200414237 玖、發明說明： 【發明所屬之技術領域】 本發明係有關於一種大電流容量之電感構件之構造以 及製造方法’而爲一種關於使線圈與端子形成爲一體、小 型且價廉、並適用在高頻區域中之使用的電感構件。 【先前技術】 爲求得電子構件之高頻對應，而特別期望小型、且大 電流容量之電感構件。 過去’此種電感構件一般係爲使用佔有體積率較高之 矩形線（rectangular Wire)以作爲線圈，不過，倘若是未 熔接至在此情況下另外準備之外部端子時，則與外部間之 連接將不充分，亦耗費熔接工時、且難以維持熔接部之信 賴性。在此’爲破壞矩形線製造之線圈端部而作爲端子， 而形成爲無須熔接之物，不過，在破壞而造成擴大方面將 在端子面積上有所限制、或是有損於線之斷面積。再者， 雖然亦提案有一種以摺疊平面框架而作爲線圈之物，不 過’係形成爲在線圈之線材間必須要有較高之絕緣性、且 亦增大平面面積。 〔專利文獻1〕日本專利特開平1 1 _ 6 7 5 5 3號公報。 〔專利文獻2〕日本專利第3 1 6 0 6 8 5號專利說明書。 【發明內容】 〔發明所欲解決之課題〕 在此’本案發明者們係提案有一種低背化、小型之大 電流用電感構件以及其製造方法，用以解決下述問題，即： 5 200414237 未有熔接至另外準備之外部端子的必要，藉由線圈與端子 之構造爲成一體狀，而無須熔接工時因而在信賴性爲較高 者；因爲有破壞線材故無擴大之舉，不致限制端子面積、 亦無損於線之斷面積；未將平面框架設爲摺疊線圈，因此， 在線圈之線材間並不需要較高的絕緣性，製造方法爲較簡 單；係可大幅取得端子面積，形成可簡單且確實的進行與 外部電路間之連接。 〔用以解決課題之手段〕 本發明係爲在壓粉電感構件中具有形成如下之線圈， 係爲，將由銅等導電性金屬板衝壓成具有一體狀之寬度較 窄、線圈形成部兩端爲較寬廣之端子部的導電元件，將線 圈形成部進行朝向邊緣縱向捲繞而形成。 【實施方式】 本發明係爲一種壓粉電感構件，其係具備有在寬度較 窄之朝向邊緣縱向捲繞線圈之兩端上以相同材料形成爲一 體狀的寬度較廣的端子，使縱向捲繞部分埋設至金屬磁性 材料粉末與結合材料之混合物中，再加以加壓成形而形 成。其線圈部分係爲在以間距捲件所形成之線間存有縫 隙，而以前述混合物來充塡至縫隙中。 此外，係爲一種壓粉電感構件之製造方法，其特徵在 於：將由導電性金屬板衝壓成具有一體狀之寬度較窄、線 圈形成部兩端爲較寬廣之端子部的導電元件，將線圈形成 部進行朝向邊緣縱向捲繞而形成線圈，縱向捲繞線圈部分 埋設至金屬磁性材料粉末與結合材料之混合物中，再加以 200414237 進行加壓成形。 此外，亦爲一種壓粉電感構件之製造方法，其特徵在 於：將由導電性金屬板衝壓成具有一體狀之寬度較窄、線 圈形成部兩端爲較寬廣之端子部的導電元件，在線圈形成 部上實施絕緣性被覆，將線圈形成部進行朝向邊緣縱向捲 繞而形成線圈，將縱向捲繞線圈埋設至金屬磁性材料粉末 與結合材料之混合物中，再加以進行加壓成形。 再者，亦爲一種壓粉電感構件之製造方法，其特徵在 於··將由導電性金屬板衝壓成具有一體狀之寬度較窄、線 · 圈形成部兩端爲較寬廣之端子部的導電元件，將線圈形成 部進行朝向邊緣縱向捲繞而形成線圈，在線圈形成部上實 施絕緣性被覆，將縱向捲繞線圈埋設至金屬磁性材料粉末 與結合材料之混合物中，再加以進行加壓成形。 〔實施例〕 以下，參照圖面說明本發明之實施的態樣。 第1圖所示係爲在本發明之壓粉電感構件之製造方法 中，表示線圈成形之各個程序。 參 第1 A圖係爲形成本發明之壓粉電感構件之線圈以及端 子的導電元件1。爲由銅等導電性金屬板藉由衝床而衝壓 成具有寬度爲略窄之線圈形成部2與將其兩端連結成一體 狀之寬度較廣之端子形成部3的導電元件框架。 因爲係以衝壓來製作，故而係可任意的設定形狀、尺 寸、厚度等。此外，主要係爲使用在高頻區域中之物品， 線圈長度係爲較短、且爲小型化者，因此藉由衝壓來製作 7 200414237 方法將無不妥之處。 另外，作爲導電元件之一例，雖然爲衝壓形成有全長 93mm、線圈形成部爲長度達63mm、寬度1.8mm、端子形 成部爲長度達1 5mm、寬度7.3mm之物’不過，亦可因應 需要來決定線圈形成部之長度。 第1 B圖所示係爲藉由導電元件1而形成線圈4之程序。 前述導電元件1之寬度較窄之線圈形成部2雖具有長 方形之斷面，不過，該種矩形線部分係將長邊藉由對於捲 軸爲垂直捲繞的朝向邊緣縱向捲繞來進行捲線、並且以具 有指定之縫隙的間距捲件來進行捲線而形成線圈4。 第1 C圖係爲將端子5進行成型之程序。 將形成爲一體之寬度較廣的端子形成部3之一方形成 至線圈4之兩端，而表示出以使雙方之端子5以形成同一 平面狀的進行成型之程序。 第2圖所示係爲磁性體之加壓成型程序。 爲捲繞線圈4、將端子5藉由成形而整形的導電元件1 而設置在模具6之中，將縱向捲件線圈部分埋設於金屬磁 性材料粉末與結合材料之混合物7之中，以進行加壓成形 的程序。 在線圈4之雨端上形成爲一體的寬度較廣之端子5，係 被維持在模具6之上模具6 a與下模具6b間。將已經過絕 緣處理之碳基鐵（carbonyl iron)、或鉬坡莫合金 (molybdenum p e rm al 1 o y )系歹IJ 或是 F e - S i - A1 系合金（商 品名：S e n d u s t )等細微粉末以環氧系列之結合材料包覆、 8 200414237 使混合物7之細微粉末充塡至孔（cavity )中。磁性材料 與結合材料之混合比例在通常重量比方面係約爲9 5至9 8 % : 2 至 5% 〇 將線圈4埋設至混合物中，藉由滑動模具6 c、6 d由上 下施加壓力而進行成形，以使縫隙與周圍爲藉由混合物7 所包圍。壓縮力係爲2至5t/cm2左右。且形成爲在所間 距捲繞之線圈4之線間，使混合物7之細微粉末充分置入 以維持絕緣。 第3圖所示係爲所加壓成形之磁性材料的壓粉電感構 件。 將端子5進行成型而整形的導電元件之縱向捲件線圈 部分埋設在金屬磁性材料粉末與結合材料之混合物中，以 進行加壓成形所形成之壓粉電感構件之立體圖。第4圖係 爲其側剖面圖。 第5圖所是係爲沿著成形兩側之端子5之磁性體8而 折曲變形的壓粉電感構件之完成側面圖。 以上，雖是列舉壓粉電感構件之一例來進行說明，不 過，爲了更加提昇線材間之絕緣性，亦可在線圈4上以環 氧系列淸漆、聚酯系列、聚亞胺系列等被覆材料來實施絕 緣被覆後，藉由磁性材料與結合材料之混合物來進行成 形。 所謂的實施絕緣性被覆係爲，在將線圈形成部以朝向 邊緣縱向捲繞而形成線圈之前、或是在將線圈形成部以朝 向邊緣縱向捲繞而形成線圈之後均可。端子亦爲只要可適 9 200414237 當的成形其位置或形狀等便可。 〔發明之效果〕 若藉由本發明時，無須熔接至另外準備的外部端子， 藉由線圈與端子之構造爲成一體狀而無須熔接工時、信賴 性爲較高者。且無須破壞線材而進行擴大，因此在端子面 積上將無限制而不致損害線之斷面積。因爲將平面框架設 成摺疊線圈，故而在線圈之線材間無須較高的絕緣性，在 製造方面爲較簡單。端子面積係可取得較大的面積，與外 部電路之間的連接亦可形成爲簡單、確實。而具有可廉價 的提供低背化、小型之大電流用電感構件的效果。 【圖式簡單說明】 第1圖係爲表示本發明之壓粉電感構件之製造方法之 各個程序的槪略圖，其中，第1A圖係爲形成本發明之線 圏以及端子的導電元件之立體圖，第1B圖係爲藉由導電 元件所形成之線圈的立體圖，第1 C圖係爲將端子進行成 形所形成之立體圖。 第2圖所示係爲在本發明中之磁性體之加壓成形程序 之模具的斷面說明圖。 第3圖所示係爲使磁性體加壓成形之壓粉電感構件的 立體圖。 第4圖所示係爲第3圖之壓粉電感構件之側剖面圖。 第5圖所示係爲本發明之壓分電感構件之完成側面圖。 【主要部分之代表符號說明】 1 :導電元件 10 200414237 2 :線圈形成部 3 :端子形成部 4 :線圈 5 :端子 6 :模具 6a :上模具 6b :下模具 6 c、6 d :滑動模具 7 :混合體 _ 8 :磁性體200414237 发明 Description of the invention: [Technical field to which the invention belongs] The present invention relates to a structure and a manufacturing method of an inductive component with a large current capacity. Inductive components used in high frequency regions. [Prior art] In order to obtain high-frequency correspondence of electronic components, a small and large inductive component with a large current capacity is particularly desired. In the past, such an inductance component generally used a rectangular wire with a high volume ratio as a coil. However, if it is not welded to an external terminal prepared in this case, it is connected to the outside. Insufficient, it also consumes welding man-hours, and it is difficult to maintain the reliability of the welding part. Here, the coil end made of rectangular wire is used as a terminal, and it is formed as a terminal without welding. However, the area of the terminal will be limited in terms of the expansion caused by the damage, or the cross-sectional area of the wire will be damaged. . Furthermore, although a type of coil having a flat planar frame as a coil is also proposed, it must be formed so as to have high insulation between the coil wires and also increase the planar area. [Patent Document 1] Japanese Patent Laid-Open No. 1 1 _ 6 7 5 5 3. [Patent Document 2] Japanese Patent No. 3,160,685 patent specification. [Summary of the Invention] [Problems to be Solved by the Invention] Here, the present inventors have proposed a low-profile, small-sized high-current inductance member and a manufacturing method thereof to solve the following problems, namely: 5 200414237 There is no need to weld to the external terminal prepared separately. The structure of the coil and the terminal is integrated, without the need for welding work, so the reliability is higher; because the wire is damaged, there is no expansion, and there is no restriction. The terminal area and the cross-sectional area of the wire are not damaged; the flat frame is not set as a folded coil, so no high insulation is required between the coil wires, and the manufacturing method is simpler; the terminal area can be obtained substantially and formed Simple and reliable connection to external circuits. [Means to Solve the Problem] The present invention has a coil formed in a powder inductor member as follows. The present invention is formed by punching a conductive metal plate such as copper to have a narrow overall width, and both ends of a coil forming portion are The conductive element of the wider terminal portion is formed by winding the coil formation portion longitudinally toward the edge. [Embodiment] The present invention is a powder inductor component, which is provided with a wide-width terminal formed of the same material on both ends of a coil with a narrow width and a longitudinally wound coil toward the edge, and a longitudinal coil The winding portion is embedded in a mixture of a metal magnetic material powder and a bonding material, and then formed by pressure forming. The coil portion is formed with a gap between the lines formed by the coils at a pitch, and the aforementioned mixture is used to fill the gap. In addition, it is a method for manufacturing a powder-powder inductance member, which is characterized in that a conductive metal plate is punched into a conductive element having a narrow width and a wide terminal portion at both ends of a coil forming portion, and forming a coil The coil is wound longitudinally toward the edge to form a coil, and the longitudinally wound coil is partially buried in a mixture of a metal magnetic material powder and a bonding material, and then 200414237 is press-molded. In addition, it is also a method for manufacturing a powdered inductor component, which is characterized in that a conductive element having a narrow width and a wide terminal portion at both ends of a coil forming portion is punched out of a conductive metal plate, and is formed in a coil. An insulating coating is applied on the part, and the coil forming part is wound longitudinally toward the edge to form a coil. The longitudinally wound coil is embedded in a mixture of a metal magnetic material powder and a bonding material, and then press-molded. Furthermore, it is also a method for manufacturing a powdered inductor member, which is characterized in that a conductive element having a narrower width and a wider terminal portion at both ends of the coil and coil forming portion is punched out of a conductive metal plate and has a wider terminal portion at both ends. The coil forming part is wound longitudinally toward the edge to form a coil, the coil forming part is covered with an insulating coating, and the longitudinally wound coil is embedded in a mixture of a metal magnetic material powder and a bonding material, and then press-molded. [Embodiment] Hereinafter, embodiments of the present invention will be described with reference to the drawings. Fig. 1 shows the procedures for forming a coil in the method for manufacturing a powder inductor component according to the present invention. Referring to Fig. 1A is a conductive element 1 forming a coil and a terminal of a powder inductor component of the present invention. A conductive element frame having a coil forming portion 2 having a slightly narrow width and a wide terminal forming portion 3 connecting both ends of the conductive forming metal plate by punching a conductive metal plate such as copper with a punch. Since it is made by pressing, the shape, size, thickness, etc. can be arbitrarily set. In addition, it is mainly used in the high-frequency region, and the coil length is short and miniaturized, so there is nothing wrong with the method of making 7 200414237 by stamping. In addition, as an example of the conductive element, although a total length of 93 mm is formed by stamping, a coil forming portion has a length of 63 mm, a width of 1.8 mm, and a terminal forming portion has a length of 15 mm and a width of 7.3 mm. Determine the length of the coil forming part. FIG. 1B shows a procedure for forming the coil 4 by the conductive element 1. Although the narrow-shaped coil forming portion 2 of the conductive element 1 has a rectangular cross-section, the rectangular wire portion is wound by winding the long side longitudinally toward the edge with a vertical winding on the winding shaft, and The coil 4 is wound by winding at a pitch having a predetermined gap. Fig. 1C is a procedure for forming the terminal 5. One of the wide terminal forming portions 3 formed integrally is formed to both ends of the coil 4, and a procedure for forming the terminals 5 on both sides to form the same plane is shown. Figure 2 shows the procedure for pressure molding of a magnetic body. In order to wind the coil 4, the terminal 5 is formed in the mold 6 by the conductive element 1 shaped by shaping, and the longitudinal coil coil portion is buried in the mixture 7 of the metal magnetic material powder and the bonding material for processing. Press forming procedure. The wide terminal 5 formed integrally on the rain end of the coil 4 is maintained between the upper mold 6a and the lower mold 6b. Carbon-based iron (Molybdenum pe rm al 1 oy) that has been treated with insulation is 歹 IJ or F e-S i-A1 series alloy (trade name: S endust), etc. The powder was coated with an epoxy-based binding material. 8 200414237 filled the fine powder of mixture 7 into the cavity. The mixing ratio of the magnetic material and the bonding material is usually about 95 to 98% by weight: 2 to 5%. The coil 4 is buried in the mixture, and the slide molds 6c and 6d are applied with pressure from up and down to The molding is performed so that the gap and the periphery are surrounded by the mixture 7. The compressive force is about 2 to 5 t / cm2. In addition, it is formed so that the fine powder of the mixture 7 is sufficiently placed between the wires of the coil 4 wound at a distance to maintain insulation. Fig. 3 shows a powder inductor structure of a pressed magnetic material. The longitudinally wound coil of the conductive element shaped by shaping the terminal 5 is partially buried in a mixture of a metal magnetic material powder and a bonding material, and a perspective view of a powder inductor member formed by press molding. Figure 4 is a side sectional view. Fig. 5 is a completed side view of a powder inductor member bent and deformed along the magnetic bodies 8 of the terminals 5 on both sides of the molding. The above is an example of a powder inductor component, but in order to improve the insulation between the wires, the coil 4 can also be coated with epoxy-based varnish, polyester-based, polyurethane-based, or other coating materials. After the insulation coating is applied, molding is performed by using a mixture of a magnetic material and a bonding material. The so-called insulating coating may be performed before the coil forming portion is wound longitudinally toward the edge to form the coil, or after the coil forming portion is wound longitudinally toward the edge to form the coil. The terminal can be formed as long as it can be appropriately shaped or its position or shape. [Effects of the Invention] According to the present invention, it is not necessary to weld to an external terminal prepared separately, and the structure of the coil and the terminal is integrated into one body, without welding man-hours, and the reliability is high. And it is not necessary to expand the wire, so there is no limit on the terminal area without damaging the cross-sectional area of the wire. Since the flat frame is provided as a folded coil, there is no need for high insulation between the coil wires, and it is relatively simple to manufacture. The terminal area can be made larger, and the connection to external circuits can be made simple and reliable. In addition, there is an effect that it is possible to provide a low-profile, small-sized high-current inductor member at low cost. [Brief description of the drawings] FIG. 1 is a schematic diagram showing each procedure of the manufacturing method of the powder inductive member of the present invention. Among them, FIG. 1A is a perspective view of the conductive elements forming the wire and terminals of the present invention Figure 1B is a perspective view of a coil formed by a conductive element, and Figure 1C is a perspective view of a terminal formed by molding. Fig. 2 is a cross-sectional explanatory view of a mold used in a pressure forming process of a magnetic body in the present invention. Fig. 3 is a perspective view of a powder inductor member formed by pressing a magnetic body. FIG. 4 is a side sectional view of the powder inductor member of FIG. 3. Fig. 5 is a completed side view of the voltage division inductance component of the present invention. [Description of representative symbols of main parts] 1: conductive element 10 200414237 2: coil forming part 3: terminal forming part 4: coil 5: terminal 6: mold 6a: upper mold 6b: lower mold 6c, 6d: slide mold 7 : Hybrid_ 8: Magnetic
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