JPH11273980A - Method for manufacturing inductor - Google Patents
Method for manufacturing inductorInfo
- Publication number
- JPH11273980A JPH11273980A JP10092584A JP9258498A JPH11273980A JP H11273980 A JPH11273980 A JP H11273980A JP 10092584 A JP10092584 A JP 10092584A JP 9258498 A JP9258498 A JP 9258498A JP H11273980 A JPH11273980 A JP H11273980A
- Authority
- JP
- Japan
- Prior art keywords
- soft magnetic
- coil
- powder
- composite material
- flat
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、電子機器、通信機
器、情報機器等の電源に用いられるインダクタの製造方
法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an inductor used for a power supply of electronic equipment, communication equipment, information equipment and the like.
【０００２】[0002]
【従来の技術】高周波で用いられるインダクタ用磁芯と
して、フェライト磁芯や圧粉磁芯が使用されている。こ
れらのうち、フェライト磁芯は、飽和磁束密度が小さい
という欠点を有している。これに対して、軟磁性金属粉
末を成形して作製される圧粉磁芯は、軟磁性フェライト
に比べて著しく大きい飽和磁束密度を持つため、直流重
畳性に優れているという長所を有している。2. Description of the Related Art Ferrite cores and dust cores are used as inductor cores used at high frequencies. Among them, the ferrite core has a disadvantage that the saturation magnetic flux density is small. On the other hand, a dust core manufactured by molding a soft magnetic metal powder has an advantage that it has an excellent DC superimposition because it has a significantly higher saturation magnetic flux density than soft magnetic ferrite. I have.
【０００３】従来の前記圧粉磁芯を有するインダクタと
しては、いわゆる積層型インダクタが多く用いられてい
る。As a conventional inductor having the dust core, a so-called laminated inductor is widely used.
【０００４】積層型インダクタは、一般に、軟磁性金属
粉末よりなるグリーンシート上に、扁平状の軟磁性金属
粉末とバインダを混合してなるペースト状の軟磁性複合
材料（磁性体ペースト）と、導電性ペーストとを、繰り
返し積層して、軟磁性金属粉末よりなる積層体の中に、
所定の巻き数を有するコイルを形成せしめ、前記積層体
の両端に、電極を設けてなる。In general, a laminated inductor is a paste-like soft magnetic composite material (magnetic paste) obtained by mixing a flat soft magnetic metal powder and a binder on a green sheet made of a soft magnetic metal powder, and a conductive material. And paste, repeatedly laminated, in a laminate made of soft magnetic metal powder,
A coil having a predetermined number of turns is formed, and electrodes are provided at both ends of the laminate.
【０００５】従来の積層型インダクタとその製造過程
を、図を参照して説明する。[0005] A conventional laminated inductor and its manufacturing process will be described with reference to the drawings.
【０００６】図２は、積層型インダクタの外観斜視図で
あり、図３は、積層型インダクタの内部構造を示す説明
図で、図４は、積層型インダクタの積層の製造過程を示
す分解斜視図である。FIG. 2 is an external perspective view of the multilayer inductor, FIG. 3 is an explanatory view showing the internal structure of the multilayer inductor, and FIG. 4 is an exploded perspective view showing a manufacturing process of the multilayer inductor. It is.
【０００７】図２に示すように、表面実装型の積層型イ
ンダクタ１は、基本的に、直方体形状の磁性体部３と、
直方体の長手方向の両端に電極２を有している。磁性体
部３の中には、図３に示すように、コイル４が形成され
ている。As shown in FIG. 2, a surface mount type laminated inductor 1 basically includes a rectangular parallelepiped magnetic body portion 3,
The rectangular parallelepiped has electrodes 2 at both ends in the longitudinal direction. A coil 4 is formed in the magnetic body 3 as shown in FIG.
【０００８】そして、積層型インダクタは、磁性粉末に
バインダを混合してなる磁性体ペーストと導電性ペース
トとを、スクリーン印刷法等によって積層して形成され
た積層体を、焼成して製造される。The laminated inductor is manufactured by firing a laminated body formed by laminating a magnetic paste obtained by mixing a magnetic powder with a binder and a conductive paste by a screen printing method or the like. .
【０００９】すなわち、図４に示すように、軟磁性金属
粉末等の磁性材料よりなる磁性体シート（グリーンシー
ト）７を基板にして、その上面にスクリーン印刷法等に
より、コイルを形成するための導体層８１を積層し、さ
らにその上面に磁性体層９１を積層する。この工程を交
互に複数回繰り返し、最後にグリーンシート７を重ね
る。That is, as shown in FIG. 4, a magnetic sheet (green sheet) 7 made of a magnetic material such as soft magnetic metal powder is used as a substrate, and a coil is formed on the upper surface thereof by screen printing or the like. The conductor layer 81 is laminated, and the magnetic layer 91 is further laminated on the upper surface thereof. This process is alternately repeated a plurality of times, and the green sheet 7 is finally stacked.
【００１０】導体層８１，８２，８３，８４は、最終的
に磁性体内部に周回状のコイルが形成されるように、複
数個に分解されたコイルの断片として構成される。The conductor layers 81, 82, 83, and 84 are formed as a plurality of coil pieces that are disassembled into plural pieces so that a spiral coil is finally formed inside the magnetic body.
【００１１】また、磁性体層９１には、切り欠き窓９１
１が設けてあり、磁性体層を挟む上下面の導体層を接続
するようにしている。これにより、磁性体部３の内部
に、導体層よりなる周回状のコイル４が形成される（図
３）。A notch window 91 is provided in the magnetic layer 91.
1 are provided to connect the upper and lower conductor layers sandwiching the magnetic layer. As a result, a circular coil 4 made of a conductor layer is formed inside the magnetic body 3 (FIG. 3).
【００１２】第１の導体層８１の一部と最終の導体層８
５の一部は、磁性体部の側面に導体が露出するようにし
ており、これが周回状のコイル４の始端と終端となる。
このコイル４の始端と終端が露出した磁性体部の両側面
に、露出したコイルの始端及び終端と電気的に接続する
ように、導電性ペーストを塗布して外部電極２を形成す
る（図２）。A part of the first conductor layer 81 and the final conductor layer 8
A part of 5 is configured such that a conductor is exposed on the side surface of the magnetic body portion, and this is the start and end of the orbital coil 4.
An external electrode 2 is formed by applying a conductive paste on both side surfaces of the magnetic material portion where the start and end of the coil 4 are exposed so as to be electrically connected to the exposed start and end of the coil (FIG. 2). ).
【００１３】上記のようにして得られた積層体を高温に
て焼成し、積層型インダクタを得る。また、所望の巻数
を得るためには、積層回数を増減すればよい。The laminated body obtained as described above is fired at a high temperature to obtain a laminated inductor. In order to obtain a desired number of turns, the number of laminations may be increased or decreased.
【００１４】[0014]
【発明が解決しようとする課題】従来の、積層型インダ
クタでは、繰り返し、磁性体ペーストと導電性ペースト
を積層する必要があり、多くの工程を要した。In a conventional laminated inductor, it is necessary to repeatedly laminate a magnetic paste and a conductive paste, and many steps are required.
【００１５】そこで、本発明の課題は、工程数の少な
い、従って、安価で、容易なインダクタの製造方法を提
供することである。An object of the present invention is to provide an inexpensive and easy method for manufacturing an inductor with a small number of steps.
【００１６】[0016]
【課題を解決するための手段】本発明は、扁平状の軟磁
性金属粉末とバインダを混合してなる軟磁性複合材料
と、螺旋状に形成された導体よりなるコイルとを、金型
中に、同時に入れて圧縮成形するインダクタの製造方法
である。SUMMARY OF THE INVENTION The present invention provides a soft magnetic composite material obtained by mixing a flat soft magnetic metal powder and a binder, and a coil formed of a spirally formed conductor in a mold. This is a method of manufacturing an inductor that is simultaneously put and compression-molded.
【００１７】また、本発明は、５以上のアスペクト比
と、５０μｍ以下の短軸長を有する軟磁性金属粉末を用
いる上記のインダクタの製造方法である。Further, the present invention is the above-mentioned method of manufacturing an inductor using a soft magnetic metal powder having an aspect ratio of 5 or more and a short axis length of 50 μm or less.
【００１８】[0018]
【発明の実施の形態】本発明で用いられる軟磁性金属粉
末としては、鉄系の軟磁性金属の粒子からなる粉末を用
いることが好ましい。鉄系の軟磁性金属としては、Ｆ
ｅ、Ｆｅ-Ａｌ-Ｓｉ、Ｆｅ−Ｎｉ、Ｆｅ-Ｃｏ、Ｆｅ−
Ｓｉ、Ｆｅ−Ｐ、Ｆｅ−Ｍｏ−Ｎｉ等より、必要な磁気
特性に応じて選択される。BEST MODE FOR CARRYING OUT THE INVENTION As the soft magnetic metal powder used in the present invention, it is preferable to use powder composed of iron-based soft magnetic metal particles. As an iron-based soft magnetic metal, F
e, Fe-Al-Si, Fe-Ni, Fe-Co, Fe-
It is selected from Si, Fe-P, Fe-Mo-Ni or the like according to the required magnetic characteristics.
【００１９】扁平状の軟磁性金属粉末は、必要な組成の
インゴットを振動ミル等で粗粉砕し、次に、圧潰作用を
持つボールミル等の粉砕機で粉砕することにより得られ
る。The flat soft magnetic metal powder can be obtained by roughly pulverizing an ingot of a required composition with a vibration mill or the like and then pulverizing it with a pulverizer such as a ball mill having a crushing action.
【００２０】上記のようにインゴットを粉砕する代わり
に、ガスアトマイズ法、水アトマイズ法、回転ディスク
法等を用いてもよい。Instead of crushing the ingot as described above, a gas atomizing method, a water atomizing method, a rotating disk method or the like may be used.
【００２１】扁平状金属粉末のアスペクト比（短軸長／
厚さ）は、５以上が望ましく、実際の短軸長としては、
１０〜５０μｍが、高い磁気特性が得られるため、望ま
しい。The aspect ratio of the flat metal powder (short axis length /
Thickness) is desirably 5 or more, and as an actual minor axis length,
A thickness of 10 to 50 μm is desirable because high magnetic properties can be obtained.
【００２２】本発明で用いられるバインダとしては、各
種有機高分子やシリコーン樹脂を用いることが可能であ
り、必要とされる磁芯の特性に応じて選択される。As the binder used in the present invention, various organic polymers and silicone resins can be used, and are selected according to the required characteristics of the magnetic core.
【００２３】[0023]
【実施例】以下に、本発明の実施例を説明する。Embodiments of the present invention will be described below.
【００２４】Ｆｅ−Ｓｉ−Ａｌ合金のインゴットを粗粉
砕した粉末をディスクミルにより粉砕し、得られた粉末
を、さらにボールミルにより５０時間粉砕し、長手方向
が平均４０μｍ，厚さが平均２μｍで、アスペクト比が
約２０である扁平状の粉末を得た。得られた扁平状の粉
末にシリコーン樹脂を３ｗｔ％混合し、扁平状の軟磁性
金属粉末とバインダを混合してなる軟磁性複合材料を得
た。The powder obtained by coarsely pulverizing the ingot of the Fe—Si—Al alloy is pulverized by a disk mill, and the obtained powder is further pulverized by a ball mill for 50 hours. The average length in the longitudinal direction is 40 μm and the average thickness is 2 μm. A flat powder having an aspect ratio of about 20 was obtained. A soft magnetic composite material was obtained by mixing 3 wt% of a silicone resin with the obtained flat powder and mixing the flat soft magnetic metal powder and a binder.
【００２５】次に、断面が０.０２×０.２８ｍｍの銀
（Ａｇ）線を１０.５ターン巻回して、周回状のコイル
を得た。Next, a silver (Ag) wire having a cross section of 0.02 × 0.28 mm was wound for 10.5 turns to obtain a spiral coil.
【００２６】図１は、本発明のインダクタの製造方法を
示す説明図である。図１に示すように、上記のようにし
て得られたコイル４を、ダイ２０と下パンチ２１よりな
る金型に入れ、同時に、前記軟磁性複合材料５もいれ
た。この時、コイルの線間に十分に軟磁性複合材料５が
入るように、コイル４に振動を与えた（図示せず）。ま
た、コイル４の端部４１を長めにとり、常にダイ２０の
側面に接するようにし、端部４１の端面が成形体の側面
に露出するようにした。FIG. 1 is an explanatory view showing a method of manufacturing an inductor according to the present invention. As shown in FIG. 1, the coil 4 obtained as described above was placed in a mold composed of a die 20 and a lower punch 21, and at the same time, the soft magnetic composite material 5 was also placed. At this time, the coil 4 was vibrated (not shown) so that the soft magnetic composite material 5 was sufficiently inserted between the coil wires. Further, the end 41 of the coil 4 was made longer so as to always contact the side surface of the die 20 so that the end surface of the end 41 was exposed to the side surface of the molded body.
【００２７】そして、上パンチ２２を用いて、コイル４
を包み込んだ軟磁性複合材料５を圧縮成形し（１０ｔ／
ｃｍ2）、成形体を得た。矢印３０は上パンチ２２の加
圧方向を示す。Then, using the upper punch 22, the coil 4
Compression-molded soft magnetic composite material 5 encapsulating (10 t /
cm 2 ) to obtain a molded body. The arrow 30 indicates the direction in which the upper punch 22 is pressed.
【００２８】次いで、得られた成形体に、７００℃×２
時間の熱処理を施し、更に、その成形体の両端に外部電
極２を形成して、本発明の製造方法によるインダクタを
得た（図２）。図中、磁性体部３は、軟磁性複合材料５
よりなっている。Next, 700 ° C. × 2
Heat treatment was performed for a long time, and external electrodes 2 were formed on both ends of the molded body to obtain an inductor according to the manufacturing method of the present invention (FIG. 2). In the figure, the magnetic part 3 is composed of a soft magnetic composite material 5.
Is made up of
【００２９】又、軟磁性金属粉末のアスぺクト比を１０
に変えた扁平状粉末を使用して、上記と同じ方法で、本
発明の製造方法によるインダクタを得た。その外径寸法
は、１２ｍｍ×１０ｍｍ×６ｍｍ（高さ）である。The aspect ratio of the soft magnetic metal powder is set to 10
An inductor according to the production method of the present invention was obtained in the same manner as described above, using the flat powder changed to. Its outer diameter is 12 mm × 10 mm × 6 mm (height).
【００３０】次に、各成形体をＹＨＰ製インピーダンス
アナライザー４１９４Ａを用いて周波数１００ｋＨｚで
のインダクタンスを測定したところ、積層による従来の
インダクタ（銀ペーストによる導体層の幅０.２８ｍ
ｍ、コイル巻数１０.５ターン、外径寸法１２ｍｍ×１
０ｍｍ×６ｍｍ）と同等の特性が得られた。Next, when the inductance at a frequency of 100 kHz was measured for each molded body using a YHP impedance analyzer 4194A, a conventional inductor (0.28 m in width of a conductive layer made of silver paste) having a laminated structure was obtained.
m, number of coil turns 10.5 turns, outer diameter 12mm x 1
0 mm x 6 mm).
【００３１】本実施例では、銀線を使用してコイルを形
成したが、銅線を用いても、あるいはアルミニウム線を
用いても、電気の良導体であれば、本発明の効果に変わ
りはない。In the present embodiment, the coil is formed by using a silver wire. However, the effect of the present invention is not changed even if a copper wire or an aluminum wire is used as long as it is a good conductor of electricity. .
【００３２】[0032]
【発明の効果】本発明によれば、工程数の少ない、従っ
て、安価で、容易なインダクタの製造方法が得られる。According to the present invention, an inexpensive and easy method for manufacturing an inductor with a small number of steps can be obtained.
【図１】本発明のインダクタの製造方法を示す説明図。FIG. 1 is an explanatory view showing a method for manufacturing an inductor of the present invention.
【図２】積層型インダクタの外観斜視図。FIG. 2 is an external perspective view of the multilayer inductor.
【図３】積層型インダクタの内部構造を示す説明図。FIG. 3 is an explanatory diagram showing an internal structure of the multilayer inductor.
【図４】従来の積層型インダクタの積層の製造過程を示
す分解斜視図。FIG. 4 is an exploded perspective view showing a manufacturing process of a conventional multilayer inductor.
１ 積層型インダクタ ２ （外部）電極 ３ 磁性体部 ４ コイル ５ 軟磁性複合材料 ７ グリーンシート ２０ （金型の）ダイ ２１ （金型の）下パンチ ２２ （金型の）上パンチ ３０ 矢印 ４１ （コイルの）端部 ８１ （第１の）導体層 ８２，８３，８４，８５ 導体層 ９１，９２，９３，９４ 磁性体層 ９１１，９２１，９３１，９４１ 切り欠き窓 REFERENCE SIGNS LIST 1 laminated inductor 2 (external) electrode 3 magnetic part 4 coil 5 soft magnetic composite material 7 green sheet 20 (die) die 21 (die) lower punch 22 (die) upper punch 30 arrow 41 ( End 81 of coil (first) conductor layer 82, 83, 84, 85 conductor layer 91, 92, 93, 94 magnetic layer 911, 921, 931, 941 Notch window
Claims (2)
合してなる軟磁性複合材料と、螺旋状に形成された導体
よりなるコイルとを、金型中に同時に入れて圧縮成形す
ることを特徴とするインダクタの製造方法。A soft magnetic composite material obtained by mixing a flat soft magnetic metal powder and a binder, and a coil made of a helically formed conductor are simultaneously placed in a mold and compression-molded. A method for manufacturing an inductor.
ペクト比と５０μｍ以下の短軸長を有する軟磁性金属粉
末を用いることを特徴とする請求項１記載のインダクタ
の製造方法。2. The method according to claim 1, wherein the soft magnetic metal powder is a soft magnetic metal powder having an aspect ratio of 5 or more and a short axis length of 50 μm or less.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP10092584A JPH11273980A (en) | 1998-03-19 | 1998-03-19 | Method for manufacturing inductor |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP10092584A JPH11273980A (en) | 1998-03-19 | 1998-03-19 | Method for manufacturing inductor |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH11273980A true JPH11273980A (en) | 1999-10-08 |
Family
ID=14058495
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP10092584A Pending JPH11273980A (en) | 1998-03-19 | 1998-03-19 | Method for manufacturing inductor |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH11273980A (en) |
Cited By (12)
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|---|---|---|---|---|
| JP2001267160A (en) * | 2000-01-12 | 2001-09-28 | Tdk Corp | Coil sealing dust core and method for manufacturing the same |
| JP2003229311A (en) * | 2002-01-31 | 2003-08-15 | Tdk Corp | Coil-enclosed powder magnetic core, method of manufacturing the same, and coil and method of manufacturing the coil |
| WO2003088281A1 (en) * | 2002-04-12 | 2003-10-23 | Humanelecs Co., Ltd. | Method of manufacturing soft magnetic powder and inductor using the same |
| US6791445B2 (en) | 2001-02-21 | 2004-09-14 | Tdk Corporation | Coil-embedded dust core and method for manufacturing the same |
| US7415757B2 (en) | 2002-03-20 | 2008-08-26 | Tdk Corporation | Method for manufacturing inductor having coil embedded dust core |
| WO2009051559A1 (en) * | 2007-10-16 | 2009-04-23 | Magnetic Components Sweden Ab | Powder based soft magnetic inductive component, and a method and a device for production thereof |
| JP2010177492A (en) * | 2009-01-30 | 2010-08-12 | Toko Inc | Method for manufacturing mold coil |
| JP2010186909A (en) * | 2009-02-13 | 2010-08-26 | Toko Inc | Method of manufacturing mode coil, and mode coil |
| JP2011504662A (en) * | 2008-03-11 | 2011-02-10 | チャン ソン コーポレイション | Multilayer power inductor using a sheet filled with soft magnetic metal powder |
| TWI486978B (en) * | 2013-07-19 | 2015-06-01 | Darfon Electronics Corp | Manufacture method for surface-mount inductor |
| JP2015220272A (en) * | 2014-05-15 | 2015-12-07 | Tdk株式会社 | Coil component |
| CN114551074A (en) * | 2022-01-05 | 2022-05-27 | 深圳市信维通信股份有限公司 | Inductor manufacturing method |
-
1998
- 1998-03-19 JP JP10092584A patent/JPH11273980A/en active Pending
Cited By (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2001267160A (en) * | 2000-01-12 | 2001-09-28 | Tdk Corp | Coil sealing dust core and method for manufacturing the same |
| US6759935B2 (en) | 2000-01-12 | 2004-07-06 | Tdk Corporation | Coil-embedded dust core production process, and coil-embedded dust core formed by the production process |
| US6791445B2 (en) | 2001-02-21 | 2004-09-14 | Tdk Corporation | Coil-embedded dust core and method for manufacturing the same |
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