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Inductor and manufacturing method thereof

A technology of inductance components and manufacturing methods, which is applied in the directions of electrical components, inductance/transformer/magnet manufacturing, transformer/inductor cores, etc., can solve the problems of insufficient coil interior, pressurization, and coil insulation coverage damage.

Active Publication Date: 2014-04-09
TDK CORPARATION
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0009] In addition, in Patent Document 2 shown below, in the process of press forming, different molds are used to make the forming process into two stages, and as in the above example, in the first forming process and the second forming process At the boundary of the separately obtained surfaces, there is a concern that the adhesion of the magnetic material is insufficient, and peeling or cracks may occur on the boundary surface
[0010] In addition, since at least the selective pressurization of the inside of the coil is not performed, the inside of the coil is not sufficiently pressurized.
Therefore, cracks are easily generated inside the coil
In addition, in the second forming step, a pressure is directly applied to the coil existing inside the core, and the coil is crushed, causing damage to the coil insulation coating and causing a short circuit failure.

Method used

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  • Inductor and manufacturing method thereof
  • Inductor and manufacturing method thereof
  • Inductor and manufacturing method thereof

Examples

Experimental program
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Effect test

no. 1 Embodiment approach

[0068] Such as figure 1 and figure 2 As shown, the inductance element 2 in one embodiment of the present invention has a core 4 which is a compression molded body, and a winding part 6 in which a conductor 6 a is wound in a coil shape inside the core 4 . The conductor 6a is composed of, for example, a wire and an insulating coating corresponding to the outer periphery of the wire that needs to be covered.

[0069] The wire is made of, for example, Cu, Al, Fe, Ag, Au, phosphor bronze, or the like. The insulating cover layer is made of, for example, polyurethane, polyamideimide, polyimide, polyester, polyesterimide, polyester nylon, or the like. The cross-sectional shape of the conductor 6a is not particularly limited, and examples thereof include a circular shape, a rectangular shape, and the like.

[0070] The core 4 is formed by compression-molding pellets containing magnetic powder and a binder. The magnetic powder is not particularly limited, and ferrite such as Mn-Zn,...

no. 2 Embodiment approach

[0097] In the above embodiment, in image 3 The particles in the first filling performed in step S2 and the particles in the second filling performed in step S3 are the same particles, but different particles are used in this embodiment. Other than that, this embodiment is the same as the above-mentioned first embodiment, and can achieve the same effect. Hereinafter, different parts will be described in detail, and descriptions of common parts will be partially omitted.

[0098] In this embodiment, if Figure 6A As shown, the first particles 4Aa filled before disposing the winding part 6 as an insertion member in the cavity 20 and the first particles 4Aa filled in the cavity 20 after disposing the winding part 6 inside the cavity 20 2 particles are different.

[0099] Thereafter, if Figure 6B As shown, low-pressure pressurization is carried out by the upper main punch press 14 . The pressing force between the upper main punch 14 and the lower main punch 12 is the same as...

Embodiment 1

[0111] First, the preparation should be filled to Figure 4A Particles within cavity 20 of mold 10 are shown. A silane coupling agent dissolved in water was added to 100 g of Fe-Si-Cr alloy (average particle size: 0.5 to 10 μm) as magnetic powder, and heated at 110°C for 30 minutes to form an insulating coating on the surface of the magnetic powder. To the above-mentioned magnetic powder, 3% by weight of epoxy resin diluted in acetone was added and stirred with respect to the weight of the magnetic powder, and then passed through a mesh with a pore size of 250 μm and dried at room temperature for 24 hours, thereby Obtain magnetic powder particles.

[0112] Such as Figure 4B As shown, in the mold 10 , the magnetic powder including the binder is put into 1 / 3 of the depth of the mold (the entire depth of the cavity to the upper surface of the lower main punch 12 ). At this time, the lower sub punch 18 in the center of the lower part of the die is lowered by about 3 mm relativ...

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Abstract

The invention provides an inductor which generates fewer cracks, has high initial magnetic permeability and is unlikely to cause short circuit failure, and a method for easily manufacturing the inductor with low cost. The magnetic powder density of the inner peripheral portion (4a) and the outer peripheral portion (4b) of a wiring portion (6) in a core portion (4) is different, and the magnetic powder density of the core portion (4) in the inner peripheral portion (4a) of the wiring portion (6) is higher than that of the core portion (4) in the outer peripheral portion (4b) of the wiring portion (6).

Description

technical field [0001] The present invention relates to an inductance element in which a winding portion wound in a coil shape is integrated inside a core portion made of a magnetic material, and a method for manufacturing the same. Background technique [0002] As an inductance element, for example, a surface mount type inductance element used as a circuit element such as a DC / DC converter mounted in a computer or a portable electronic device is known. [0003] As an example of this inductance element, there is known a dust core obtained by adding a binder to metal magnetic powder and press-molding (a core insulated from the surface of metal magnetic powder and press-molded). The inductance element of the coil is buried inside. Since the inductance element has a structure in which the terminal electrodes are in direct contact with the powder core, insulation is required for the metal magnetic powder. Therefore, the surface of the particles of the metal magnetic powder is ...

Claims

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Application Information

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IPC IPC(8): H01F41/00H01F41/02H01F27/24
Inventor 山下保英佐藤千绪美会田智彦石山茂树
Owner TDK CORPARATION
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