JP3612028B2 - Coil parts manufacturing method - Google Patents

Coil parts manufacturing method Download PDF

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Publication number
JP3612028B2
JP3612028B2 JP2001051803A JP2001051803A JP3612028B2 JP 3612028 B2 JP3612028 B2 JP 3612028B2 JP 2001051803 A JP2001051803 A JP 2001051803A JP 2001051803 A JP2001051803 A JP 2001051803A JP 3612028 B2 JP3612028 B2 JP 3612028B2
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JP
Japan
Prior art keywords
coil
green compact
hardness
exterior
shape
Prior art date
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JP2001051803A
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Japanese (ja)
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JP2002252120A (en
Inventor
英敏 樋渡
智一 北川
洋行 濱本
恒次 今西
俊之 中田
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Panasonic Corp
Panasonic Holdings Corp
Original Assignee
Panasonic Corp
Matsushita Electric Industrial Co Ltd
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Priority to JP2001051803A priority Critical patent/JP3612028B2/en
Application filed by Panasonic Corp, Matsushita Electric Industrial Co Ltd filed Critical Panasonic Corp
Priority to DE60208523T priority patent/DE60208523T2/en
Priority to US10/451,777 priority patent/US7015783B2/en
Priority to PCT/JP2002/001736 priority patent/WO2002069360A2/en
Priority to CNB028033302A priority patent/CN1215494C/en
Priority to EP02700796A priority patent/EP1356479B1/en
Priority to MYPI20020662A priority patent/MY128606A/en
Publication of JP2002252120A publication Critical patent/JP2002252120A/en
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Publication of JP3612028B2 publication Critical patent/JP3612028B2/en
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  • Coils Or Transformers For Communication (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、各種民生機器等に用いるコイル部品の製造方法に関するものである。
【０００２】
【従来の技術】
以下、従来のコイル部品について図面を参照しながら説明する。
【０００３】
図９は従来のコイル部品の斜視図、図１０は同コイル部品の断面図、図１１は同コイル部品の製造工程の一部を示す断面図である。
【０００４】
図９〜図１１において、従来のコイル部品は、コイル部５２と、このコイル部５２を内包した磁性体からなる外装部５３と、コイル部５２に接続するとともに、外装部５３から突出した端子５４とを備え、外装部５３は、コイル部５２を被覆するように磁性粉末５５を加圧成形して成形した構成である。
【０００５】
外装部５３を成形する際は、上下の金型５９によって、コイル部５２を挟むように磁性粉末５５を加圧して所定の形状を形成するものである。
【０００６】
【発明が解決しようとする課題】
上記従来の構成では、外装部５３がコイル部５２を被覆するように磁性粉末５５を加圧成形して成形したものなので、金型５９とコイル部５２との間に充填される磁性粉末５５の量が加圧成形時に金型５９の動きによって変動したりしやすい。
【０００７】
そのために、外装部５３の被覆厚さがコイル部５２の周囲全体に渡って不均一になりやすく、成形密度をコントロールできずに特性バラツキを生じたり、磁性粉末５５自体は全体として流動性があるので、コイル部５２を支持することができずにコイル部５２を傾斜した状態で成形して外装部５３の不良成形を生じたりするという問題点を有していた。
【０００８】
本発明は上記問題点を解決するもので、外装部の被覆厚さがコイル部の周囲全体に渡って不均一になりにくく、特性バラツキを抑制するとともに、コイル部の位置決めを的確にして外装部の不良成形を防止したコイル部品の製造方法を提供することを目的としている。
【０００９】
【課題を解決するための手段】
上記目的を達成するために本発明は以下の構成を有する。
【００１０】
本発明の請求項１記載の発明は、特に、外装部形成工程は、熱硬化性樹脂を含有した結合剤と磁性粉末とを前記熱硬化性樹脂が完全硬化しない非加熱状態で混合するとともに加圧成形して２個の圧粉体を成形する工程と、前記圧粉体で前記コイル部を挟み込むように再加圧成形して前記コイル部を被覆するとともに、加熱して前記熱硬化性樹脂を完全硬化させて前記外装部を形成する工程とし、前記圧粉体の形状は背面部に中脚部と外脚部とを有したＥ字形状にし、前記圧粉体には再加圧成形する際に前記圧粉体の形状がくずれない硬度の強硬度部と前記再加圧成形する際に前記圧粉体の形状がくずれる硬度の弱硬度部とを設けるとともに、前記背面部を強硬度部にし、前記中脚部および前記外脚部を弱硬度部にし、前記外装部は少なくとも一方の前記圧粉体の前記強硬度部が前記コイル部の一面を支持するとともに、前記弱硬度部が前記コイル部の他面を被覆するように前記圧粉体を再加圧成形した構成である。
【００１１】
上記構成により、一般的に加圧成形には通常金型を用いて成形するが、圧粉体が固形物となるので、金型とコイル部との間で圧粉体の量が再加圧成形時に変動しにくく、外装部の被覆厚さがコイル部の周囲全体に渡って均一になりやすく、特性バラツキを抑制できるとともに、圧粉体自体によってコイル部を支持できるのでコイル部の位置決めが的確になり外装部の不良成形を防止できる。
【００１２】
特に、圧粉体には再加圧成形する際に圧粉体の形状がくずれる硬度の弱硬度部を設けて、この弱硬度部がコイル部を被覆するように圧粉体を再加圧成形しているので、コイル部を的確に被覆することができ、圧粉体とコイル部との間を隙間なく充填することもでき、磁気ギャップを減少させて磁気効率を向上することができる。
【００１３】
また、圧粉体の強硬度部はコイル部の一面を強固に支持するので、再加圧成形時にコイル部の位置ずれが生じにくく、コイル部の位置決めが的確にできるとともに、圧粉体の弱硬度部はその形をくずしながらコイル部の他面を容易に被覆することができ、外装部の被覆厚さをコイル部の周囲全体に渡って均一にさせやすく、特性バラツキを抑制できる。
【００１４】
【発明の実施の形態】
（実施の形態）
以下、本発明の実施の形態において、請求項１記載の発明について図面を参照しながら説明する。
【００１５】
図１は本発明の一実施の形態におけるコイル部品の断面図、図２は同コイル部品の斜視図、図３は同コイル部品の製造工程の一部を示す図、図４は同コイル部品の圧粉体の斜視図、図５は同コイル部品の端子を接続したコイル部の斜視図、図６は端子形成前における同コイル部品の斜視図である。
【００１６】
図１〜図６において、本発明の一実施の形態におけるコイル部品は、高さ２〜５ｍｍで１０ｍｍ角形状の大きさであって、貫通孔である空芯１を有したコイル部２と、このコイル部２を内包した磁性体からなる外装部３と、コイル部２に接続するとともに、外装部３から突出した端子４とを備えている。
【００１７】
また、外装部３は、エポキシ系またはシリコン系の熱硬化性樹脂を含有した結合剤と磁性粉末とを熱硬化性樹脂が完全硬化しない非加熱状態で混合するとともに１．０〜２．０ｔ／ｃｍ2で加圧成形した圧粉体５を、コイル部２を被覆するように３．０〜４．０ｔ／ｃｍ2で再加圧成形するとともに熱硬化性樹脂が完全硬化するように１００〜１５０℃で加熱して形成している。
【００１８】
さらに、圧粉体５は２個用いており、この圧粉体５には再加圧成形する際に圧粉体５の形状がくずれない硬度の強硬度部と再加圧成形する際に圧粉体５の形状がくずれる硬度の弱硬度部とを設け、圧粉体５の形状を背面部６に中脚部７と外脚部８とを有したＥ字形状にし、背面部６を強硬度部にするとともに、中脚部７と外脚部８を弱硬度部にしている。この弱硬度部および強硬度部は、圧粉体の密度を小さくした部分（弱硬度部）と密度を大きくした部分（強硬度部）とにより形成している。弱硬度部は数ｋｇ／ｃｍ2の加圧により形状がくずれる硬度にしている。
【００１９】
ここで、圧粉体５の形状がくずれる硬度とは、磁性粉末の粒子サイズでくずれることであり、圧粉体５の形状がくずれない硬度の強硬度部において、ブロック的（団塊になって）にくずれた状態は、磁性粉末の粒子サイズでくずれてないので、くずれる硬度の範囲には含まないものとしている。
【００２０】
そして、外装部３は一方の圧粉体５および他方の圧粉体５の両方の圧粉体５の強硬度部がコイル部２の一面（上下面）を互いに支持するとともに、弱硬度部がコイル部２の他面（側面および空芯面）を被覆するように圧粉体を再加圧成形し、かつ熱硬化性樹脂が完全硬化するように加熱したものである。
【００２１】
上記コイル部品の製造方法では、端子４が接続されたコイル部２を、端子４が突出するように磁性体からなる外装部３で内包する外装部形成工程と、外装部３に沿うように端子４を折曲加工する端子形成工程とを備えている。
【００２２】
外装部形成工程では、まず、熱硬化性樹脂を含有した結合剤と磁性粉末とを熱硬化性樹脂が完全硬化しないように非加熱状態で混合するとともに加圧成形して２個の圧粉体５を成形する。
【００２３】
このとき、圧粉体５は、その形状を背面部６に中脚部７と外脚部８とを有したＥ字形状にし、さらに、背面部６は再加圧成形する際に圧粉体５の形状がくずれない硬度の強硬度部にするとともに、中脚部および外脚部は再加圧成形する際に圧粉体の形状がくずれる硬度の弱硬度部にしている。
【００２４】
次に、２個の圧粉体５の強硬度部がコイル部２の一面（上下面）を互いに支持するとともに、弱硬度部がコイル部２の他面（側面および空芯面）を被覆するように、２個の圧粉体５でコイル部２を挟み込むように再加圧成形し、かつ熱硬化性樹脂が完全硬化するように加熱成形して外装部３を成形する。
【００２５】
このとき、２個の圧粉体５の背面部６がコイル部２を支持しつつ、２つの金型９が圧粉体５の弱硬度部の中脚部７と外脚部８を押圧して、圧粉体５の弱硬度部をくずしつつコイル部２の他面（側面および空芯面）を被覆させて加圧している。
【００２６】
特に、この場合では、コイル部２の他面（空芯面）に対向した圧粉体５の背面部６（強硬度部）が、コイル部２の空芯１の中にブロック的に埋没するとともに、端子４に対向した圧粉体５の背面部６（強硬度部）が、端子４に向かってブロック的に埋没しつつ、圧粉体５の中脚部７（弱硬度部）および外脚部８（弱硬度部）がくずれて、コイル部２の他面（側面および空芯面）を被覆している。
【００２７】
上記構成および方法により、一般的に加圧成形には通常金型を用いて成形するが、圧粉体５が固形物となるので、金型９とコイル部２との間で圧粉体５の量が再加圧成形時に変動しにくく、外装部３の被覆厚さがコイル部２の周囲全体に渡って均一になりやすく、インダクタンス値およびインダクタンス値の直流重畳時の飽和特性および磁気損失等の特性バラツキを抑制できるとともに、圧粉体５自体によってコイル部２を支持できるのでコイル部２の位置決めが的確になり外装部３の不良成形を防止できる。
【００２８】
特に、圧粉体５は再加圧成形してコイル部２を被覆するので、コイル部２を的確に被覆することができ、圧粉体５とコイル部２との間を隙間なく充填することもでき、磁気ギャップを減少させて磁気効率を向上することができる。
【００２９】
また、圧粉体５の強硬度部はコイル部２の一面を強固に支持するので、再加圧成形時にコイル部２の位置ずれが生じにくく、圧粉体５の弱硬度部がその形をくずしながらコイル部２の他面を容易に被覆することができ、外装部３の被覆厚さをコイル部２の周囲全体に渡って均一にさせやすく、特性バラツキを抑制できる。
【００３０】
さらに、圧粉体５の形状は背面部６に中脚部７と外脚部８とを有したＥ字形状にし、背面部６を強硬度部にするとともに、中脚部７および外脚部８を弱硬度部にしているので、より一層、圧粉体５の強硬度部に対して位置ずれが生じにくく、コイル部２の他面を容易に被覆することができ、特性バラツキを抑制できる。
【００３１】
このように本発明の実施の形態によれば、外装部３の被覆厚さがコイル部２の周囲全体に渡って均一になりやすく、特性バラツキを抑制できる。
【００３２】
なお、本発明の実施の形態では、圧粉体５の形状をＥ字形状にしたが、本発明の趣旨を逸脱しない範囲において、中脚部７の長さを外脚部８の長さよりも長くしたり、短くしたり、それ以外の形状でもよい。特に、背面部６に中脚部７のみを形成したＴ字形状や外脚部８のみを形成したコ字形状は略Ｅ字形状とみなしている。
【００３３】
また、コイル部２と圧粉体５との位置関係も、２個の圧粉体５の強硬度部がコイル部２の一面を支持しなくても、少なくとも一方の圧粉体５の強硬度部がコイル部２の一面を支持するようになっていればよい。
【００３４】
他の例としては、図７、図８に示すように、一方の圧粉体５は強硬度部の背面部６がコイル部２の一面を支持するようにし、他方の圧粉体５はコイル部２の貫通孔の空芯面１に中脚部７を挿入するようにして、再加圧成形したり、２つの圧粉体５の中脚部７および外脚部８の先端に微小凹凸部１０を設けるとともに、２つの圧粉体５の中脚部７および外脚部８が互いに対向するようにして、再加圧成形したり、圧粉体５の背面部６に分割用の分割溝を設けて、再加圧成形したりしてもよく、ともに、より一層、コイル部２の他面を容易に被覆することができ、特性バラツキを抑制できる。
【００３５】
この際、本発明の実施の形態では、再加圧成形前、または再加圧成形中において、圧粉体５の強硬度部がコイル部２の一面を支持しているが、再加圧成形後においても、圧粉体の強硬度部がコイル部２の一面を支持するようにすることが望ましい。
【００３６】
【発明の効果】
以上のように本発明によれば、一般的に加圧成形には通常金型を用いて成形するが、圧粉体が固形物となるので、金型とコイル部との間で圧粉体の量が再加圧成形時に変動しにくく、外装部の被覆厚さがコイル部の周囲全体に渡って均一になりやすく、特性バラツキを抑制できるとともに、圧粉体自体によってコイル部を支持できるのでコイル部の位置決めが的確になり外装部の不良成形も防止したコイル部品の製造方法を提供できる。
【００３７】
特に、圧粉体には再加圧成形する際に圧粉体の形状がくずれる硬度の弱硬度部を設けて、この弱硬度部がコイル部を被覆するように圧粉体を再加圧成形しているので、コイル部を的確に被覆することができ、圧粉体とコイル部との間を隙間なく充填することもでき、磁気ギャップを減少させて磁気効率を向上することもできる。
【図面の簡単な説明】
【図１】本発明の一実施の形態におけるコイル部品の断面図
【図２】同コイル部品の斜視図
【図３】（ａ）〜（ｅ）はそれぞれ同コイル部品の製造工程の一部を示す図
【図４】同コイル部品の圧粉体の斜視図
【図５】同コイル部品の端子を接続したコイル部の斜視図
【図６】端子形成前における同コイル部品の斜視図
【図７】（ａ）〜（ｅ）はそれぞれ他のコイル部品の製造工程の一部を示す図
【図８】（ａ）〜（ｄ）はそれぞれさらに他のコイル部品の製造工程の一部を示す図
【図９】従来のコイル部品の斜視図
【図１０】同コイル部品の断面図
【図１１】同コイル部品の製造工程の一部を示す断面図
【符号の説明】
１ 空芯
２ コイル部
３ 外装部
４ 端子
５ 圧粉体
６ 背面部
７ 中脚部
８ 外脚部
９ 金型
１０ 微小凹凸部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of manufacturing a coil component used for various consumer devices.
[0002]
[Prior art]
Hereinafter, conventional coil components will be described with reference to the drawings.
[0003]
9 is a perspective view of a conventional coil component, FIG. 10 is a sectional view of the coil component, and FIG. 11 is a sectional view showing a part of the manufacturing process of the coil component.
[0004]
9 to 11, the conventional coil component includes a coil portion 52, an exterior portion 53 made of a magnetic material that encloses the coil portion 52, and a terminal 54 that is connected to the coil portion 52 and protrudes from the exterior portion 53. The exterior portion 53 is configured by press-molding the magnetic powder 55 so as to cover the coil portion 52.
[0005]
When molding the exterior part 53, the upper and lower molds 59 press the magnetic powder 55 so as to sandwich the coil part 52, thereby forming a predetermined shape.
[0006]
[Problems to be solved by the invention]
In the above-described conventional configuration, the magnetic powder 55 is formed by pressure molding so that the exterior portion 53 covers the coil portion 52, and therefore the magnetic powder 55 filled between the mold 59 and the coil portion 52 is formed. The amount tends to fluctuate due to the movement of the mold 59 during pressure molding.
[0007]
Therefore, the coating thickness of the exterior portion 53 tends to be non-uniform over the entire periphery of the coil portion 52, and the molding density cannot be controlled, resulting in characteristic variation, or the magnetic powder 55 itself is fluid as a whole. As a result, the coil part 52 cannot be supported, and the coil part 52 is molded in an inclined state to cause defective molding of the exterior part 53.
[0008]
The present invention solves the above-mentioned problems, and the coating thickness of the exterior part is less likely to be uneven over the entire periphery of the coil part, suppresses variation in characteristics, and accurately positions the coil part to ensure the exterior part. An object of the present invention is to provide a method of manufacturing a coil component that prevents the defective molding of the coil .
[0009]
[Means for Solving the Problems]
In order to achieve the above object, the present invention has the following configuration.
[0010]
In the invention described in claim 1 of the present invention, in particular, in the exterior portion forming step, the binder containing the thermosetting resin and the magnetic powder are mixed and mixed in an unheated state where the thermosetting resin is not completely cured. The step of forming two green compacts by pressure molding, and re-press molding so as to sandwich the coil portion between the green compacts to cover the coil portion and heating the thermosetting resin was a step of forming the outer portion by completely cured, the shape of the green compact is in E-shape and a center leg and the outer leg portion to the rear portion, the the green compact re pressing Providing a high hardness portion having a hardness that does not cause the green compact shape to collapse and a weak hardness portion having a hardness that causes the green compact shape to collapse in the re-press molding, and providing the back portion with a high hardness. The middle leg part and the outer leg part are weakly hardened parts, and the exterior part is at least The green compact is formed by repressurizing the green compact so that the strong hardness portion of the green compact supports one surface of the coil portion and the weak hardness portion covers the other surface of the coil portion. is there.
[0011]
Due to the above configuration, generally molding is usually performed using a mold for pressure molding, but since the green compact becomes a solid material, the amount of green compact is re-pressurized between the mold and the coil part. It is difficult to change at the time of molding, and the coating thickness of the exterior part is likely to be uniform over the entire periphery of the coil part, and it is possible to suppress the characteristic variation and to support the coil part by the green compact itself, so that the coil part can be positioned accurately. Therefore, defective molding of the exterior part can be prevented.
[0012]
In particular, the green compact is provided with a weak hardness part that is hard enough to deform the shape of the green compact during re-press molding, and the green compact is re-press molded so that the weak hardness part covers the coil part. Therefore, the coil portion can be accurately covered, the gap between the green compact and the coil portion can be filled without any gap, and the magnetic gap can be reduced to improve the magnetic efficiency.
[0013]
In addition, since the strong hardness part of the green compact firmly supports one surface of the coil part, it is difficult for the coil part to be displaced during re-press molding, so that the coil part can be positioned accurately and the green compact is weak. The hardness part can easily cover the other surface of the coil part while breaking its shape, and it is easy to make the coating thickness of the exterior part uniform over the entire periphery of the coil part, thereby suppressing variation in characteristics.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
(Embodiment)
Hereinafter, in an embodiment of the present invention, the invention described in claim 1 will be described with reference to the drawings.
[0015]
1 is a cross-sectional view of a coil component according to an embodiment of the present invention, FIG. 2 is a perspective view of the coil component, FIG. 3 is a diagram showing a part of the manufacturing process of the coil component, and FIG. Fig. 5 is a perspective view of the green compact, Fig. 5 is a perspective view of a coil portion to which terminals of the coil component are connected, and Fig. 6 is a perspective view of the coil component before terminal formation.
[0016]
1 to 6, the coil component in one embodiment of the present invention has a coil portion 2 having a height of 2 to 5 mm, a size of 10 mm square, and an air core 1 that is a through hole, The exterior part 3 which consists of a magnetic body which included this coil part 2 and the terminal 4 which protruded from the exterior part 3 while connecting to the coil part 2 are provided.
[0017]
In addition, the exterior portion 3 is prepared by mixing a binder containing an epoxy-based or silicon-based thermosetting resin and magnetic powder in a non-heated state where the thermosetting resin is not completely cured, and 1.0 to 2.0 t / 100 green compact 5 which is molded under pressure in cm 2, as the thermosetting resin as well as re-pressed at 3.0~4.0t / cm 2 so as to cover the coil portion 2 is completely cured It is formed by heating at 150 ° C.
[0018]
In addition, two green compacts 5 are used. The green compact 5 has a hard portion having a hardness that does not break the shape of the green compact 5 during re-pressure molding and a green compact 5 during re-press molding. The shape of the powder 5 is provided with a weak hardness part, and the shape of the green compact 5 is changed to an E shape having a back leg part 6 and an intermediate leg part 7 and an outer leg part 8, and the back part 6 is hardened. The intermediate leg portion 7 and the outer leg portion 8 are weakly hardened portions. The weak hardness portion and the strong hardness portion are formed of a portion where the density of the green compact is reduced (weak hardness portion) and a portion where the density is increased (strong hardness portion). The weak hardness part is set to a hardness at which the shape is broken by pressurization of several kg / cm 2 .
[0019]
Here, the hardness at which the shape of the green compact 5 breaks down means that it breaks down with the particle size of the magnetic powder. Since the broken state is not broken by the particle size of the magnetic powder, it is not included in the range of broken hardness.
[0020]
And the exterior part 3 supports the one surface (upper and lower surfaces) of the coil part 2 mutually while the strong hardness part of the green compact 5 of one green compact 5 and the other green compact 5 mutually has a weak hardness part. The green compact is re-press-molded so as to cover the other surface (side surface and air core surface) of the coil portion 2 and heated so that the thermosetting resin is completely cured.
[0021]
In the coil component manufacturing method, the coil part 2 to which the terminal 4 is connected is enclosed by the exterior part 3 made of a magnetic material so that the terminal 4 protrudes, and the terminal is provided along the exterior part 3. And a terminal forming step of bending 4.
[0022]
In the exterior part forming step, first, a binder containing a thermosetting resin and a magnetic powder are mixed in a non-heated state so that the thermosetting resin is not completely cured, and then pressed to form two green compacts. 5 molded.
[0023]
At this time, the green compact 5 is formed into an E shape having a back leg portion 6 having a middle leg portion 7 and an outer leg portion 8, and the back face portion 6 is compacted during re-press molding. 5 is a hard part with a hardness that does not break down, and the middle leg part and the outer leg part are weak hard parts with a hardness at which the shape of the green compact is deformed during re-press molding.
[0024]
Next, the strong hardness portions of the two green compacts 5 support one surface (upper and lower surfaces) of the coil portion 2 and the weak hardness portions cover the other surfaces (side surface and air core surface) of the coil portion 2. as the two green compacts 5 were re-molded under pressure so as to sandwich the coil unit 2 by, and you forming an exterior portion 3 with heat molding as the thermosetting resin is completely cured.
[0025]
At this time, two molds 9 press the middle leg portion 7 and the outer leg portion 8 of the low hardness portion of the green compact 5 while the back portions 6 of the two green compacts 5 support the coil portion 2. Thus, the other surface (side surface and air core surface) of the coil portion 2 is covered and pressed while the weak hardness portion of the green compact 5 is broken.
[0026]
In particular, in this case, the back surface portion 6 (strong hardness portion) of the green compact 5 facing the other surface (air core surface) of the coil portion 2 is embedded in the air core 1 of the coil portion 2 in blocks. At the same time, the back surface portion 6 (strong hardness portion) of the green compact 5 facing the terminal 4 is buried in blocks toward the terminal 4 while the middle leg portion 7 (weak hardness portion) of the green compact 5 and the outside. The leg portion 8 (weak hardness portion) is broken and covers the other surface (side surface and air core surface) of the coil portion 2.
[0027]
According to the above-described configuration and method, generally, pressure molding is usually performed using a mold. However, since the green compact 5 becomes a solid, the green compact 5 is formed between the mold 9 and the coil portion 2. Is less likely to fluctuate during re-press molding, and the coating thickness of the exterior portion 3 tends to be uniform over the entire periphery of the coil portion 2, and the inductance value, saturation characteristics when the inductance value is superimposed on DC, magnetic loss, etc. And the coil part 2 can be supported by the green compact 5 itself, so that the coil part 2 can be accurately positioned and defective molding of the exterior part 3 can be prevented.
[0028]
In particular, since the green compact 5 is re-press-molded to cover the coil portion 2, the coil portion 2 can be accurately covered, and the space between the green compact 5 and the coil portion 2 can be filled without any gap. The magnetic efficiency can be improved by reducing the magnetic gap.
[0029]
In addition, since the strong hardness part of the green compact 5 firmly supports one surface of the coil part 2, the coil part 2 is less likely to be displaced during re-pressure molding, and the weak hardness part of the green compact 5 has its shape. The other surface of the coil portion 2 can be easily covered while being crushed, and the coating thickness of the exterior portion 3 can be easily made uniform over the entire periphery of the coil portion 2, thereby suppressing variation in characteristics.
[0030]
Further, the green compact 5 is formed in an E shape having a middle leg portion 7 and an outer leg portion 8 on the back surface portion 6, and the back surface portion 6 is a hardened portion, and the middle leg portion 7 and the outer leg portion are also formed. Since 8 is a weak hardness part, it is even more difficult for a position shift to occur with respect to the strong hardness part of the green compact 5, and the other surface of the coil part 2 can be covered easily, and variation in characteristics can be suppressed. .
[0031]
As described above, according to the embodiment of the present invention, the coating thickness of the exterior portion 3 tends to be uniform over the entire periphery of the coil portion 2, and variation in characteristics can be suppressed.
[0032]
In the embodiment of the present invention, the shape of the green compact 5 is an E shape. However, the length of the middle leg portion 7 is longer than the length of the outer leg portion 8 without departing from the spirit of the present invention. It may be longer, shorter, or other shapes. In particular, a T-shape in which only the middle leg portion 7 is formed on the back surface portion 6 and a U-shape in which only the outer leg portion 8 is formed are regarded as a substantially E-shape.
[0033]
Further, the positional relationship between the coil part 2 and the green compact 5 is such that even if the strong hardness parts of the two green compacts 5 do not support one surface of the coil part 2, at least one of the green compacts 5 has a high hardness. The part should just support one surface of the coil part 2. FIG.
[0034]
As another example, as shown in FIGS. 7 and 8, one green compact 5 has a back surface portion 6 of a hardened portion supporting one surface of the coil portion 2, and the other green compact 5 is a coil. The intermediate leg 7 is inserted into the air core surface 1 of the through-hole of the part 2 and re-press molding is performed, or minute irregularities are formed at the tips of the middle leg 7 and the outer leg 8 of the two green compacts 5. In addition to providing the portion 10, re-pressure molding is performed so that the middle leg portion 7 and the outer leg portion 8 of the two green compacts 5 face each other, or the back portion 6 of the green compact 5 is divided for division. A groove may be provided and re-pressure molding may be performed. In addition, the other surface of the coil portion 2 can be more easily covered, and the variation in characteristics can be suppressed.
[0035]
At this time, in the embodiment of the present invention, the strong hardness part of the green compact 5 supports one surface of the coil part 2 before or during the re-pressure molding. Even later, it is desirable that the strong hardness portion of the green compact supports one surface of the coil portion 2.
[0036]
【The invention's effect】
As described above, according to the present invention, generally, pressure molding is usually performed using a mold, but since the green compact becomes a solid, the green compact is formed between the mold and the coil portion. The amount of coating is less likely to fluctuate during re-press molding, and the coating thickness of the exterior part is likely to be uniform over the entire circumference of the coil part, so that variation in characteristics can be suppressed and the coil part can be supported by the green compact itself. It is possible to provide a method for manufacturing a coil component in which the positioning of the coil portion is accurate and defective molding of the exterior portion is prevented.
[0037]
In particular, the green compact is provided with a weak hardness part that is hard enough to deform the shape of the green compact during re-press molding, and the green compact is re-press molded so that the weak hardness part covers the coil part. Therefore, the coil portion can be accurately covered, the gap between the green compact and the coil portion can be filled without any gap, and the magnetic gap can be reduced to improve the magnetic efficiency.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a coil component in an embodiment of the present invention. FIG. 2 is a perspective view of the coil component. FIGS. 3 (a) to 3 (e) show part of the manufacturing process of the coil component. Fig. 4 is a perspective view of a green compact of the coil component. Fig. 5 is a perspective view of a coil portion where terminals of the coil component are connected. Fig. 6 is a perspective view of the coil component before terminal formation. FIGS. 8A to 8E are diagrams showing a part of the manufacturing process of another coil component. FIGS. 8A to 8D are views showing a part of the manufacturing process of another coil component. 9 is a perspective view of a conventional coil component. FIG. 10 is a cross-sectional view of the coil component. FIG. 11 is a cross-sectional view showing a part of the manufacturing process of the coil component.
DESCRIPTION OF SYMBOLS 1 Air core 2 Coil part 3 Exterior part 4 Terminal 5 Green compact 6 Back part 7 Middle leg part 8 Outer leg part 9 Mold 10 Micro uneven part

Claims (1)

コイル部を磁性体からなる外装部で内包する外装部形成工程を備え、前記外装部形成工程は、熱硬化性樹脂を含有した結合剤と磁性粉末とを前記熱硬化性樹脂が完全硬化しない非加熱状態で混合するとともに加圧成形して２個の圧粉体を成形する工程と、前記圧粉体で前記コイル部を挟み込むように再加圧成形して前記コイル部を被覆するとともに、加熱して前記熱硬化性樹脂を完全硬化させて前記外装部を形成する工程とし、前記圧粉体の形状は背面部に中脚部と外脚部とを有したＥ字形状にし、前記圧粉体には再加圧成形する際に前記圧粉体の形状がくずれない硬度の強硬度部と前記再加圧成形する際に前記圧粉体の形状がくずれる硬度の弱硬度部とを設けるとともに、前記背面部を強硬度部にし、前記中脚部および前記外脚部を弱硬度部にし、前記外装部は少なくとも一方の前記圧粉体の前記強硬度部が前記コイル部の一面を支持するとともに、前記弱硬度部が前記コイル部の他面を被覆するように前記圧粉体を再加圧成形したコイル部品の製造方法。An exterior portion forming step of enclosing the coil portion with an exterior portion made of a magnetic material , wherein the exterior portion forming step is a step in which the thermosetting resin does not completely cure the binder containing the thermosetting resin and the magnetic powder. Mixing and pressing in the heated state to form two green compacts, and re-press forming to sandwich the coil part with the green compact to cover the coil part and heating Then, the thermosetting resin is completely cured to form the exterior part, and the green compact has an E shape with a middle leg part and an outer leg part on the back part, and the green compact The body is provided with a high hardness portion having a hardness that does not break the shape of the green compact during re-press molding and a weak hardness portion with a hardness that does not break the shape of the green compact during the re-press molding. The back part is a hard part, and the middle leg part and the outer leg part are weak hardness parts. And the exterior portion includes the green compact so that the strong hardness portion of at least one of the green compacts supports one surface of the coil portion, and the weak hardness portion covers the other surface of the coil portion. Manufacturing method of re-pressurized coil parts.
JP2001051803A 2001-02-27 2001-02-27 Coil parts manufacturing method Expired - Lifetime JP3612028B2 (en)

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JP2001051803A JP3612028B2 (en) 2001-02-27 2001-02-27 Coil parts manufacturing method
US10/451,777 US7015783B2 (en) 2001-02-27 2002-02-26 Coil component and method of manufacturing the same
PCT/JP2002/001736 WO2002069360A2 (en) 2001-02-27 2002-02-26 Coil component and method of manufacturing the same
CNB028033302A CN1215494C (en) 2001-02-27 2002-02-26 Coil component and method of mfg. same
DE60208523T DE60208523T2 (en) 2001-02-27 2002-02-26 COIL COMPONENT AND METHOD FOR THE PRODUCTION THEREOF
EP02700796A EP1356479B1 (en) 2001-02-27 2002-02-26 Coil component and method of manufacturing the same
MYPI20020662A MY128606A (en) 2001-02-27 2002-02-26 Coil component and method of manufacturing the same.

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JP3654251B2 (en) * 2002-01-22 2005-06-02 松下電器産業株式会社 Coil parts
JP3654254B2 (en) * 2002-01-24 2005-06-02 松下電器産業株式会社 Coil parts manufacturing method
JP3707461B2 (en) * 2002-09-13 2005-10-19 松下電器産業株式会社 Coil parts manufacturing method
JP3707460B2 (en) * 2002-09-13 2005-10-19 松下電器産業株式会社 Coil parts
JP4665603B2 (en) * 2005-05-19 2011-04-06 パナソニック株式会社 Coil parts
JP4720286B2 (en) * 2005-05-19 2011-07-13 パナソニック株式会社 Coil parts
US20100277267A1 (en) * 2009-05-04 2010-11-04 Robert James Bogert Magnetic components and methods of manufacturing the same
JP4755321B1 (en) * 2011-02-22 2011-08-24 義純 福井 Molded coil manufacturing method
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