Wire-wound inductors and their manufacturing methods

Abstract

A wire-wound inductor and a method for manufacturing the same are provided. According to an exemplary embodiment of the present disclosure, the wire-wound inductor includes a winding coil, a magnetic core in which the winding coil is embedded, and an adhesive portion disposed between the magnetic core and the winding coil and surrounding the winding coil.

Description

[0001] This application is a divisional application of the invention patent application filed on September 19, 2018, with application number 201811097372.5 and invention title "Wire-wound inductor and manufacturing method thereof". Technical Field

[0002] This disclosure relates to a wire-wound inductor and a method for manufacturing the same. Background Technology

[0003] An inductor is a basic passive component used to provide a stable voltage to various components in a product, or to increase or decrease the voltage level.

[0004] Currently, various types of inductors have been developed and are in use. Among these various types of inductors, wire-wound inductors have a structure in which the winding coil is embedded in a magnetic core. Here, the winding coil and the magnetic core need to be insulated from each other, while at the same time, they need to have sufficient bonding force. Summary of the Invention

[0005] One aspect of this disclosure is to provide a wire-wound inductor.

[0006] Another aspect of this disclosure provides a method for manufacturing a wire-wound inductor.

[0007] According to one aspect of this disclosure, a wound inductor may include: a winding coil; a magnetic core in which the winding coil is embedded; and an adhesive portion disposed between the magnetic core and the winding coil and surrounding the winding coil.

[0008] According to another aspect of this disclosure, a method of manufacturing a wire-wound inductor may include: attaching a strip to a first surface of a frame having a hole; inserting at least one winding coil into the hole of the frame, the at least one winding coil being attached to the strip; coating a first insulating adhesive film on a second surface of the frame opposite to the first surface; and removing the strip attached to the first surface of the frame. Attached Figure Description

[0009] The above and other aspects, features, and advantages of this disclosure will become more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0010] Figures 1A to 1C This is a schematic diagram illustrating the construction of a wire-wound inductor according to exemplary embodiments of the present disclosure;

[0011] Figures 2A to 2C This is a schematic diagram illustrating the construction of a wire-wound inductor according to another exemplary embodiment of this disclosure;

[0012] Figure 3This is a diagram used to explain a method of manufacturing a wire-wound inductor according to exemplary embodiments of the present disclosure;

[0013] Figure 4 This is a flowchart for explaining a method of manufacturing a wire-wound inductor according to exemplary embodiments of the present disclosure;

[0014] Figure 5 This is a flowchart for explaining a method of manufacturing a wire-wound inductor according to another exemplary embodiment of the present disclosure. Detailed Implementation

[0015] Exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings.

[0016] Figures 1A to 1C These are perspective views, plan views, and cross-sectional views, respectively, schematically illustrating the construction of a wire-wound inductor according to exemplary embodiments of the present disclosure. The wire-wound inductor according to exemplary embodiments of the present disclosure may include a winding coil 11, an adhesive portion 21, and a magnetic core 31.

[0017] The winding coil 11 is a coil formed by winding at least one turn of conductive wire, and may be stacked in two or more layers if necessary. The winding coil 11 may be a flat wire coil type, and the wire-wound inductor according to the exemplary embodiments of this disclosure may therefore be a chip type. However, the types of winding coils and wire-wound inductors may vary.

[0018] The winding coil 11 can be formed using any one or a mixture of at least two of precious metals such as silver (Ag), platinum (Pt), lead (Pb), nickel (Ni), and copper (Cu) that have good conductivity. Additionally, the winding coil 11 may include an insulating film coated on the surface of the conductors to ensure insulation between the conductors of the winding coil 11.

[0019] Furthermore, the end of the winding coil 11 may extend outward from the magnetic core 31, and the extended portion may be electrically connected to an external electrode (not shown).

[0020] The adhesive portion 21 can be implemented using an insulating adhesive film. For example, the adhesive portion 21 can be formed using Ajinomoto Build-up Film (ABF). Furthermore, the adhesive portion 21 can be formed to surround the entire winding coil 11. Additionally, the adhesive portion 21 can be formed even in the central and outer portions of the winding coil 11. The adhesive portions 21 formed in the central and outer portions of the winding coil 11 can be located near the center of the winding coil 11 in the thickness direction. Therefore, the magnetic core 31 can be formed above and below the adhesive portions 21 formed in the central and outer portions of the winding coil 11. The adhesive portion 21 can insulate the winding coil 11 from the magnetic core 31, while simultaneously improving the bonding force between the winding coil 11 and the magnetic core 31. Furthermore, in the process of manufacturing the wound inductor, the adhesive portion 21 can ensure the connection between the winding coil 11 and the frame, thereby reducing defects caused by winding coil misalignment during the manufacturing of the wound inductor. In addition, in the manufacturing process of the wire-wound inductor, the bonding portion 21 can suppress the separation of the frame from the winding coil 11 before and / or during the stacking of the sheets, thereby reducing the defect of frame separation.

[0021] The magnetic core 31 can be formed using a magnetic resin composite material containing a mixture of metallic magnetic powder and resin. The metallic magnetic powder can be formed using at least one of, for example, Fe-Ni, Fe (e.g., amorphous Fe), Fe-Cr-Si alloy, and Fe-Si-Al alloy, and the resin mixture can be formed using at least one of, for example, epoxy resin, polyimide, and liquid crystal polymer (LCP), but the raw materials for the metallic magnetic powder and resin mixture are not limited thereto. The magnetic core 31 can serve as a space for forming a magnetic circuit, which is the path through which the magnetic flux induced in the winding coil 11 travels when a current is applied to the winding coil 11. The magnetic core 31 can be formed such that the winding coil 11 is embedded therein. In this case, at least a portion of each of the two ends of the winding coil 11 can be exposed to the outside of the magnetic core 31 for connection to external electrodes.

[0022] Figures 2A to 2C These are, respectively, perspective views, plan views, and cross-sectional views schematically illustrating the construction of a wire-wound inductor according to another exemplary embodiment of the present disclosure.

[0023] The winding coil 12 and the magnetic core 32 can be connected with Figures 1A to 1C The winding coil 11 and magnetic core 31 described herein are the same.

[0024] In addition, with Figures 1A to 1C Compared to the adhesive portion 21 described herein, except that the adhesive portion 22 is not formed in the center portion of the winding coil 12, the adhesive portion 22 can be formed with... Figures 1A to 1C The adhesive portion 21 described herein is the same.

[0025] Figure 3 This is a diagram used to explain a method of manufacturing a wire-wound inductor according to exemplary embodiments of the present disclosure.

[0026] In a method of manufacturing a wound inductor according to an exemplary embodiment of the present disclosure, a plurality of winding coils 10 may be inserted into a hollow portion formed in a frame 40.

[0027] Then, insulating adhesive film 20-1 can be positioned and subsequently pressed onto one surface of frame 40, and insulating adhesive film 20-2 can be positioned and subsequently pressed onto the other surface of frame 40 to form an adhesive portion. Figures 1A to 1C 21 or Figures 2A to 2C (22) The insulating adhesive film 20-1 and the insulating adhesive film 20-2 are films that combine adhesiveness and insulation, and can be Ajinomoto laminated film (ABF).

[0028] Furthermore, at least one magnetic sheet 30-1 can be positioned and subsequently pressed onto one surface of the frame 40, and at least one magnetic sheet 30-2 can be positioned and subsequently pressed onto the other surface of the frame 40 to form a magnetic core. Figures 1A to 1C 31 or Figures 2A to 2C (32 in the text). Individual structures, including the corresponding magnetic core, the corresponding winding coil, and the corresponding insulating adhesive film, can be separated from the frame 40 and become wire-wound inductors. Therefore, when the individual structures are separated from the frame 40, multiple wire-wound inductors can be formed.

[0029] After the insulating adhesive film 20-1 is pressed, and before the insulating adhesive film 20-2 is attached to the winding coil 10 and pressed, a strip attached to another surface of the frame 40 can be removed, allowing the winding coil 10 to be positioned within the receiving space provided by the frame 40 and the strip. In this process, a separation may occur between one part of the frame 40 and another part of the frame 40 when the strip is removed from the frame. However, according to the method of manufacturing a wound inductor according to exemplary embodiments of this disclosure, the insulating adhesive film 20-1, which increases the bonding force between the winding coil 10 and the frame 40, can prevent separation when the strip is removed from the frame 40.

[0030] Figure 4 This is a flowchart for explaining a method of manufacturing a wire-wound inductor according to exemplary embodiments of the present disclosure.

[0031] The following will refer to Figure 3 and Figure 4 This describes a method of manufacturing a wire-wound inductor according to exemplary embodiments of the present disclosure.

[0032] First, the winding coil 10 and the frame 40 (S110) can be prepared.

[0033] Next, each winding coil 10 can be inserted into the designated position in the frame 40 (S120).

[0034] Next, the insulating adhesive film 20-1 can be applied to one surface (e.g., the upper surface) of the frame 40 in which the winding coil 10 is mounted (S130). For example, the insulating adhesive film 20-1 can be positioned and then pressed onto one surface of the frame 40.

[0035] Next, at least one magnetic sheet 30-1 can be positioned and subsequently pressed onto one surface of the frame 40 on which the insulating adhesive film 20-1 is coated (S140). As described above, according to the exemplary embodiments of this disclosure, the connectivity between the winding coil 10 and the frame 40 can be adequately guaranteed by the insulating adhesive film, thereby preventing coil misalignment when pressing the magnetic sheet 30-1. Therefore, according to the exemplary embodiments of this disclosure, the yield can be improved.

[0036] Next, the strip attached to the other surface of the frame 40 can be removed (S150). As described above, according to the exemplary embodiments of this disclosure, the bonding force between the winding coil 10 and the frame 40 is increased by the insulating adhesive film 20-1, thereby suppressing the separation of the frame 40. Therefore, according to the exemplary embodiments of this disclosure, the yield can be improved.

[0037] Next, the insulating adhesive film 20-2 can be applied to another surface (e.g., the lower surface) of the frame 40 in which the winding coil 10 is mounted (S160). For example, the insulating adhesive film 20-2 can be positioned and then pressed onto the other surface of the frame 40.

[0038] Next, at least one magnetic sheet 30-2 can be positioned and subsequently pressed onto another surface of the frame 40 coated with the insulating adhesive film 20-2 (S170). Individual structures comprising the respective magnetic core, the respective winding coil, and the respective insulating adhesive film can be separated from the frame 40 and become wire-wound inductors. Therefore, when the individual structures are separated from the frame 40, multiple wire-wound inductors can be formed.

[0039] Figure 5 This is a flowchart for explaining a method of manufacturing a wire-wound inductor according to another example embodiment of this disclosure.

[0040] The following will refer to Figure 3 and Figure 5 This describes a method of manufacturing a wire-wound inductor according to exemplary embodiments of the present disclosure.

[0041] First, the winding coil 10 and the frame 40 (S210) can be prepared.

[0042] Next, each winding coil 10 can be inserted into the designated position in the frame 40 (S220).

[0043] Next, the insulating adhesive film 20-1 can be applied to one surface (e.g., the upper surface) of the frame 40 in which the winding coil 10 is mounted (S230). For example, the insulating adhesive film 20-1 can be positioned and then pressed onto one surface of the frame 40.

[0044] Next, the strip attached to the other surface of the frame 40 can be removed (S240). As described above, according to the exemplary embodiments of this disclosure, the bonding force between the winding coil 10 and the frame 40 is increased by the insulating adhesive film 20-1, thereby suppressing the separation of the frame 40. Therefore, according to the exemplary embodiments of this disclosure, the yield can be improved.

[0045] Next, the insulating adhesive film 20-2 can be applied to another surface (e.g., the lower surface) of the frame 40 in which the winding coil 10 is mounted (S250). For example, the insulating adhesive film 20-2 can be positioned and then pressed onto the other surface of the frame 40.

[0046] Next, the insulating adhesive films 20-1 and 20-2 located at the center portion of the winding coil 10 can be removed by laser processing (S260). Laser processing can be performed by irradiating the center portion of the first insulating adhesive film 20-1 and the second insulating adhesive film 20-2 with a laser beam to remove the center portion of the first insulating adhesive film 20-1 and the second insulating adhesive film 20-2.

[0047] Next, at least one magnetic sheet 30-1 can be positioned and subsequently pressed onto one surface of the frame 40 on which the insulating adhesive film 20-1 is coated (S270). As described above, according to the exemplary embodiments of this disclosure, the connectivity between the winding coil 10 and the frame 40 can be adequately guaranteed by the insulating adhesive film, thereby preventing coil misalignment when pressing the magnetic sheet 30-1. Therefore, according to the exemplary embodiments of this disclosure, the yield can be improved.

[0048] Next, at least one magnetic sheet 30-2 can be positioned and subsequently pressed onto another surface of the frame 40 coated with the insulating adhesive film 20-2 (S280). Individual structures, including corresponding magnetic cores, corresponding winding coils, and corresponding insulating adhesive films, can be separated from the frame 40 and become wire-wound inductors. Therefore, when the individual structures are separated from the frame 40, multiple wire-wound inductors can be formed.

[0049] As described above, according to the exemplary embodiments of the wire-wound inductor and its manufacturing method in this disclosure, the insulation between the winding coil and the magnetic core can be guaranteed, while the bonding force between them can be strengthened, thereby enhancing the durability of the wire-wound inductor. Furthermore, in the manufacturing process of the wire-wound inductor, the connectivity between the coil and the frame can be guaranteed, thereby reducing defects caused by coil misalignment. Additionally, separation of the frame and the coil can be suppressed, thereby reducing defects caused by frame separation during the stacking of magnetic sheets.

[0050] While exemplary embodiments have been shown and described above, it will be apparent to those skilled in the art that modifications and variations may be made without departing from the scope of the invention as defined by the appended claims.

Claims

1. A wire-wound inductor, comprising: Winding coil; The magnetic core, in which the winding coil is embedded; as well as An adhesive portion is disposed between the magnetic core and the winding coil, wherein the adhesive portion wraps around the winding coil and has an extension extending to a central portion surrounded by the winding coil, and the extension is thinner than the winding coil.

2. The wire-wound inductor according to claim 1, wherein, The adhesive portion extends further to the outer portion of the winding coil, and the magnetic core is disposed above and below the extension of the adhesive portion located at the outer portion of the winding coil.

3. The wire-wound inductor according to claim 2, wherein, The magnetic core is also disposed above and below the extension portion of the adhesive portion located at the center portion.

4. The wire-wound inductor according to claim 1, wherein, The adhesive portion is made using Ajinomoto laminate film.

5. The wire-wound inductor according to claim 1, wherein, The winding coil includes a conductive wire wound with at least one turn.

6. The wire-wound inductor according to claim 1, wherein, At least a portion of each of the two ends of the winding coil is exposed to the outside of the magnetic core.

7. The wire-wound inductor according to claim 2, wherein, The winding coil is located between the extension portion and the outer portion of the adhesive portion.

Images