion 21A, the end portions 8A and 8B of the coil 2 are sandwiched from above. Since the elastic member 7 is deformed in contact with the ends 8A and 8B of the coil 2, it is possible to prevent the powder 9 from leaking from the gap between the upper mold 3A and the lower mold 4A. The height (depth) of the groove 21D is preferably deeper than half the height of the core 11 completed as a product. The contact receiving portions other than the groove portion 21A and the groove pressing portion 22A with which the end portion 8A of the coil 2 of the contact receiving portion is in contact can be in contact with each other. As a result, it is possible to manufacture a dust-molded inductor member in which the end portion 8A of the coil 2 is extended to the outside from the compressed powder portion that has been compression-molded, and to further reduce the size of the compressed powder portion. it can. In this case, if the groove 21A has an opening part 26A having a predetermined width L and an arrangement part 27A having a width M narrower than the predetermined width L, and a groove pressing part 22A corresponding to the shape, the cross section V You may make it shapes, such as U shape other than character shape.
　図５（ｂ）に示すように、上金型３Ａと下金型４Ａとでコイル２の端部８Ａを挟み込んだ状態においては、溝部２１Ａの配置部位２７Ａにコイル２の端部８Ａが配置された状態で、コイル２の端部８Ａを上側から溝押さえ部２２Ａで挟み込むことができる。これにより、コイル２の端部８Ａが当接している溝部２１Ａおよび溝押さえ部２２Ａ以外の部分は、上金型３Ａが下金型４Ａの当接面に当接するため、上金型３Ａと下金型４Ａとが隙間なく当接し、また、溝部２１Ａおよび溝押さえ部２２Ａでコイル２の端部８Ａを隙間なく挟み込めることができる。このため、粉体供給部１０より供給された粉体９が上パンチ５Ａおよび下パンチ５Ｂにより加圧されたときに、当接受け部により挟み込まれているコイル２の端部８Ａ側に、粉体９が漏れて流れていくのを防ぐことができる。 As shown in FIG. 5B, in the state where the end 8A of the coil 2 is sandwiched between the upper mold 3A and the lower mold 4A, the end 8A of the coil 2 is arranged in the arrangement portion 27A of the groove 21A. In this state, the end portion 8A of the coil 2 can be sandwiched by the groove pressing portion 22A from above. As a result, the upper mold 3A comes into contact with the contact surface of the lower mold 4A at portions other than the groove 21A and the groove pressing section 22A with which the end 8A of the coil 2 is in contact. The mold 4A is in contact with no gap, and the end portion 8A of the coil 2 can be sandwiched between the groove portion 21A and the groove pressing portion 22A without any gap. For this reason, when the powder 9 supplied from the powder supply unit 10 is pressurized by the upper punch 5A and the lower punch 5B, the powder 9 is placed on the end 8A side of the coil 2 sandwiched by the contact receiving unit. It is possible to prevent the body 9 from leaking and flowing.
　上述したような本第２実施例における当接受け部を設けておき、図４（ｂ）に示すように、コイル２の端部８Ａが、上金型３Ａと下金型４Ａとにより挟み込まれた状態で、下パンチ５Ｂをコア１１の大きさに対応するような適切な位置まで上昇させるとともに、粉体供給部１０を孔部６Ａ・６Ｂにあるコイル２の螺旋部８Ｃ上の位置まで移動させる。その後、図４（ｃ）に示すように、粉体供給部１０から粉体９を所定量供給する。下パンチ５Ｂには、粉体供給部１０から供給される粉体の供給量を重量などにより測量するセンサを設けておき、粉体９が所定量供給された際に、供給を停止させるようにしてもよい。つぎに、図４（ｄ）に示すように、粉体供給部１０は、粉体９の供給後に側部に移動する際に、粉体９の上面をスライドすることで、粉体供給部１０の下面で粉体９を擦切るようにしている。粉体９は、コイル２の螺旋部８Ｃの表面を全て覆うように孔部６Ａ・６Ｂに供給される。そして、上パンチ５Ａを下側方向に移動させて、上パンチ５Ａおよび下パンチ５Ｂにより、図４（ｅ）に示すように、上下からそれぞれ同時に加圧して、粉体９およびコイル２を圧縮する。上下からそれぞれ同時に加圧することで、粉体９の密度を均一にすることができ、また、コイル２の配置位置が上下に移動することなく密封される。この圧縮により、コア１１が形成される。図４（ｆ）に示すように、上パンチ５Ａおよび下パンチ５Ｂと、上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂとをそれぞれ移動させることで開放することで、図１（ｂ）に示すような圧粉成型インダクタ部材１２の製造が完成する。その後、コア１１の両側部に端子電極部１４Ａ・１４Ｂを装着し、端子電極部１４Ａ・１４Ｂを導線の端部８Ａ・８Ｂに導通するように接続させる。これにより、図１（ｃ）に示すような圧粉成型インダクタ部材１３の製造が完成する。図４（ｅ）に示すように、分割されている上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂの互いに当接する当接面（溝部２１と溝押さえ部２２以外の部分）の位置を、成形された際のコア１１の上辺の位置に設定することが可能となるので、分割されている上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂの当接面において粉体９が漏れ出ることで生じる圧粉成型インダクタ部材のパーティングラインを無くすことが可能となる。 The contact receiving portion in the second embodiment as described above is provided, and as shown in FIG. 4B, the end portion 8A of the coil 2 is sandwiched between the upper die 3A and the lower die 4A. In this state, the lower punch 5B is raised to an appropriate position corresponding to the size of the core 11, and the powder supply unit 10 is moved to a position on the spiral portion 8C of the coil 2 in the holes 6A and 6B. Let Thereafter, as shown in FIG. 4C, a predetermined amount of the powder 9 is supplied from the powder supply unit 10. The lower punch 5B is provided with a sensor for measuring the supply amount of the powder supplied from the powder supply unit 10 by weight or the like so that the supply is stopped when a predetermined amount of the powder 9 is supplied. May be. Next, as shown in FIG. 4 (d), the powder supply unit 10 slides on the upper surface of the powder 9 when moving to the side after supplying the powder 9, so that the powder supply unit 10. The powder 9 is scraped off on the lower surface of. The powder 9 is supplied to the holes 6A and 6B so as to cover the entire surface of the spiral portion 8C of the coil 2. Then, the upper punch 5A is moved downward, and the upper punch 5A and the lower punch 5B are simultaneously pressed from above and below as shown in FIG. 4E to compress the powder 9 and the coil 2. . By simultaneously pressing from above and below, the density of the powder 9 can be made uniform, and the arrangement position of the coil 2 is sealed without moving up and down. The core 11 is formed by this compression. As shown in FIG. 4 (f), the upper punch 5A and the lower punch 5B and the upper molds 3A and 3B and the lower molds 4A and 4B are opened by moving them, respectively, so that FIG. The production of the compacted inductor member 12 as shown is completed. Thereafter, terminal electrode portions 14A and 14B are mounted on both sides of the core 11, and the terminal electrode portions 14A and 14B are connected to the conductive wire ends 8A and 8B so as to be conducted. Thereby, manufacture of the compacting inductor member 13 as shown in FIG.1 (c) is completed. As shown in FIG. 4 (e), the positions of the contact surfaces (portions other than the groove 21 and the groove pressing portion 22) of the divided upper molds 3A and 3B and the lower molds 4A and 4B are as follows. Since it is possible to set the position of the upper side of the core 11 when it is molded, the powder 9 leaks out at the contact surfaces of the divided upper molds 3A and 3B and lower molds 4A and 4B. It is possible to eliminate the parting line of the dust-molded inductor member generated in step (b).
　第２実施例における溝部２１Ａ、２１Ｂおよび溝押さえ部２２Ａ、２２Ｂの形状としては、図５に示すような構成の他に、例えば、図６～図９に示すような構成とすることができる。図６～図９には、第２実施例の他の構成における圧粉成型インダクタ部材の製造工程の一部拡大図（ａ）および（ｂ）を示している。図６～図９においては、上金型３Ａと、下金型４Ａとの縦断面を示している。 As the shapes of the groove portions 21A and 21B and the groove pressing portions 22A and 22B in the second embodiment, for example, the configurations shown in FIGS. 6 to 9 can be adopted in addition to the configuration shown in FIG. 6 to 9 are partially enlarged views (a) and (b) of the manufacturing process of the dust-molded inductor member in another configuration of the second embodiment. 6 to 9 show longitudinal sections of the upper mold 3A and the lower mold 4A.
　図６においては、第２実施例の他の構成として、溝部２１Ｃおよび溝押さえ部２２Ｃの構成を示している。溝部２１Ｃは、コイル２の端部８Ａを配置する配置部位２７Ｃの幅Ｍが、コイル２の端部８Ａの径の大きさに相当するような幅とし、また、配置部位２７Ｃの底面の形状がコイル２の端部８Ａの下側の周囲に沿うような丸みを帯びた形状としている。また、開口部位２６Ｃの所定幅Ｌをこの配置部位２７Ｃの幅Ｍより広くして溝部２１Ｃの断面を略V字形状とした溝状に形成しておくことで、開口部位２６Ｃにおいてコイル２の端部８Ａを受け入れやすくなり、所定幅Ｌより幅狭な配置部位２７Ｃにコイル２の端部８Ａが導かれて適切に溝部２１Ｃの配置部位２７Ｃに嵌まり込むようにできる。また、上金型３Ａには、断面略V字形状とした突状であって、その突状の先端部分を、コイル２の端部８Ａの径の大きさに相当し、コイル２の端部８Ａの周囲に沿うような丸みを帯びた半円形状分カットされたような形状の溝押さえ部２２Ｃを形成しておく。図６（ｂ）に示すように、溝部２１Ｃに溝押さえ部２２Ｃが嵌まり込んだ際に、コイル２の端部８Ａを挟み込んだ場合に、溝押さえ部２２Ｃの突状の先端部分と、溝部２１Ｃの底面部分とがコイル２の端部８Ａの形状に沿うような形状に構成されているため、コイル２の端部８Ａにそれぞれ当接できるのでコイル２の端部８Ａを潰さないようにでき、上金型３Ａと下金型４Ａとの隙間から粉体９の漏れが生じるのを防止することができる。この場合、形状をコイル２の端部８Ａの形状に溝部２１Ｃと溝押さえ部２２Ｃとの材質を、金型と同一の材質にしたような場合にも、上金型３Ａと下金型４Ａとの隙間から粉体９の漏れが生じるのを防止することができる。 FIG. 6 shows the configuration of the groove portion 21C and the groove pressing portion 22C as another configuration of the second embodiment. The groove portion 21C has such a width that the width M of the arrangement portion 27C where the end portion 8A of the coil 2 is arranged corresponds to the diameter of the end portion 8A of the coil 2, and the shape of the bottom surface of the arrangement portion 27C is The coil 2 has a rounded shape along the lower periphery of the end 8 </ b> A of the coil 2. Further, the predetermined width L of the opening portion 26C is made wider than the width M of the arrangement portion 27C, and the groove portion 21C is formed in a groove shape having a substantially V-shaped cross section. The portion 8A can be easily received, and the end portion 8A of the coil 2 can be guided to the arrangement portion 27C narrower than the predetermined width L, and can be appropriately fitted into the arrangement portion 27C of the groove portion 21C. Further, the upper mold 3A has a protruding shape with a substantially V-shaped cross section, and the protruding tip portion corresponds to the size of the diameter of the end portion 8A of the coil 2, and the end portion of the coil 2 A groove pressing portion 22C having a shape that is cut by a rounded semicircular shape along the periphery of 8A is formed. As shown in FIG. 6B, when the end portion 8A of the coil 2 is sandwiched when the groove holding portion 22C is fitted into the groove portion 21C, the protruding tip portion of the groove holding portion 22C and the groove portion Since the bottom surface portion of 21C is configured to conform to the shape of the end portion 8A of the coil 2, the end portion 8A of the coil 2 can be prevented from being crushed because it can be brought into contact with the end portion 8A of the coil 2 respectively. The leakage of the powder 9 from the gap between the upper mold 3A and the lower mold 4A can be prevented. In this case, even when the shape of the end portion 8A of the coil 2 is the same as the material of the groove 21C and the groove pressing portion 22C, the upper die 3A and the lower die 4A It is possible to prevent the leakage of the powder 9 from the gap.
　また、図７においては、第２実施例の他の構成として、溝部２１Ｄの構成と、上金型３Ａの構成を示している。図７においては、上金型３Ａに溝押さえ部を備えない場合を例にしている。溝部２１Ｄは、配置部位２７Ｄの幅Ｍが、コイル２の端部８Ａの径の大きさに相当するような幅とし、また、配置部位２７Ｄの形状がコイル２の端部８Ａに周囲に沿うような丸みを帯びた形状としている。また、開口部位２６Ｄの所定幅Ｌをこの配置部位２７Ｄの幅Ｍより広くして断面を略Ｕ字形状とした溝状に形成しておくことで、開口部位２６Ｄにおいてはコイル２の端部８Ａを受け入れやすくなり、所定幅Ｌより幅狭な配置部位２７Ｄにコイル２の端部８Ａが導かれて適切に溝部２１Ｄの配置部位２７Ｄに嵌まり込むようにできる。また、溝部２１Ｄの溝部分の断面積をコイルの端部８Ａの断面積とほぼ等しくなるようにしておき、溝部２１Ｄの高さ（深さ）は、コイルの端部８Ａの直径よりも小さく、例えば、コイルの端部８Ａの半径相当分ぐらいにしておく。図７（ｂ）に示すように、溝部２１Ｄに配置されたコイル２の端部８Ａを上側から上金型３Ａで挟み込むことで、溝部２１Ｄの高さがコイルの端部８Ａの直径よりも小さいため、コイル２の端部８Ａが押し潰されて溝部２１Ｄ内に嵌まり込み、溝部２１Ｄ内がコイル２の端部８Ａに埋め尽くされることで隙間が無くなり、上金型３Ａと下金型４Ａとの隙間から粉体９の漏れが生じるのを防止することができる。溝部２１Ｄの形状は、断面Ｕ字状以外にも、コ字状などにしてもよい。図７に示す例によれば、上金型３Ａが溝押さえ部を備えないので、金型が劣化しにくくなる。 FIG. 7 shows the configuration of the groove 21D and the configuration of the upper mold 3A as another configuration of the second embodiment. FIG. 7 shows an example in which the upper mold 3A is not provided with a groove pressing portion. The groove portion 21D has a width such that the width M of the arrangement portion 27D corresponds to the size of the diameter of the end portion 8A of the coil 2, and the shape of the arrangement portion 27D extends along the periphery of the end portion 8A of the coil 2. It has a rounded shape. Further, by forming a predetermined width L of the opening portion 26D larger than the width M of the arrangement portion 27D and forming a groove having a substantially U-shaped cross section, the end portion 8A of the coil 2 is formed in the opening portion 26D. The end portion 8A of the coil 2 is guided to the arrangement portion 27D narrower than the predetermined width L, and can be appropriately fitted into the arrangement portion 27D of the groove portion 21D. In addition, the cross-sectional area of the groove portion of the groove portion 21D is made substantially equal to the cross-sectional area of the coil end portion 8A, and the height (depth) of the groove portion 21D is smaller than the diameter of the coil end portion 8A. For example, it is set to a portion corresponding to the radius of the end portion 8A of the coil. As shown in FIG. 7B, the height of the groove 21D is smaller than the diameter of the coil end 8A by sandwiching the end 8A of the coil 2 disposed in the groove 21D with the upper mold 3A from above. Therefore, the end portion 8A of the coil 2 is crushed and fitted into the groove portion 21D, and the groove portion 21D is completely filled with the end portion 8A of the coil 2, thereby eliminating the gap, and the upper mold 3A and the lower mold 4A. It is possible to prevent the powder 9 from leaking from the gap. The shape of the groove 21D may be a U-shape other than the U-shaped cross section. According to the example shown in FIG. 7, since the upper mold 3A does not include the groove pressing portion, the mold is hardly deteriorated.
　また、図８においては、第２実施例の他の構成として、溝部２１Ｅおよび溝押さえ部２２Ｅの構成を示している。溝部２１Ｅおよび溝押さえ部２２Ｅは、縦断面をコ字状の凹凸形状としている。この場合、溝部２１Ｅの所定幅の開口部位と、配置部位の幅とを同じ幅に設定し、また、溝押さえ部２２Ｅの突部分の幅もほぼ同じ幅としている。溝部２１Ｅは、開口部位２６Ｅの幅Ｌと配置部位２７Ｅの幅Ｍは、コイル２の端部８Ａの径の大きさより大きな幅としている。また、上金型３Ａには、溝部２１Ｅに対応するようなコ字状の突形状の溝押さえ部２２Ｅを形成しておく。この場合、溝部２１Ｅの高さ（深さ）は、溝押さえ部２２Ｅの断面の高さより大きくしておくことで、図８（ｂ）に示すように、溝部２１Ｅに溝押さえ部２２Ｅが嵌まり込んだ際に、隙間が生じるようにしている。コイル２の端部８Ａを上側から挟み込む際に、溝押さえ部２２Ｅによりコイル２の端部８Ａが押し潰されて、溝部２１Ｅ内に嵌まり込み、溝部２１Ｅ内がコイル２の端部８Ａに埋め尽くされることで隙間が無くなり、上金型３Ａと下金型４Ａとの隙間から粉体９の漏れが生じるのを防止することができる。図８に示す例によれば、溝部２１Ｅが、開口部位２６Ｅの幅Ｌと配置部位２７Ｅの幅Ｍが、コイル２の端部８Ａの径の大きさより大きな幅としているので、コイル２の端部８Ａをより受け入れやすくすることができる。また、溝部２１Ｅおよび溝押さえ部２２Ｅの凹凸で挟み込むことで、コイル２の端部８Ａの位置を固定して挟み込むことができ、押圧力が分散され、溝部２１Ｅおよび溝押さえ部２２Ｅにおけるコア１１のパーティングライン（上下の境目）を無くすことができる。 FIG. 8 shows the configuration of the groove 21E and the groove pressing portion 22E as another configuration of the second embodiment. The groove portion 21E and the groove pressing portion 22E have a U-shaped uneven shape in the longitudinal section. In this case, the opening part of the predetermined width of the groove 21E and the width of the arrangement part are set to the same width, and the width of the protruding part of the groove pressing part 22E is also substantially the same. In the groove 21E, the width L of the opening part 26E and the width M of the arrangement part 27E are larger than the diameter of the end 8A of the coil 2. Further, the upper mold 3A is formed with a U-shaped protruding groove pressing portion 22E corresponding to the groove portion 21E. In this case, by making the height (depth) of the groove 21E larger than the height of the cross section of the groove pressing portion 22E, the groove pressing portion 22E fits into the groove 21E as shown in FIG. 8B. When it is inserted, a gap is created. When the end portion 8A of the coil 2 is sandwiched from above, the end portion 8A of the coil 2 is crushed by the groove pressing portion 22E and fitted into the groove portion 21E, and the inside of the groove portion 21E is buried in the end portion 8A of the coil 2. By being exhausted, there is no gap and it is possible to prevent leakage of the powder 9 from the gap between the upper mold 3A and the lower mold 4A. According to the example shown in FIG. 8, since the groove portion 21E has a width L of the opening portion 26E and a width M of the arrangement portion 27E larger than the diameter of the end portion 8A of the coil 2, the end portion of the coil 2 8A can be made easier to accept. Further, by sandwiching the groove portion 21E and the groove pressing portion 22E between the concave and convex portions, the position of the end portion 8A of the coil 2 can be fixed and sandwiched, the pressing force is dispersed, and the core 11 in the groove portion 21E and the groove pressing portion 22E is dispersed. The parting line (upper and lower boundaries) can be eliminated.
　また、図９においては、第２実施例の他の構成として、溝部２１Ｆおよび溝押さえ部２２Ｆの構成を示している。図９においては、図５に示した構成において、溝押さえ部２２の突状の先端部分を弾性部材７により構成している場合を例にしている。溝部２１Ｆは、図６に示した溝部２１Ｃと同様な形状であり、コイル２の端部８Ａを配置する配置部位２７Ｆの幅Ｍが、コイル２の端部８Ａの径の大きさに相当するような幅とし、また、配置部位２７Ｆの底面の形状がコイル２の端部８Ａの下側の周囲に沿うような丸みを帯びた形状としている。また、開口部位２６Ｆの所定幅Ｌをこの配置部位２７Ｆの幅Ｍより広くして溝部２１Ｆの断面を略V字形状とした溝状に形成しておくことで、開口部位２６Ｆにおいてコイル２の端部８Ａを受け入れやすくなり、所定幅Ｌより幅狭な配置部位２７Ｆにコイル２の端部８Ａが導かれて適切に溝部２１Ｆの配置部位２７Ｆに嵌まり込むようにできる。また、上金型３Ａには、断面略V字形状とした突状であって、その突状の先端部分を弾性部材７により構成し、コイル２の端部８Ａの周囲に沿って弾性変形するように溝押さえ部２２Ｆを形成しておく。図９（ｂ）に示すように、溝部２１Ｆに溝押さえ部２２Ｆが嵌まり込んだ際に、溝押さえ部２２Ｆの弾性部材７が、コイル２の端部８Ａの表面に隙間なく接触するとともに、下金型４Ａの溝部２１Ａに隙間なく接触することができる。このため、コイル２の端部８Ａが、上金型３Ａと下金型４Ａとにより挟み込まれたときに、潰されることや切断されることがない。コイル２の端部８Ａを挟み込んだ場合に、溝押さえ部２２Ｆの突状の先端部分が、溝部２１Ｆの底面部分とがコイル２の端部８Ａの形状に沿うように弾性変形するため、コイル２の端部８Ａにそれぞれ当接できるのでコイル２の端部８Ａを潰さないようにでき、上金型３Ａと下金型４Ａとの隙間から粉体９の漏れが生じるのを防止することができる。この場合、溝押さえ部２２の弾性部材７は、取り換え可能に着脱できる構成としておくことで、弾性部材７が劣化したときに新しいものに取り換えることができる。 FIG. 9 shows the configuration of the groove portion 21F and the groove pressing portion 22F as another configuration of the second embodiment. FIG. 9 illustrates an example in which the protruding tip portion of the groove pressing portion 22 is configured by the elastic member 7 in the configuration illustrated in FIG. 5. The groove portion 21F has the same shape as the groove portion 21C shown in FIG. 6, and the width M of the arrangement portion 27F where the end portion 8A of the coil 2 is disposed corresponds to the size of the diameter of the end portion 8A of the coil 2. Further, the bottom surface of the arrangement portion 27F is rounded so as to be along the lower periphery of the end portion 8A of the coil 2. Further, the predetermined width L of the opening portion 26F is made wider than the width M of the arrangement portion 27F and the groove portion 21F is formed in a groove shape having a substantially V-shaped cross section, so that the end of the coil 2 is formed in the opening portion 26F. The portion 8A can be easily received, and the end portion 8A of the coil 2 can be guided to the arrangement portion 27F narrower than the predetermined width L, and can be appropriately fitted into the arrangement portion 27F of the groove portion 21F. Further, the upper mold 3A has a protruding shape having a substantially V-shaped cross section, and the protruding tip end portion is constituted by the elastic member 7, and is elastically deformed along the periphery of the end portion 8A of the coil 2. Thus, the groove pressing portion 22F is formed. As shown in FIG. 9B, when the groove pressing portion 22F is fitted into the groove portion 21F, the elastic member 7 of the groove pressing portion 22F contacts the surface of the end portion 8A of the coil 2 without a gap, It is possible to contact the groove portion 21A of the lower mold 4A without a gap. For this reason, when the end portion 8A of the coil 2 is sandwiched between the upper mold 3A and the lower mold 4A, it is not crushed or cut. When the end portion 8A of the coil 2 is sandwiched, the protruding tip portion of the groove pressing portion 22F is elastically deformed so that the bottom surface portion of the groove portion 21F conforms to the shape of the end portion 8A of the coil 2. Since the end portion 8A of the coil 2 can be prevented from being crushed, it is possible to prevent the powder 9 from leaking from the gap between the upper die 3A and the lower die 4A. . In this case, the elastic member 7 of the groove pressing portion 22 is configured to be detachable so that it can be replaced with a new one when the elastic member 7 deteriorates.
　以上、本第２実施例における圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３の製造方法によれば、コイル２の螺旋部８Ｃに粉体９を充填後、圧縮工程を１度行うだけで、コア１１を圧縮成型できるため、工程数を少なくでき、容易に製造することができる。また、成形型部の当接受け部の溝部２１において、溝部２１の所定幅Ｌの開口部位２６よりコイル２の端部８を受け入れて、配置部位２７が、開口部位２６の所定幅Ｌより幅狭の幅Ｍに設定されていることで、溝部２１の配置部位２７にコイル２の端部８が導かれやすくなり、溝部２１の配置部位２７にコイル２の端部８を嵌まり込ませて、より適切にコイルの端部を配置部位である一定の位置に配置させることができる。成形型部の下金型４Ａ、４Ｂに溝部２１を作成し、コイル２の端部８をそれにはめることで、粉体９との接触面積が減り、弾性部材７にかかる圧力を軽減することができる。また、毎回同じ配置部位の位置にコイル２の端部８が配置されるため、弾性部材７が劣化しにくくなる。コイル２の端部８の位置が多少ずれて開口部位２６より受け入れても、溝部２１がV字状に形成されているため、毎回同じ配置部位２７の位置に配置されることになるため、完成した圧粉成型インダクタ部材の製品の形状を、製品ごとに同じ形状で製造させることができる。また、上下の金型の中間で押圧していても、Ｖ字状の溝部２１を設けることによって、押圧力が分散され、溝部２１におけるコア１１のパーティングライン（上下の境目）を無くすことができる。また、分割されている上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂの互いに当接する当接面の位置を、成形された際のコア１１の上辺の位置に設定することが可能となるので、分割されている上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂの当接面において粉体９が漏れ出ることで生じる圧粉成型インダクタ部材のパーティングラインを無くすことが可能となる。また、粉体供給部１０より供給された粉体９が上パンチ５Ａおよび下パンチ５Ｂにより加圧されたときに、当接受け部により挟み込まれているコイル２の端部８側には、粉体９が漏れて流れていくのを防ぐことができ、圧粉成型インダクタ部材の外側に粉体が漏れることによるバリの発生を防ぐことができる。当接受け部の溝部２１は、例えば、配置部位２７の幅Ｍを、コイル２の端部８の径の大きさに相当するような幅とする場合には、開口部位２６の所定幅Ｌをこの配置部位の幅より広くしておくことで、開口部位２６においてはコイル２の端部８を受け入れやすくなり、また、所定幅Ｌより幅狭な幅Ｍの配置部位にコイル２の端部８が導かれて適切に溝部２１に嵌まり込むようにでき、また、当接受け部のコイル２の端部８が当接している以外の部分は互いに当接しておくようにできる。これにより、圧縮成型されたコア１１より外部にコイル２の端部８が延出された状態の圧粉成型インダクタ部材を製造することができ、コア１１をより小型化することができる。また、これにより、圧縮成型されたコア１１より外部であって外側にコイル２の端部８Ａ・８Ｂが延出された状態の圧粉成型インダクタ部材１２を製造することができる。この製造方法によれば、圧縮の際に、粉体９が端部８Ａおよび８Ｂ側に漏れてしまう恐れがなく、上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂの成形型と同じ大きさのコア１１を作成することができるため、コア１１の大きさをより小型化することができ、圧粉成型インダクタ部材１２の大きさをより小型化することができる。 As described above, according to the method of manufacturing the dust-molded inductor member 12 and the dust-molded inductor member 13 in the second embodiment, after the powder 9 is filled in the spiral portion 8C of the coil 2, the compression process is performed only once. Since the core 11 can be compression molded, the number of steps can be reduced and the core 11 can be easily manufactured. Further, in the groove portion 21 of the contact receiving portion of the molding die portion, the end portion 8 of the coil 2 is received from the opening portion 26 having the predetermined width L of the groove portion 21, and the arrangement portion 27 is wider than the predetermined width L of the opening portion 26. By setting the narrow width M, the end portion 8 of the coil 2 is easily guided to the arrangement portion 27 of the groove portion 21, and the end portion 8 of the coil 2 is fitted into the arrangement portion 27 of the groove portion 21. The end of the coil can be more appropriately arranged at a certain position as the arrangement site. The groove 21 is formed in the lower molds 4A and 4B of the molding die and the end 8 of the coil 2 is fitted thereto, thereby reducing the contact area with the powder 9 and reducing the pressure applied to the elastic member 7. it can. Further, since the end portion 8 of the coil 2 is arranged at the same arrangement site every time, the elastic member 7 is hardly deteriorated. Even if the position of the end portion 8 of the coil 2 is slightly deviated and received from the opening portion 26, the groove portion 21 is formed in a V shape, so that it is arranged at the same arrangement portion 27 every time. The product shape of the compacted molded inductor member can be manufactured in the same shape for each product. Even if pressing is performed between the upper and lower molds, the provision of the V-shaped groove 21 disperses the pressing force and eliminates the parting line (upper and lower boundaries) of the core 11 in the groove 21. it can. In addition, the position of the contact surfaces of the divided upper molds 3A and 3B and the lower molds 4A and 4B that are in contact with each other can be set to the position of the upper side of the core 11 when molded. In addition, it is possible to eliminate the parting line of the powder-molded inductor member generated by the powder 9 leaking out at the contact surfaces of the divided upper molds 3A and 3B and lower molds 4A and 4B. Further, when the powder 9 supplied from the powder supply unit 10 is pressurized by the upper punch 5A and the lower punch 5B, the end portion 8 side of the coil 2 sandwiched by the contact receiving unit has no powder. The body 9 can be prevented from leaking and flowing, and the generation of burrs due to the powder leaking to the outside of the dust-molded inductor member can be prevented. For example, when the width M of the arrangement portion 27 is set to a width corresponding to the diameter of the end portion 8 of the coil 2, the groove portion 21 of the contact receiving portion has a predetermined width L of the opening portion 26. By making it wider than the width of the arrangement part, the end part 8 of the coil 2 can be easily received in the opening part 26, and the end part 8 of the coil 2 is arranged in the arrangement part of the width M narrower than the predetermined width L. Can be appropriately fitted into the groove portion 21, and portions other than the end portion 8 of the coil 2 of the contact receiving portion in contact with each other can be in contact with each other. Thereby, the dust-molded inductor member in a state in which the end 8 of the coil 2 is extended to the outside from the compression-molded core 11 can be manufactured, and the core 11 can be further downsized. This also makes it possible to manufacture the dust-molded inductor member 12 in the state where the ends 8A and 8B of the coil 2 are extended outside the compression-molded core 11 and outside. According to this manufacturing method, there is no possibility that the powder 9 leaks to the end portions 8A and 8B during compression, and the same size as the molds of the upper molds 3A and 3B and the lower molds 4A and 4B. Therefore, the size of the core 11 can be further reduced, and the size of the dust-molded inductor member 12 can be further reduced.
　また、当接受け部に、溝部２１に嵌まり込み、コイル２の端部８を挟み込む溝押さえ部２２を有することで、溝押さえ部２２が溝部２１に嵌まり込み、溝押さえ部２２と溝部２１とでコイル２の端部８を挟み込むため、溝押さえ部によりコイル端部が押さえられ、コイル端部の位置を固定することができ、粉体供給部１０より供給された粉体９が加圧部により加圧されたときに、溝押さえ部２２と溝部２１とにより挟み込まれているコイルの端部８側には、粉体９が漏れて流れていくのをより防ぐことができ、圧粉成型インダクタ部材の外側に粉体が漏れることによるバリの発生を防ぐことができる。溝押さえ部２２と溝部２１とのコイルの端部の当接面側のうち少なくとも一方を弾性部材７により構成する場合には、弾性部材がコイルの端部の形状に合わせて変形するため、挟み込まれたときにコイルの端部が潰されることや切断されることがないのでより好ましい。また、コイルの端部が潰されることや切断されることがないので、コイル２の導線を、通常利用する断面が円状または方形の細い導線を利用できる。 Further, since the contact receiving portion has the groove pressing portion 22 that fits into the groove portion 21 and sandwiches the end portion 8 of the coil 2, the groove pressing portion 22 fits into the groove portion 21, and the groove pressing portion 22 and the groove portion. 21, the end portion 8 of the coil 2 is sandwiched between the end portions of the coil 2, so that the end portion of the coil can be pressed by the groove pressing portion to fix the position of the coil end portion, and the powder 9 supplied from the powder supply portion 10 can be added. When pressed by the pressure part, it is possible to further prevent the powder 9 from leaking and flowing to the end 8 side of the coil sandwiched between the groove pressing part 22 and the groove part 21. Generation | occurrence | production of the burr | flash by powder leaking to the outer side of a powder shaping | molding inductor member can be prevented. When at least one of the contact surfaces of the end portions of the coil between the groove pressing portion 22 and the groove portion 21 is constituted by the elastic member 7, the elastic member is deformed in accordance with the shape of the end portion of the coil. It is more preferable because the end of the coil is not crushed or cut when it is removed. In addition, since the end portion of the coil is not crushed or cut, a conductive wire of the coil 2 can be used as a thin conductive wire having a circular or square cross section.
　また、本実施例によれば、コア１１の外側には粉体９が漏れ出ておらず、粉体９が漏れることによるバリの発生がなく、また、コイル２の端部８は、上金型３Ａと下金型４Ａにより押し潰されてなく、コイル２の端部８をそのまま維持した状態の圧粉成型インダクタ部材を提供できる。 Further, according to the present embodiment, the powder 9 does not leak out of the core 11, no burrs are generated due to the leakage of the powder 9, and the end 8 of the coil 2 is It is possible to provide a dust-molded inductor member that is not crushed by the mold 3A and the lower mold 4A but maintains the end 8 of the coil 2 as it is.
　また、当接受け部は、コイル２の端部８Ａを受け入れる凹部と、凹部に受け入れられたコイル２の端部８Ａを挟み込む凸部とを有するようにしてもよい。成形型部の当接受け部において、凹部でコイルの端部を受け入れて、凸部で凹部に受け入れられた前記コイルの端部を挟み込むことで、当接受け部の凹部と凸部とでコイルの端部を挟み込み、当該コイルの端部が当接している凹部と凸部以外の部分が互いに当接するため、粉体供給部１０より供給された粉体９が上パンチ５Ａおよび下パンチ５Ｂにより加圧されたときに、当接受け部により挟み込まれているコイル２の端部８Ａ側には、粉体９が漏れて流れていくのを防ぐことができる。当接受け部の凹部は、例えば、凹部の幅を、コイルの端部の径の大きさより広くしておくことで、凹部においてコイルの端部を受け入れやすくなり、また、凸部を凹部と同様の幅としておくことで適切に凹部と凸部で嵌まり込むようにでき、また、当接受け部のコイル２の端部８Ａが当接している凹部と凸部以外の部分は互いに当接しておくようにできる。これにより、圧縮成型されたコア１１より外部にコイル２の端部８Ａが延出された状態の圧粉成型インダクタ部材を製造することができ、コア１１をより小型化することができる。 Further, the contact receiving portion may have a concave portion that receives the end portion 8A of the coil 2 and a convex portion that sandwiches the end portion 8A of the coil 2 that is received in the concave portion. In the contact receiving part of the mold part, the coil end is received by the concave part and the coil end received by the convex part is sandwiched between the concave part and the convex part of the coil. The portion other than the concave portion and the convex portion with which the end portion of the coil is in contact with each other comes into contact with each other, so that the powder 9 supplied from the powder supply portion 10 is fed by the upper punch 5A and the lower punch 5B. When pressurized, it is possible to prevent the powder 9 from leaking and flowing to the end 8A side of the coil 2 sandwiched between the contact receiving portions. For example, by setting the width of the concave portion wider than the diameter of the end portion of the coil, the concave portion of the contact receiving portion can easily receive the end portion of the coil in the concave portion, and the convex portion is the same as the concave portion. It is possible to fit the concave portion and the convex portion appropriately, and the portions other than the concave portion and the convex portion where the end portion 8A of the coil 2 of the contact receiving portion is in contact with each other are in contact with each other. You can leave. Thereby, the dust-molded inductor member in a state in which the end portion 8A of the coil 2 is extended outside the compression-molded core 11 can be manufactured, and the core 11 can be further downsized.
　また、本第２実施例による圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３は、より小型化が図れるため、配置した場合に省スペース化が可能となる。また、圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３は、閉磁路タイプで、コイル２の螺旋部８Ｃを磁性材で覆うため、漏れ磁束を少なくすることができ、他の隣接部品への磁気による影響を少なくすることができる。圧粉成型インダクタ部材１３は、端子電極部をコア１１の外側に外付けするため、コア１１の寸法ギリギリまで螺旋部８Ｃの直径を大きくすることができる。これにより、圧粉成型インダクタ部材１３は、インダクタンスを大きくすることができ、発熱しにくくなり、放熱しやすくなるという効果がある。圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３は、コイル２の封入と同時にコアを成形することで、コイル２を密封させる粉体９がコア１１になる。これにより粉体９がコイル２の全面に隙間無くいきわたり、コア１１を成形することができる。コイル２とコア１１の間に隙間が生じないため、インダクタンスの低下を防止することができる。また、粉体９の密度を均一にすることができるため、品質を向上させることができる。 In addition, since the compacted inductor member 12 and the compacted inductor member 13 according to the second embodiment can be further reduced in size, it is possible to save space when arranged. Moreover, since the dust-molded inductor member 12 and the dust-molded inductor member 13 are closed magnetic circuit types and the spiral portion 8C of the coil 2 is covered with a magnetic material, leakage magnetic flux can be reduced, and other adjacent components can be reduced. The influence of magnetism can be reduced. Since the dust-molded inductor member 13 externally attaches the terminal electrode portion to the outside of the core 11, the diameter of the spiral portion 8 </ b> C can be increased to the size of the core 11. Thereby, the dust-molded inductor member 13 has an effect that the inductance can be increased, the heat generation becomes difficult, and the heat dissipation becomes easy. In the powder-molded inductor member 12 and the powder-molded inductor member 13, the core 9 is molded simultaneously with the encapsulation of the coil 2, so that the powder 9 that seals the coil 2 becomes the core 11. As a result, the powder 9 can pass through the entire surface of the coil 2 without a gap, and the core 11 can be formed. Since there is no gap between the coil 2 and the core 11, a decrease in inductance can be prevented. Moreover, since the density of the powder 9 can be made uniform, the quality can be improved.
　本第２実施例による圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３は、例えば、電源回路に用いられるパワーチョーク、高周波回路におけるインピーダンス整合のためのインダクタ、ノイズ対策のためのフィルタ等に利用することができる。特に、圧粉成型インダクタ部材１２、圧粉成型インダクタ部材１３は、コイルを巻線タイプの螺旋状にしているため、定格電流を大きくすることができ、抵抗をより低くでき、損失を少なくすることができる。 The dust-molded inductor member 12 and the dust-molded inductor member 13 according to the second embodiment are used for, for example, a power choke used in a power supply circuit, an inductor for impedance matching in a high-frequency circuit, a filter for noise countermeasures, and the like. can do. In particular, the dust-molded inductor member 12 and the dust-molded inductor member 13 have a coil of a winding type spiral shape, so that the rated current can be increased, the resistance can be lowered, and the loss can be reduced. Can do.
　以上、本発明の実施例を図面により説明してきたが、具体的な構成はこれら実施例に限られるものではなく、本発明の要旨を逸脱しない範囲における変更や追加があっても本発明に含まれる。 Although the embodiments of the present invention have been described with reference to the drawings, the specific configuration is not limited to these embodiments, and modifications and additions within the scope of the present invention are included in the present invention. It is.
　例えば、上述した実施例においては、圧粉成型インダクタ部材製造装置１、１Ａにおいて、一つの圧粉成型インダクタ部材１２を製造する場合を説明しているが、図１に示すような構成の成形部を複数並列に備えることで、同時に複数の圧粉成型インダクタ部材１２を製造するようにしてもよい。この場合、上金型３Ａ・３Ｂおよび下金型４Ａ・４Ｂ、粉体供給部１０、上パンチ５Ａおよび下パンチ５Ｂを少なくとも備える成形部を複数備えることにより構成できる。また、この場合、長手方向に複数のコイル２を、間隔を隔てて配置できるようなリードフレームを用いることで、リードフレームを移送部により移送することで、コイル２を各成形部の孔部６Ｂの中央に配置することができる。 For example, in the above-described embodiment, the case where one dust-molded inductor member 12 is manufactured in the dust-molded inductor member manufacturing apparatus 1 or 1A has been described. A plurality of powder compacted inductor members 12 may be manufactured at the same time by providing a plurality of these in parallel. In this case, it can be configured by including a plurality of molding parts including at least the upper molds 3A and 3B and the lower molds 4A and 4B, the powder supply unit 10, the upper punch 5A, and the lower punch 5B. Further, in this case, by using a lead frame in which a plurality of coils 2 can be arranged at intervals in the longitudinal direction, the lead frame is transferred by the transfer unit, so that the coil 2 is in the hole 6B of each molding unit. Can be placed in the center of
　また、第２実施例における溝部２１と溝押さえ部２２との構成は、上述したようなコイル２の端部８Ａの接触する部分の形状を備えていればよく、上金型３Ａと、下金型４Ａの部分に嵌まり込むような形状にしてもよい。例えば、図６、図９に示すように、溝押さえ部２２は、上金型３Ａに対して嵌まり込むような形状にしてもよい。また、溝部２１についても、溝形状を有するような部材としておき、下金型４Ａの部分に嵌まり込むような形状にしてもよい。 Moreover, the structure of the groove part 21 and the groove pressing part 22 in 2nd Example should just be provided with the shape of the part which the edge part 8A of the coil 2 contacts as mentioned above, and the upper metal mold | die 3A and a lower metal mold | die You may make it the shape which fits into the part of type | mold 4A. For example, as shown in FIGS. 6 and 9, the groove pressing portion 22 may be shaped to fit into the upper mold 3 </ b> A. Also, the groove portion 21 may be a member having a groove shape and may be shaped to fit into the lower mold 4A.
　また、第２実施例における溝部２１と溝押さえ部２２とは、上下どちらの金型に備えるようにしてもよい。例えば、溝部２１を上金型３Ａ・３Ｂに備え、溝押さえ部２２を下金型４Ａ・４Ｂに備えるようにしてもよい。 Further, the groove portion 21 and the groove pressing portion 22 in the second embodiment may be provided in either the upper or lower mold. For example, the groove part 21 may be provided in the upper molds 3A and 3B, and the groove pressing part 22 may be provided in the lower molds 4A and 4B.
　第２実施例における図５～図９に示した構成例においては、上述した形状だけでなく、他の形状にしてもよいし、また、溝部２１と溝押さえ部２２の素材についても、金型の素材だけでなく、弾性部材７を適宜用いるようにしてもよい。また、溝部２１と溝押さえ部２２との組合せは、各図に示した組合せだけでなく、図５～図９にそれぞれ示した溝部２１と、他の図における溝押さえ部２２と組み合わせてもよい。 In the configuration example shown in FIGS. 5 to 9 in the second embodiment, not only the shape described above but also other shapes may be used, and the material of the groove portion 21 and the groove pressing portion 22 may be a mold. The elastic member 7 may be used as appropriate in addition to the material. Further, the combination of the groove portion 21 and the groove pressing portion 22 is not limited to the combination shown in each drawing, but may be combined with the groove portion 21 shown in FIGS. 5 to 9 and the groove pressing portion 22 in other drawings. .
１、１Ａ　　　　　圧粉成型インダクタ部材製造装置
２　　　　　　　　コイル
３Ａ・３Ｂ　　　　上金型
４Ａ・４Ｂ　　　　下金型
５Ａ　　　　　　　上パンチ
５Ｂ　　　　　　　下パンチ
６Ａ・６Ｂ　　　　孔部
７　　　　　　　　弾性部材
８Ａ・８Ｂ　　　　端部
９　　　　　　　　粉体
１０　　　　　　　粉体供給部
１１　　　　　　　コア
１２、１３　　　　圧粉成型インダクタ部材
１４Ａ・１４Ｂ　　端子電極部
２１Ａ・２１Ｂ・２１Ｃ・２１Ｄ・２１Ｅ・２１Ｆ　　溝部
２２Ａ・２２Ｂ・２２Ｃ・２２Ｄ・２２Ｅ・２２Ｆ　　溝押さえ部
２６Ａ・２６Ｃ・２６Ｄ・２６Ｅ・２６Ｆ　　　　　　開口部位
２７Ａ・２７Ｃ・２７Ｄ・２７Ｅ・２７Ｆ　　　　　　配置部位 DESCRIPTION OF SYMBOLS 1, 1A Powder shaping | molding inductor member manufacturing apparatus 2 Coil 3A * 3B Upper metal mold | die 4A * 4B Lower metal mold | die 5A Upper punch 5B Lower punch 6A * 6B Hole part 7 Elastic member 8A * 8B End part 9 Powder 10 Powder supply Part 11 Core 12, 13 Powder molding inductor member 14A / 14B Terminal electrode part 21A / 21B / 21C / 21D / 21E / 21F Groove part 22A / 22B / 22C / 22D / 22E / 22F Groove holding part 26A / 26C / 26D / 26E・ 26F Opening part 27A ・ 27C ・ 27D ・ 27E ・ 27F Placement part

Claims (10)

  1. 　コイルを粉体内に封入して圧縮成型された圧粉成型インダクタ部材を製造する圧粉成型インダクタ部材製造装置において、
    　前記圧縮成型する際の形状が構成された成形型部と、
    　前記粉体を供給する供給部と、
    　前記成形型部内に配置された前記コイルを、前記供給部より供給された粉体とともに加圧する加圧部と、
    　を有し、
    　前記成形型部は、前記コイルが配置され、前記供給部により粉体が供給される孔部と、当該孔部の周囲側に設けられ、前記コイルの端部を挟み込み、当該コイルの端部が当接している以外の部分が互いに当接する当接受け部と、を備え、
    　前記当接受け部は、前記コイルの端部を受け入れる溝部と、当該溝部に受け入れられた前記コイルの端部を挟み込んで前記溝部に嵌まり込む溝押さえ部とを有することを特徴とする圧粉成型インダクタ部材製造装置。     In a dust-molded inductor member manufacturing apparatus that manufactures a dust-molded inductor member that is compression-molded by enclosing a coil in powder,
    A mold part in which the shape at the time of compression molding is configured; and
    A supply unit for supplying the powder;
    A pressurizing unit that pressurizes the coil disposed in the mold part together with the powder supplied from the supply unit;
    Have
    The mold part is provided on the peripheral side of the hole part in which the coil is arranged and the powder is supplied by the supply part, and the end part of the coil is sandwiched between the end part of the coil. A contact receiving portion where the portions other than the contact are in contact with each other,
    The contact receiving portion includes a groove portion that receives an end portion of the coil, and a groove pressing portion that sandwiches the end portion of the coil received in the groove portion and fits into the groove portion. Molded inductor member manufacturing equipment.
  2. 　前記溝部は、前記コイルの端部を受け入れる所定幅の開口部位と、当該開口部位の前記所定幅より幅狭な前記コイルの端部を配置する配置部位とを備えることを特徴とする請求項１に記載の圧粉成型インダクタ部材製造装置。 2. The groove portion includes an opening portion having a predetermined width for receiving an end portion of the coil, and an arrangement portion for disposing an end portion of the coil that is narrower than the predetermined width of the opening portion. 2. The apparatus for producing a compacted inductor member according to 1.
  3. 　前記溝部と前記溝押さえ部とのうち少なくとも一方は、前記コイルの端部の当接面側に、弾性変形する弾性部材を備えることを特徴とする請求項２に記載の圧粉成型インダクタ部材製造装置。 3. The dust-molded inductor member production according to claim 2, wherein at least one of the groove portion and the groove pressing portion includes an elastic member that is elastically deformed on a contact surface side of the end portion of the coil. apparatus.
  4. 　前記成形型部は、分割されて、互いに当接する当接面を備える第一成形型手段および第二成形型手段を有し、
    　前記第一成形型手段は、前記溝部と前記溝押さえ部とのうち一方を備え、
    　前記第二成形型手段は、前記溝部と前記溝押さえ部とのうち他方を備えることを特徴とする請求項１ないし３のいずれかに記載の圧粉成型インダクタ部材製造装置。     The mold part has first mold means and second mold means that are divided and have contact surfaces that contact each other,
    The first mold means comprises one of the groove part and the groove pressing part,
    The said 2nd shaping | molding die means is equipped with the other of the said groove part and the said groove pressing part, The powder-molding inductor member manufacturing apparatus in any one of Claim 1 thru | or 3 characterized by the above-mentioned.
  5. 　コイルを粉体内に封入して圧縮成型された圧粉成型インダクタ部材を製造する圧粉成型インダクタ部材製造方法において、
    　前記圧縮成型する際の形状が構成された成形型部の孔部に、螺旋状に形成されたコイルを配置し、
    　当該コイルの端部を、前記成形型部の前記孔部の周囲側に設けられる溝部より受け入れて配置するとともに、前記溝部に嵌まり込む溝押さえ部により当該コイルの端部を挟み込み、
    　前記成形型部の前記孔部に前記粉体を供給し、
    　前記成形型部の前記孔部に配置された前記コイルを、供給された粉体とともに加圧することを特徴とする圧粉成型インダクタ部材の製造方法。     In a dust-molded inductor member manufacturing method for manufacturing a dust-molded inductor member that is compression-molded by enclosing a coil in powder,
    A coil formed in a spiral shape is disposed in the hole portion of the mold part in which the shape at the time of compression molding is configured,
    The end of the coil is received and arranged from the groove provided on the peripheral side of the hole of the mold part, and the end of the coil is sandwiched by the groove pressing part fitted into the groove,
    Supplying the powder to the hole of the mold part,
    A method for producing a dust-molded inductor member, wherein the coil disposed in the hole of the mold part is pressed together with the supplied powder.
  6. 　前記コイルの端部を、前記溝部に受け入れる際に、当該溝部の所定幅の開口部位より受け入れるとともに、当該開口部位の前記所定幅より幅狭な溝部の配置部位に配置し、当該コイルの端部を前記溝押さえ部により挟み込むことを特徴とする請求項５に記載の圧粉成型インダクタ部材の製造方法。 When the end of the coil is received in the groove, the coil is received from an opening portion having a predetermined width of the groove, and is disposed in a portion where the groove is narrower than the predetermined width. The method for manufacturing a dust-molded inductor member according to claim 5, wherein:
  7. 　前記溝部と前記溝押さえ部とのうち少なくともいずれか一方の前記コイルの端部の当接面側に備える弾性変形する弾性部材により前記コイルの端部を挟み込むことを特徴とする請求項６に記載の圧粉成型インダクタ部材の製造方法。 The end portion of the coil is sandwiched by an elastic member that is elastically deformed and provided on the contact surface side of the end portion of the coil of at least one of the groove portion and the groove pressing portion. Manufacturing method of powder compacted inductor member.
  8. 　請求項５～７のいずれかに記載の圧粉成型インダクタ部材の製造方法により製造されたことを特徴とする圧粉成型インダクタ部材。 A dust-molded inductor member manufactured by the method for producing a dust-molded inductor member according to any one of claims 5 to 7.
  9. 　コイルを粉体内に封入して圧縮成型された圧粉成型インダクタ部材において、
    　前記圧縮成型された圧縮粉体部と、前記圧縮粉体部に封入された前記コイルとを有し、
    　前記コイルは、導線を螺旋状に形成した螺旋部と、前記螺旋部から延びる導線の端部とを備え、
    　前記導線の前記螺旋部は、前記圧縮粉体部に封入され、
    　前記圧縮粉体部の外側には、パーティングラインを備えておらず、
    　前記導線の前記端部は、前記圧縮成型により押し潰されていないことを特徴とする圧粉成型インダクタ部材。     In a compacted inductor member that is compression molded by enclosing a coil in powder,
    The compressed powder part that is compression-molded, and the coil enclosed in the compressed powder part,
    The coil includes a spiral portion in which a conducting wire is formed in a spiral shape, and an end portion of the conducting wire extending from the spiral portion,
    The spiral portion of the conducting wire is enclosed in the compressed powder portion,
    The outside of the compressed powder part does not have a parting line,
    The dust-molded inductor member, wherein the end portion of the conducting wire is not crushed by the compression molding.
  10. 　コイルを粉体内に封入して圧縮成型された圧粉成型インダクタ部材を製造する圧粉成型インダクタ部材製造装置において、
    　前記圧縮成型する際の形状が構成された成形型部と、
    　前記粉体を供給する供給部と、
    　前記成形型部内に配置された前記コイルを、前記供給部より供給された粉体とともに加圧する加圧部と、
    　を有し、
    　前記成形型部は、前記コイルが配置され、前記供給部により粉体が供給される孔部と、当該孔部の周囲側に設けられ、前記コイルの端部を挟み込み、当該コイルの端部が当接している以外の部分が互いに当接する当接受け部と、を備え、
    　前記当接受け部は、前記コイルの端部を挟み込むときに、前記コイルの端部を受け入れる所定幅の開口部位と、当該開口部位の前記所定幅より幅狭な前記コイルの端部を配置する配置部位とを備える溝部を有することを特徴とする圧粉成型インダクタ部材製造装置。     In a dust-molded inductor member manufacturing apparatus that manufactures a dust-molded inductor member that is compression-molded by enclosing a coil in powder,
    A mold part in which the shape at the time of compression molding is configured; and
    A supply unit for supplying the powder;
    A pressurizing unit that pressurizes the coil disposed in the mold part together with the powder supplied from the supply unit;
    Have
    The mold part is provided on the peripheral side of the hole part in which the coil is arranged and the powder is supplied by the supply part, and the end part of the coil is sandwiched between the end part of the coil. A contact receiving portion where the portions other than the contact are in contact with each other,
    The contact receiving portion arranges an opening portion having a predetermined width for receiving the end portion of the coil when the end portion of the coil is sandwiched, and an end portion of the coil narrower than the predetermined width of the opening portion. An apparatus for manufacturing a dust-molded inductor member, comprising a groove portion provided with an arrangement site.
PCT/JP2012/081287 2012-06-04 2012-12-03 Compressed powder molded inductor member production device, production method for compressed powder molded inductor member, and compressed powder molded inductor member WO2013183183A1 (en)

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