Method for manufacturing an inductor and inductor

Abstract

This invention provides a method for manufacturing an inductor and an inductor itself. [Solution] The present invention relates to a method for manufacturing an inductor and an inductor. The method for manufacturing an inductor includes a wire winding step of winding a wire around the periphery of a core having a pair of terminals separated from each other on both sides of its bottom surface; a bending step of bending both ends of the wire wound around the core to bring them into contact with the terminals; a soldering step of soldering the wire, which is in contact with the terminals, to the terminals; a coating step of applying a viscous protective material to the core winding portion and the soldered portion of the wire; a drying step of drying the applied protective material; and an inspection step of inspecting the contact state between the wire and the terminals. The inductor manufactured by the above method has excellent structural stability because the close contact state of the soldered portion between the wire and the terminals is maintained by epoxy, and there is no need to worry about wire breakage due to external impact.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing an inductor and an inductor. More specifically, since the adhesion state of the soldered portion between the wire and the terminal is stably maintained, even when an external impact is applied, there is no worry of disconnection. The present invention relates to a method for manufacturing an inductor and an inductor.

Background Art

[0002] An inductor, which is one of various basic components constituting an electric circuit, is a circuit element that induces a voltage proportional to the change amount of current, and is applied to an oscillation circuit, a power supply circuit, etc. to prevent sudden changes in current and play a role in filtering electrical noise.

[0003] Such inductors are applied to various electronic circuits including power supply devices, voltage regulators, or DC-DC converters. Also, they are combined with capacitors to form a resonance circuit, used in filter circuits, and also used for impedance matching.

[0004] Inductors can be classified into wound type, multilayer type, thin film type, and laser helix type. The wound type has a high magnetic resonance frequency due to the small resistance value of the conductor, and has characteristics of high capacitance and high withstand voltage. The multilayer type has advantages of excellent miniaturization and mass productivity and being inexpensive, and the thin film type is used when fine capacitance control is required.

[0005] As background art related to inductors, Patent Document 1 (inductor for printed circuit board) is disclosed.

[0006] The disclosed inductor comprises a hexahedron housing having an assembly hole through the center and being electrically mounted on a printed circuit board, and a known structure including a core inserted into the assembly hole of the housing and having flanges at the upper and lower ends of the body, wherein the inductor comprises a pair of coil pull-out grooves configured to be outwardly recessed and facing the inner edge of the assembly hole, a terminal mounting groove configured to be recessed to a predetermined depth in the bottom surface of the housing in a state directly connected to the coil pull-out groove, and terminals provided with a coating of a certain thickness on the bottom surface and a part of the periphery of the terminal mounting groove. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] Registered Utility Model Gazette No. 20-0420303, Republic of Korea [Overview of the Initiative] [Problems that the invention aims to solve]

[0008] The purpose of this invention is to provide a method for manufacturing an inductor and an inductor that eliminates the worry of wire breakage due to external impact, as the soldered portion between the wire and the terminal is stably maintained in a tight seal. [Means for solving the problem]

[0009] The present invention provides a method for manufacturing an inductor as a means of solving the problems for achieving the above objective, comprising: a wire winding step of winding a wire around the periphery of a core having a pair of terminals separated from each other on both sides of its bottom surface; a bending step of bending both ends of the wire wound around the core to bring them into contact with the terminals; a soldering step of soldering the wire, which is in contact with the terminals, to the terminals; a coating step of applying a viscous protective material to the core winding portion and the soldered portion of the wire; a drying step of drying the applied protective material; and an inspection step of inspecting the contact state between the wire and the terminals.

[0010] Furthermore, the coating step includes a first coating step of applying the protective material to the core winding portion of the wire, and a second coating step of applying the protective material to the soldering portion.

[0011] Furthermore, the viscosity of the protective material used in the first coating step and the second coating step is either the same or different.

[0012] Furthermore, the protective material is prepared by mixing and stirring 45 to 50 parts by weight of epoxy, 45 to 50 parts by weight of ferrite powder, and 3 to 5 parts by weight of diluent per 100 parts by weight of the total.

[0013] Furthermore, the inductor of the present invention includes a core having a pair of terminals separated from each other on both sides of its bottom surface, a wire wound around the periphery of the core and having both ends soldered to the terminals, a first protective material portion covering the wire wound around the core, and a second protective material portion covering the soldered portions at both ends of the wire.

[0014] Furthermore, the terminal has a soldering groove for accommodating the end of the wire.

[0015] Furthermore, the protective material constituting the first protective material section is prepared by mixing and stirring 45 to 50 parts by weight of epoxy, 45 to 50 parts by weight of ferrite powder, and 3 to 5 parts by weight of diluent per 100 parts by weight of the total. [Effects of the Invention]

[0016] As described above, the inductor of the present invention has excellent structural stability and eliminates concerns about wire breakage due to external impact, because the close contact between the soldered portion of the wire and the terminal is maintained by a protective material containing epoxy. [Brief explanation of the drawing]

[0017] [Figure 1] This is a perspective view of the removal of an inductor according to one embodiment of the present invention. [Figure 2] This diagram shows the shape of the inductor shown in Figure 1, viewed from a different angle. [Figure 3]A drawing schematically showing a method for manufacturing an inductor according to an embodiment of the present invention. [Figure 4] A flowchart showing a method for manufacturing an inductor according to an embodiment of the present invention.

Embodiments for Carrying Out the Invention

[0018] Hereinafter, an embodiment according to the present invention will be described in more detail with reference to the accompanying drawings.

[0019] FIG. 1 is a cutaway perspective view of an inductor 10 according to an embodiment of the present invention, and FIG. 2 is a drawing showing the shape of the inductor shown in FIG. 1 viewed from another angle.

[0020] As shown, the inductor 10 according to the present embodiment includes a core 11, a wire 15, a first protective material portion 17, and a second protective material portion 19.

[0021] The core 11 can be made of an iron core, ferrite, or a powdered iron core. As is known, a core made of an iron core can provide a high magnetic flux density and handle a large current. Also, a core made of ferrite has low losses and high resistance and is effective at high frequencies. A core made of a powdered iron core has uniform magnetic properties and is mainly applied to filter and power application fields.

[0022] Flange portions 11a are located at the upper and lower portions of the core 11. The flange portions 11a prevent the wire 15 from detaching vertically. And a pair of terminals 13 are fixed to the lower flange portion 11a. The terminals 13 are components that are electrically connected to a PCB substrate (not shown) and are parallel to each other.

[0023] Soldering grooves 13a are provided on the bottom surface of both terminals 13. As shown in Figure 2, the soldering grooves 13a are grooves that are open at the bottom. The ends 15a of the wire 15 are housed in the soldering grooves 13a. The ends 15a of the wire 15, while housed in the soldering grooves 13a, contact the bottom surface of the terminal 13 and are connected to the terminal 13 by soldering.

[0024] The wire 15 is an electrical element that is wound around the core 11. The winding of the wire 15 around the core 11 is done by placing the wire 15 on the core 11 and then rotating the core while maintaining tension. The wire 15 is wound around the flange portions 11a on both sides by repeatedly moving back and forth. After the ends of the wire 15 wound around the core 11 are bent downwards and then soldered to the terminal 13 while being housed in the soldering grooves 13a of the terminal 13.

[0025] The first protective material section 17 covers and protects the wire 15 wound around the core 11. The first protective material section 17 is a protective layer formed by the curing of applied epoxy. The first protective material section 17 maintains the structural stability of the wire 15 and protects the coil from the external environment. For example, it prevents the wire 15 from being affected by temperature changes and humidity, and absorbs shocks when external impacts are applied, preventing damage to the coil.

[0026] The protective material constituting the first protective material section 17 can be manufactured by mixing epoxy, ferrite powder, and a diluent in a predetermined ratio. For example, it can be manufactured by mixing and stirring 45 to 50 parts by weight of epoxy, 45 to 50 parts by weight of ferrite powder, and 3 to 5 parts by weight of diluent per 100 parts by weight of the total. The aforementioned mixing ratio can be adjusted depending on the specifications and size of the inductor.

[0027] The reason for distributing ferrite powder in the protective material is to improve the performance of the inductor. For example, by improving the magnetic performance of the inductor and reducing the core losses that occur when current flows, higher efficiency can be achieved, and heat is effectively dispersed to suppress the temperature rise of the inductor. If the temperature rise is suppressed, thermal damage can be prevented during prolonged use.

[0028] The diluent is used to adjust the viscosity of the first protective material and the second protective material, which will be described later. In other words, the amount of diluent added is adjusted to increase or decrease the viscosity.

[0029] Furthermore, the second protective material portion 19 covers the soldered portion of the wire 15, preventing it from falling off the terminal 13. In other words, it prevents the soldered portion from falling off even if an external impact is applied. This second protective material portion 19 is adhesively fixed to the terminal 13 with a portion of the end of the wire 15 enclosed inside.

[0030] The viscosity and composition of the protective material constituting the second protective material section 19 may be the same as or different from that of the first protective material section 17. In particular, the viscosity of the second protective material section 19 and the first protective material section 17 are determined differently depending on the size of the inductor. That is, the viscosity of the first protective material section and the second protective material section can be set differently depending on the size of the product.

[0031] The inductor of this embodiment having the above configuration is manufactured through the inductor manufacturing method described later.

[0032] Figure 3 is a schematic diagram showing a method for manufacturing an inductor according to one embodiment of the present invention, and Figure 4 is a flowchart showing a method for manufacturing an inductor according to one embodiment of the present invention.

[0033] As shown, the method for manufacturing an inductor according to this embodiment includes a wire winding step (101), a bending step (103), a soldering step (105), a coating step (107), a drying step (109), and an inspection step (111).

[0034] The winding stage (101) is the process of winding the wire 15 around the periphery of the core 11. The periphery is the space between the upper and lower flange portions 11a. The method of winding the wire 15 around the core 11 is a common method, so a detailed explanation of it will be omitted.

[0035] As shown in Figure 3(a), both ends 15a of the wire 15 after the winding stage (101) are extended parallel to the wound portion.

[0036] The bending step (103) is the process of bending both ends 15a of the wire 15 to bring them into contact with the terminal 13. That is, the ends 15a of the wire 15 are bent in the direction of arrow a and inserted into the soldering groove 13a of the terminal 13, as shown in Figure 3(b).

[0037] Once the bending step (103) is completed, the soldering step (105) is performed. The soldering step (105) is the process of soldering the wire 15, which is in contact with the bottom surface of the terminal 13, to the terminal.

[0038] The coating step (107) is a process of applying the protective material to the core winding portion and the soldering portion of the wire, and includes a first coating step (107a) and a second coating step (107b).

[0039] The first coating step (107a) is a step to form the first protective material portion 17, and the second coating step (107b) is a step to form the second protective material portion 19.

[0040] The first coating step (107a) is a process of applying the first protective material to the wire 15 wrapped around the periphery of the terminal 13 to form the first protective material portion 17. As mentioned above, the protective material used in the first coating step (107a) is a mixture of epoxy, ferrite powder, and a diluent. Through the first coating step (107a), the wrapped wire 15 becomes completely covered with the first protective material portion 17, as shown in Figure 3(c).

[0041] The second coating step (107b) is a step in which the end of the wire, which is soldered to the terminal 13, is covered with the second protective material section 19. By applying the protective material through the second coating step (107b), there is no need to worry about the end of the wire 15a being short-circuited from the terminal. In addition, since the soldered portion is sealed, moisture cannot penetrate.

[0042] The subsequent drying stage (109) is the process of drying the coated first protective material portion 17 and the second protective material portion 19. Various drying methods are applicable. For example, drying may be carried out by natural drying or heat drying.

[0043] The inspection stage (111) is a process of inspecting the contact condition between the wire and the terminal, and in particular confirming whether the soldered portion is completely sealed by the second protective material portion 19.

[0044] The inductor is manufactured through the aforementioned process.

[0045] Although the present invention has been described in detail through specific embodiments above, the present invention is not limited to the embodiments described above, and various modifications are possible by those skilled in the art within the scope of the technical idea of ​​the present invention. [Explanation of symbols]

[0046] 10: Inductor 11: Core 11a: Flange section 13: Terminals 13a: Soldering groove 15: Wire 15a: End 17: 1st protective material part 19:Second protective material part

Claims

1. A wire winding step in which a wire is wound around the periphery of a core having a pair of terminals separated from each other on both sides of the bottom surface, A bending step in which both ends of the wire wrapped around the core are bent to make contact with the terminal, A soldering step in which a wire in contact with the terminal is soldered to the terminal, A coating step in which a viscous protective material is applied to the core winding portion and the soldering portion of the wire, A drying step to dry the applied protective material, An inspection step to check the contact state between the wire and the terminal, A method for manufacturing an inductor, including [the following].

2. The aforementioned coating step is A first coating step involves applying a protective material to the core winding portion of the wire, A second coating step involves applying a protective material to the soldered portion, A method for manufacturing an inductor according to claim 1, including the following:

3. The method for manufacturing an inductor according to claim 2, wherein the viscosity of the protective material used in the first coating step and the second coating step is the same or different.

4. The aforementioned protective material is A method for manufacturing an inductor according to claim 1, wherein the inductor is manufactured by mixing and stirring 45 to 50 parts by weight of epoxy, 45 to 50 parts by weight of ferrite powder, and 3 to 5 parts by weight of a diluent per 100 parts by weight of the total.

5. A core having a pair of terminals separated from each other on both sides of the bottom surface, A wire is wrapped around the periphery of the core, with both ends soldered to the terminals, A first protective material portion that covers the wire wrapped around the core, A second protective material portion covers the soldered portions at both ends of the aforementioned wire, An inductor, including one.

6. The aforementioned terminals are: The inductor according to claim 5, wherein a soldering groove for accommodating the end of the wire is formed.

7. The protective material constituting the first protective material section is The inductor according to claim 5, manufactured by mixing and stirring 45 to 50 parts by weight of epoxy, 45 to 50 parts by weight of ferrite powder, and 3 to 5 parts by weight of diluent per 100 parts by weight of the total.

Images