TW201947618A - Power inductor and manufacturing method thereof - Google Patents
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本發明係關於一種電感器(inductor)及其製作方法，特別是關於一種功率電感器(power inductor)及其製作方法。The invention relates to an inductor and a manufacturing method thereof, in particular to a power inductor and a manufacturing method thereof.
電感器是一種經常與電容器一起組成電子電路的被動元件，主要應用於如電子裝置中的DC-DC轉換器等的電源電路中，也可被用於消除雜訊的元件，或者是形成LC諧振電路的元件。其中隨著手機、平板電腦、數位相機的發展，功率電感器應用逐漸增加，用來減少電流損失及增進效率。An inductor is a passive component that often forms an electronic circuit with a capacitor. It is mainly used in power circuits such as DC-DC converters in electronic devices. It can also be used to eliminate noise components or form LC resonance. Components of the circuit. Among them, with the development of mobile phones, tablet computers, and digital cameras, the application of power inductors has gradually increased to reduce current loss and improve efficiency.
功率電感器是一種兩端子的被動元件，以磁場形式儲存能量。習知的功率電感器包括主體及電感線圈。電感線圈乃是利用導線形成一繞線體，通常為螺旋狀且具有多數圈。繞線體置入於鑄模中，並於鑄模中注入較佳為膠狀的磁性混合材料成型。該磁性混合材料通常包含樹脂以及其中的金屬磁性材料。磁性混合材料乾燥後成為塊體，脫模後，於塊體兩端製作連接於繞線體兩端的外接電極，即得習知的貼片式(surface-mount type)功率電感器。A power inductor is a two-terminal passive component that stores energy in the form of a magnetic field. The conventional power inductor includes a main body and an inductive coil. Inductive coils use wires to form a winding body, which is usually spiral and has many turns. The winding body is placed in a mold, and a magnetic mixed material, which is preferably gelatinous, is injected into the mold to be molded. The magnetic hybrid material generally contains a resin and a metallic magnetic material therein. After the magnetic mixed material is dried, it becomes a block body. After demolding, external electrodes connected to both ends of the winding body are made on both ends of the block body to obtain a conventional surface-mount type power inductor.
然而，習知的功率電感器中主體暴露於外界環境中，在不利或不穩定的溫度或濕度條件下，金屬磁性材料有氧化等風險，容易造成功率電感器外觀氧化和電性偏差。另外，傳統製作過程中，主體進行切割時，可能發生切割面中的磁性材料掉落形成孔洞的問題，而影響後續與電極的連接。However, the main body of the conventional power inductor is exposed to the external environment. Under adverse or unstable temperature or humidity conditions, the metal magnetic material has the risk of oxidation and the like, which easily causes the appearance and oxidation of the power inductor to be deviated. In addition, in the traditional manufacturing process, when the main body is cut, the problem that the magnetic material in the cut surface falls to form a hole may affect the subsequent connection with the electrode.
為解決前述問題，本發明提供一種功率電感器及其製作方法，利用隔離層覆蓋功率電感器的主體來隔絕外界環境，避免功率電感器因受潮或氧化，而降低其電性表現。In order to solve the foregoing problems, the present invention provides a power inductor and a method for manufacturing the same. The main body of the power inductor is covered by an isolation layer to isolate the external environment to prevent the power inductor from reducing its electrical performance due to moisture or oxidation.
根據本發明的第一方面，揭露一種功率電感器，其包含主體、隔離層、電感線圈、第一電極和第二電極。該主體包含第一端部和第二端部，該第二端部位於該第一端部的相對側。隔離層至少包覆該主體中除了第一端部和第二端部之外的表面。該電感線圈設置於所述主體中，包含自該主體中延伸至該第一端部的第一延伸端，以及自該主體中延伸至該第二端部的第二延伸端。第一電極設於該第一端部，且連接該第一延伸端。第二電極設於該第二端部，且連接該第二延伸端。According to a first aspect of the present invention, a power inductor is disclosed, which includes a main body, an isolation layer, an inductance coil, a first electrode, and a second electrode. The main body includes a first end portion and a second end portion, and the second end portion is located on an opposite side of the first end portion. The isolation layer covers at least the surface of the body except the first end portion and the second end portion. The inductance coil is disposed in the main body, and includes a first extending end extending from the main body to the first end portion, and a second extending end extending from the main body to the second end portion. A first electrode is disposed on the first end portion and is connected to the first extended end. A second electrode is disposed on the second end portion and is connected to the second extended end.
一實施例中，該隔離層用於隔離氧氣和水氣。In one embodiment, the isolation layer is used to isolate oxygen and water vapor.
一實施例中，該隔離層的氧滲透率在0.35 cm3 ⋅mm/m2 ⋅atm⋅day以下。In one embodiment, the oxygen permeability of the isolation layer is below 0.35 cm 3 ⋅mm / m 2 ⋅atm⋅day.
一實施例中，該主體包含聚合物及散佈其中的金屬磁性填料。In one embodiment, the main body includes a polymer and a metallic magnetic filler dispersed therein.
一實施例中，該磁性填料包含鐵(Fe)、矽(Si)、鉻(Cr)、鎳(Ni)、鈷(Co)之合金。In one embodiment, the magnetic filler comprises an alloy of iron (Fe), silicon (Si), chromium (Cr), nickel (Ni), and cobalt (Co).
一實施例中，該隔離層還覆蓋第一端部和第二端部的部分表面。In one embodiment, the isolation layer further covers a part of the surface of the first end portion and the second end portion.
一實施例中，該隔離層於第一端部所佔面積比大於75%，且該隔離層於該第二端部所佔面積比大於75%。In one embodiment, the area ratio of the isolation layer at the first end portion is greater than 75%, and the area ratio of the isolation layer at the second end portion is greater than 75%.
一實施例中，該隔離層的材質包含氧化矽類、烷類或苯環類官能基的聚合物。In one embodiment, the material of the isolation layer includes a polymer of silicon oxide type, alkyl type or benzene ring type functional group.
一實施例中，該隔離層的附著強度F/T在0.2~3kg/mm，其中F為施加於隔離層的推力值，T為隔離層厚度。In one embodiment, the adhesion strength F / T of the isolation layer is 0.2 to 3 kg / mm, where F is a thrust value applied to the isolation layer, and T is the thickness of the isolation layer.
一實施例中，該電感線圈的橫切面為垂直向，且包含由外而內的上部纏繞和由內而外的下部纏繞。In one embodiment, the cross section of the inductor coil is vertical and includes an upper winding from the outside and an inner winding from the lower portion.
根據本發明的第二方面，揭露一種功率電感器的製作方法，包含以下步驟：(1)壓合製造一聚集體，該聚集體包含複數個元件體，各元件體包含主體和設置於所述主體中的電感線圈，各電感線圈包含兩側的延伸端，相鄰元件體中相鄰或相連接的延伸端間隔地橫向依序排列於該聚集體的上半部及下半部；(2)切割該延伸端相應處之主體，形成橫向間隔排列的上下缺口；(3)形成隔離層包覆該聚集體；(4)於該缺口處切斷該聚集體及相應處的隔離層，分割出複數個上下表面具有該隔離層的元件體；以及(5)分別於該元件體的第一端部形成第一電極和第二端部形成第二電極。According to a second aspect of the present invention, a method for manufacturing a power inductor is disclosed, including the following steps: (1) pressing to produce an aggregate, the aggregate including a plurality of element bodies, each element body including a main body and disposed on the body; Inductive coils in the main body, each of which includes extension ends on both sides, and adjacent or connected extension ends of adjacent element bodies are arranged laterally and sequentially in the upper half and the lower half of the aggregate; (2 ) Cutting the main body at the corresponding end of the extension end to form a horizontally spaced upper and lower gap; (3) forming an isolation layer to cover the aggregate; (4) cutting the aggregate and the corresponding isolation layer at the gap and dividing A plurality of element bodies having the isolation layer on the upper and lower surfaces; and (5) forming a first electrode and a second electrode on the first end portion of the element body, respectively.
本發明利用創新的製作方法，利用隔離層覆蓋主體以阻絕水氣和氧氣的侵入，從而防止功率電感器中材料的氧化，因而可避免電性偏差，可延長使用壽命和避免功率電感器失效。The invention utilizes an innovative manufacturing method and covers the main body with an isolation layer to block the intrusion of water and oxygen, thereby preventing the oxidation of materials in the power inductor, thereby avoiding electrical deviations, extending the service life and preventing power inductor failure.
為讓本發明之上述和其他技術內容、特徵和優點能更明顯易懂，下文特舉出相關實施例，並配合所附圖式，作詳細說明如下。In order to make the above and other technical contents, features, and advantages of the present invention more comprehensible, the following specifically lists related embodiments and cooperates with the accompanying drawings for detailed descriptions as follows.
圖1~4顯示本發明一實施例之功率電感器的製作過程。參照圖1，利用堆疊和壓合技術，將電感線圈13置於主體12中而製作出聚集體10。壓合可使用熱壓或冷壓技術，將主體12和電感線圈13壓合製作出片狀或條狀的聚集體10。申言之，聚集體10包含複數個元件體11（以兩虛線之間表示單一個元件體），各元件體11包含主體12和設置於所述主體12中的電感線圈13。電感線圈13為利用導線形成的繞線體，為螺旋狀且具有多數圈，其表面可包覆絕緣層。各電感線圈13包含兩側的延伸端14，相鄰元件體11中該電感線圈13的延伸端14相連接。因應電感線圈13的繞線體結構，連接的延伸端14間隔地橫向依序排列於該聚集體10的上半部及下半部。1 to 4 show a manufacturing process of a power inductor according to an embodiment of the present invention. Referring to FIG. 1, using the stacking and compression technology, the inductive coil 13 is placed in the main body 12 to produce an aggregate 10. The pressing can be performed by hot pressing or cold pressing, and the main body 12 and the inductor 13 are pressed together to form a sheet or strip-shaped aggregate 10. In summary, the aggregate 10 includes a plurality of element bodies 11 (a single element body is shown between two dashed lines), and each element body 11 includes a main body 12 and an inductor 13 disposed in the main body 12. The inductance coil 13 is a winding body formed by a conductive wire, has a spiral shape and has a plurality of turns, and a surface thereof may be covered with an insulating layer. Each inductive coil 13 includes extended ends 14 on both sides, and the extended ends 14 of the inductive coils 13 in adjacent element bodies 11 are connected. In accordance with the winding body structure of the inductive coil 13, the connected extended ends 14 are horizontally and sequentially arranged at intervals on the upper half and the lower half of the aggregate 10.
參照圖2，於相鄰電感線圈13的延伸端14的連接位置相應處的主體12切出多個缺口15，但僅止於主體12本身，不會切割到電感線圈13的延伸端14。換言之，切割深度需具有一定的精準度。依本實施例而言，因應延伸端14間隔地橫向依序排列於該聚集體10的上半部及下半部，缺口15依序橫向間隔地以開口朝下和朝上的方式排列。另一實施例中，電感線圈13間的延伸端14不見得是連續的，當延伸端14是不連續時，仍能夠透過整列治具的調控得到類似或相同的線圈排列，從而進行如圖2所示上下輪替的半切割以形成缺口15。參照圖3，於聚集體10表面披覆一層隔離層16，而將主體12整個包覆於該隔離層16內，從而隔絕主體12與外界的接觸。該隔離層16會填入缺口15中，相當於在元件體11的端部也形成隔離保護。之後，於該缺口15相應處進行第二次切割，切斷各元件體11之間的連接部分，從而獨立出個別的元件體11。接著於個別元件體11左邊的第一端部21和右邊的第二端部22分別例如以電鍍方式製作第一電極17和第二電極18，形成如圖4所示的功率電感器40。圖5為圖4之功率電感器40的立體示意圖。圖中的電感線圈13的纏繞方式和緊密度僅為示意，並不以此為限。電感線圈13表面可以披覆如漆包線的絕緣層，如此電感線圈13纏繞時即使上下圈直接接觸，其間也有絕緣層作為隔離。Referring to FIG. 2, a plurality of notches 15 are cut out from the main body 12 corresponding to the connection position of the extended ends 14 of the adjacent inductive coils 13, but only to the main body 12 itself, and not to the extended ends 14 of the inductive coils 13. In other words, the cutting depth needs to have a certain degree of accuracy. According to this embodiment, in accordance with the extended end 14 arranged laterally and sequentially at the upper half and the lower half of the aggregate 10 at intervals, the notches 15 are arranged laterally and spaced at the openings downward and upward. In another embodiment, the extended ends 14 between the inductor coils 13 may not be continuous. When the extended ends 14 are discontinuous, similar or identical coil arrangements can still be obtained through the adjustment of the entire row of fixtures, so as to perform the process shown in FIG. 2. A half cut is shown to form the notch 15. Referring to FIG. 3, a surface of the aggregate 10 is covered with an isolation layer 16, and the main body 12 is entirely covered within the isolation layer 16, so as to isolate contact between the main body 12 and the outside. The isolation layer 16 is filled in the notch 15, which is equivalent to forming an isolation protection at the end of the element body 11. After that, a second cut is performed at the corresponding position of the notch 15 to cut off the connection portion between the element bodies 11 so as to separate the individual element bodies 11 independently. Then, a first electrode 17 and a second electrode 18 are formed on the left first end portion 21 and the right second end portion 22 of the individual element body 11, for example, by electroplating to form a power inductor 40 as shown in FIG. 4. FIG. 5 is a schematic perspective view of the power inductor 40 of FIG. 4. The winding manner and tightness of the inductor coil 13 in the figure are merely schematic, and are not limited thereto. The surface of the inductance coil 13 may be covered with an insulation layer such as an enameled wire. In this way, even if the upper and lower coils are directly contacted when the inductance coil 13 is wound, there is an insulation layer therebetween as an isolation.
綜言之，製作功率電感器40大致包含幾個步驟：(1)壓合製造一聚集體10，該聚集體10包含複數個元件體11，各元件體11包含主體12和設置於所述主體11中的電感線圈13，各電感線圈13包含兩側的延伸端14，相鄰元件體11中該電感線圈13的延伸端14相連接，且該連接的延伸端14間隔地橫向依序排列於該聚集體10的上半部及下半部；(2) 切割該延伸端14相應處之主體12，形成橫向間隔排列的上下缺口15；(3)形成隔離層16包覆該聚集體10；(4)於該缺口15處切斷該聚集體10及相應處的隔離層16，分割出複數個表面具有該隔離層16的該元件體11；以及(5)分別於該元件體11的第一端部21形成第一電極17和第二端部22形成第二電極18。本製作方法整合堆疊、壓合、切割等技術，製程簡單，具成本效益。In summary, the production of the power inductor 40 generally includes several steps: (1) pressing to produce an aggregate 10, the aggregate 10 includes a plurality of element bodies 11, each element body 11 includes a main body 12, and is disposed on the main body; Inductance coils 13 in 11, each of which includes extension ends 14 on both sides, the extension ends 14 of the inductance coils 13 in adjacent element bodies 11 are connected, and the connected extension ends 14 are arranged laterally and sequentially at intervals. The upper half and the lower half of the aggregate 10; (2) the main body 12 corresponding to the extended end 14 is cut to form a horizontally spaced up and down notch 15; (3) an isolation layer 16 is formed to cover the aggregate 10; (4) cutting the aggregate 10 and the corresponding isolation layer 16 at the notch 15 to divide the element body 11 having the isolation layer 16 on the surface; and (5) the first One end portion 21 forms a first electrode 17 and the second end portion 22 forms a second electrode 18. The manufacturing method integrates technologies such as stacking, pressing, and cutting, and the manufacturing process is simple and cost-effective.
一般來說，若先分割成個別元件後再形成隔離層，隔離層通常會想到以浸泡或噴塗來施作，因此必須先保護產品端面的線圈之引出端，隔離層施作後再去除保護層，避免污染導致內外電極的接觸不良，但保護層的施作與去除本身也是相當麻煩的。因此本發明作法是在切割時先切一半(無引出端處)，再進行隔離層的施作，再把連接部份切斷（二次切割），如此的作法可省去保護層的施作與去除，省時也省材料。In general, if the isolation layer is formed after being divided into individual components, the isolation layer is usually thought of being applied by immersion or spray coating. Therefore, it is necessary to protect the lead-out ends of the coils on the end face of the product, and then remove the protective layer after the isolation layer is applied. To avoid poor contact between the internal and external electrodes caused by pollution, but the application and removal of the protective layer itself is also quite troublesome. Therefore, the method of the present invention is to cut in half (without the lead-out end) when cutting, and then apply the isolation layer, and then cut the connection part (secondary cutting). This method can eliminate the application of the protective layer Save time and materials with removal.
復參圖4和圖5，功率電感器40包含主體12、電感線圈13、隔離層16、第一電極17及第二電極18。該主體12包含左側的第一端部21和右側的第二端部22，該第二端部22位於該第一端部21的相對側。電感線圈13設置於所述主體12中，包含分別延伸或連接至第一端部21的第一延伸端14，和延伸或連接至第二端部22的第二延伸端14’。本實施例中，隔離層16包覆主體12未被第一電極17和第二電極18覆蓋的部分，亦即包覆該主體12中除了第一端部21和第二端部22以外的表面。換言之，隔離層16包覆主體12的第一端部21和第二端部22以外的四個表面，也就是主體12的上表面、下表面和兩個側表面。另外，隔離層16也覆蓋第一端部21和第二端部22的大部分區域，只有第一延伸端14連接第一端部21的部位附近以及第二延伸端14’連接第二端部22的部位附近沒有隔離層16覆蓋。一實施例中，隔離層16佔第一端面21的面積比例大於75%，或85%，隔離層16佔第二端面22的面積比例也是大於75%，或85%。第一電極17設於第一端部21，且連接至該電感線圈13位於第一端部21的第一延伸端14。第二電極18設於該第二端部22，且連接至該電感線圈13位於第二端部22的第二延伸端14’。主體12包含聚合物及散佈於聚合物中的金屬磁性填料。該金屬磁性填料包含Fe、Si、Cr、Ni、Co之合金。該金屬磁性材料占該主體12的重量百分比為10~95%。傳統上，形成電極的端部通常為切割面，主體中的金屬磁性填料常會因切割作用掉落而形成孔洞。本發明的第一電極17和第二電極18大部分面積直接接觸該隔離層16，只有小部分接觸包含金屬磁性填料的主體12，因此第一電極17和第二電極18基本上不受切割面金屬磁性填料掉落而產生孔洞的影響。Referring again to FIGS. 4 and 5, the power inductor 40 includes a main body 12, an inductance coil 13, an isolation layer 16, a first electrode 17, and a second electrode 18. The main body 12 includes a first end portion 21 on the left side and a second end portion 22 on the right side, and the second end portion 22 is located on the opposite side of the first end portion 21. The inductance coil 13 is disposed in the main body 12 and includes a first extension end 14 extending or connected to the first end portion 21 and a second extension end 14 'extending or connected to the second end portion 22, respectively. In this embodiment, the isolation layer 16 covers the portion of the main body 12 that is not covered by the first electrode 17 and the second electrode 18, that is, the surface of the main body 12 except the first end portion 21 and the second end portion 22. . In other words, the isolation layer 16 covers four surfaces other than the first end portion 21 and the second end portion 22 of the main body 12, that is, the upper surface, the lower surface, and two side surfaces of the main body 12. In addition, the isolation layer 16 also covers most areas of the first end portion 21 and the second end portion 22, and only the vicinity of the portion where the first extended end 14 is connected to the first end portion 21 and the second extended end 14 'is connected to the second end portion. The portion 22 is not covered with the isolation layer 16 near the portion. In one embodiment, the area ratio of the isolation layer 16 to the first end surface 21 is greater than 75%, or 85%, and the area ratio of the isolation layer 16 to the second end surface 22 is also greater than 75%, or 85%. The first electrode 17 is disposed on the first end portion 21 and is connected to the first extension end 14 of the inductance coil 13 on the first end portion 21. The second electrode 18 is disposed on the second end portion 22 and is connected to the second extension end 14 'of the inductor coil 13 on the second end portion 22. The main body 12 includes a polymer and a metal magnetic filler dispersed in the polymer. The metallic magnetic filler contains an alloy of Fe, Si, Cr, Ni, and Co. The weight percentage of the metallic magnetic material to the main body 12 is 10 to 95%. Traditionally, the end forming the electrode is usually a cut surface, and the metallic magnetic filler in the main body often drops due to cutting to form a hole. Most of the first electrode 17 and the second electrode 18 of the present invention directly contact the isolation layer 16, and only a small part contacts the main body 12 containing the metal magnetic filler, so the first electrode 17 and the second electrode 18 are substantially not cut by the cutting surface. The effect of holes is caused by the metal magnetic filler falling off.
一實施例中，該隔離層16的材質包含氧化矽類((SiO2 )n )、烷類(Cn H2n+1 )或苯環類(C6 H6 )n (n≧1)官能基的聚合物。該隔離層16的氧滲透率在0.35 cm3 ⋅mm/m2 ⋅atm⋅day以下，提供優良的氧氣阻絕效果。隔離層16是在具有在一平方公尺的面積上透過一毫米的厚度樣品的氧的立方公分數所測得的氧滲透率，在24小時期間內，在0%相對濕度、23o C的溫度下在1大氣壓的分壓差下測量滲透率。氧滲透率可以根據ASTM F1927規範測得。因應前述氧滲透率，該隔離層16的厚度較佳地小於1mm或特別是小於0.5mm。Embodiment, the material of the spacer layer 16 comprises silicon oxide-based ((SiO 2) n), alkanes (C n H 2n + 1) or a benzene ring (C 6 H 6) n ( n ≧ 1) a functional embodiment Based polymer. The oxygen permeability of the isolation layer 16 is below 0.35 cm 3 ⋅mm / m 2 ⋅atm⋅day, which provides an excellent oxygen barrier effect. The isolation layer 16 is an oxygen permeability measured at a cubic centimeter of oxygen permeating a sample of a thickness of one millimeter over an area of one square meter. The oxygen permeability is measured at 0% relative humidity and 23 o C over a 24 hour period Permeability was measured at a partial pressure difference of 1 atmosphere at temperature. The oxygen permeability can be measured according to the ASTM F1927 specification. In accordance with the aforementioned oxygen permeability, the thickness of the isolation layer 16 is preferably less than 1 mm or particularly less than 0.5 mm.
前述實施例的電感線圈是以臥式纏繞，亦即電感線圈橫切面為水平向。實務上依據不同的感值需求，電感線圈可作出多種纏繞方式。圖6顯示以立式纏繞的另一實施例電感線圈功率電感器，也就是電感線圈橫切面為垂直向。功率電感器60包含主體62、電感線圈63、隔離層66、第一電極67及第二電極68。該主體62包含左側的第一端部71和右側的第二端部72，該第二端部72位於該第一端部71的相對側。電感線圈63設置於所述主體62中，包含分別延伸或連接至第一端部71的第一延伸端64，以及延伸或連接至第二端部72的第二延伸端64’。本實施例中，隔離層66包覆主體62未被第一電極67和第二電極68覆蓋的部分，亦即包覆該主體62中除了第一端部71和第二端部72以外的表面。換言之，隔離層66包覆主體62的第一端部71和第二端部72以外的四個表面，也就是主體62的上表面、下表面和兩個側表面。另外，隔離層66也覆蓋第一端部71和第二端部72的大部分區域，只有第一延伸端64連接第一端部71的部位附近以及第二延伸端64’連接第二端部72的部位附近沒有隔離層66覆蓋。一實施例中，隔離層66佔第一端面71的面積比例大於75%，或85%，隔離層66佔第二端面72的面積比例也是大於75%，或85%。第一電極67設於第一端部71，且連接至該電感線圈63位於第一端部71的第一延伸端64。第二電極68設於該第二端部72，且連接至該電感線圈63位於第二端部72的第二延伸端64’。該電感線圈63採用立式纏繞，因此電感線圈63橫切面為垂直向，第一延伸端64自第一端部71上方延伸入主體62且由外而內纏繞形成上部纏繞，之後延伸至下方由內而外纏繞形成下部纏繞，之後由第二延伸端64’延伸至第二端部72。類似的，主體62包含聚合物及散佈於聚合物中的金屬磁性填料。功率電感器60可以利用類似於圖1~3所示製程加以製作。The inductor coil of the foregoing embodiment is wound horizontally, that is, the cross section of the inductor coil is horizontal. In practice, inductive coils can be made in various winding modes based on different inductance requirements. FIG. 6 shows another embodiment of an inductive coil power inductor wound vertically, that is, the cross section of the inductive coil is vertical. The power inductor 60 includes a main body 62, an inductance coil 63, an isolation layer 66, a first electrode 67, and a second electrode 68. The main body 62 includes a first end portion 71 on the left side and a second end portion 72 on the right side, and the second end portion 72 is located on the opposite side of the first end portion 71. The inductance coil 63 is disposed in the main body 62 and includes a first extension end 64 extending or connected to the first end portion 71 and a second extension end 64 'extending or connected to the second end portion 72, respectively. In this embodiment, the isolation layer 66 covers the portion of the main body 62 that is not covered by the first electrode 67 and the second electrode 68, that is, the surface of the main body 62 except the first end portion 71 and the second end portion 72. . In other words, the isolation layer 66 covers four surfaces other than the first end portion 71 and the second end portion 72 of the main body 62, that is, the upper surface, the lower surface, and the two side surfaces of the main body 62. In addition, the isolation layer 66 also covers most of the first end portion 71 and the second end portion 72, and only the vicinity of the portion where the first extended end 64 is connected to the first end portion 71 and the second extended end 64 'is connected to the second end portion. The area around 72 is not covered by the isolation layer 66. In one embodiment, the area ratio of the isolation layer 66 to the first end surface 71 is greater than 75%, or 85%, and the area ratio of the isolation layer 66 to the second end surface 72 is also greater than 75%, or 85%. The first electrode 67 is disposed on the first end portion 71 and is connected to the first extension end 64 of the inductance coil 63 on the first end portion 71. The second electrode 68 is disposed on the second end portion 72 and is connected to the second extension end 64 'of the inductance coil 63 on the second end portion 72. The inductance coil 63 is vertically wound, so the cross section of the inductance coil 63 is vertical. The first extension end 64 extends from above the first end portion 71 into the main body 62 and is wound from the outside to the inside to form the upper winding, and then extends to the lower side. The inner and outer windings form a lower winding, and then extend from the second extension end 64 ′ to the second end portion 72. Similarly, the body 62 includes a polymer and a metallic magnetic filler dispersed in the polymer. The power inductor 60 can be manufactured by a process similar to that shown in FIGS. 1 to 3.
以下進行功率電感器的防鏽或抗氧化測試。先將主體進行長短邊裁切，形成長寬厚分別為2.15mm、1.42mm及1.0mm的元件。之後，浸泡披覆隔離層，烘烤進行固化。功率電感器製作隔離層且固化後的長寬厚分別約2.6mm、1.9mm、1.5mm。之後在溫度37℃、鹽量5 wt%的鹽霧中進行防鏽測試48小時。測試完後測量功率電感器的電阻達103 ~107 Ω，顯示仍具有良好的絕緣性，而有優異的抗氧化及防鏽效果。The rust or oxidation test of the power inductor is performed below. Firstly, the main body is cut on the long and short sides to form components with length, width and thickness of 2.15mm, 1.42mm and 1.0mm, respectively. After that, it is soaked and covered with a barrier layer and baked to be cured. The power inductor is made of an isolation layer and the length, width, and thickness after curing are about 2.6mm, 1.9mm, and 1.5mm, respectively. Thereafter, the rust prevention test was performed in a salt spray having a temperature of 37 ° C. and a salt content of 5 wt% for 48 hours. After the test, the resistance of the power inductor is measured to reach 10 3 to 10 7 Ω, which shows that it still has good insulation and excellent anti-oxidation and anti-rust effects.
以下就功率電感器進行不同的隔離層厚度的推膠測試，其中先行製作主體，其長寬厚分別為1cm、0.5cm及0.5cm，之後將隔離層膠體形成於主體側邊，並通過萬能拉力機由上而下以定速施加推力於隔離層，記錄拉力機上反饋的推力值F，此推力值F即為隔離層附著於主體的剪力強度。總共測試4組不同的隔離層厚度A、B、C和D，各組取10個樣本，測試結果如下表1所示，其中顯示功率電感器的隔離層的推力F除以隔離層厚度T的附著強度值F/T在0.2~3kg/mm，足夠的附著強度方能抵抗後續製程而提供良好的抗氧化保護。The following is a push test of different insulation layer thicknesses for power inductors. Among them, the main body is first produced, and its length, width, and thickness are 1cm, 0.5cm, and 0.5cm, respectively. After that, the insulation layer gel is formed on the side of the body and passed through a universal tensile machine The thrust is applied to the insulation layer at a constant speed from top to bottom, and the thrust value F fed back from the tensile machine is recorded. This thrust value F is the shear strength of the insulation layer attached to the main body. A total of 4 groups of different isolation layer thicknesses A, B, C, and D were tested, and 10 samples were taken from each group. The test results are shown in Table 1 below, which shows the thrust F of the isolation layer of the power inductor divided by the thickness of the isolation layer T. The adhesion strength value F / T is 0.2 ~ 3kg / mm, sufficient adhesion strength can resist the subsequent process and provide good oxidation protection.
表1
本發明的功率電感器提供絕佳的耐候特性，可有效阻絕氧氣和水氣，排除其對材料的影響，而維持長期電性的穩定，且隔離層有良好的端面附著強度。本發明技術特性為習知的功率電感器所不及，具有實質上的特點和突出的進步。The power inductor of the present invention provides excellent weather resistance characteristics, can effectively block oxygen and water vapor, exclude effects on the material, and maintain long-term electrical stability, and has good end surface adhesion strength of the isolation layer. The technical characteristics of the present invention are beyond the reach of conventional power inductors, and have substantial characteristics and outstanding progress.
本發明之技術內容及技術特點已揭示如上，然而本領域具有通常知識之技術人士仍可能基於本發明之教示及揭示而作種種不背離本發明精神之替換及修飾。因此，本發明之保護範圍應不限於實施例所揭示者，而應包括各種不背離本發明之替換及修飾，並為以下之申請專利範圍所涵蓋。The technical content and technical features of the present invention have been disclosed as above. However, those skilled in the art with ordinary knowledge may still make various substitutions and modifications based on the teaching and disclosure of the present invention without departing from the spirit of the present invention. Therefore, the protection scope of the present invention should not be limited to those disclosed in the embodiments, but should include various substitutions and modifications that do not depart from the present invention, and are covered by the following patent application scope.
10‧‧‧聚集體10‧‧‧ aggregate
11‧‧‧元件體11‧‧‧ element body
12、62‧‧‧主體12, 62‧‧‧ Subject
13、63‧‧‧電感線圈13, 63‧‧‧ Inductive coils
14、64‧‧‧第一延伸端14, 64‧‧‧ first extension
14’、64’‧‧‧第二延伸端14 ’, 64’ ‧‧‧ second extension
15‧‧‧缺口15‧‧‧ gap
16、66‧‧‧隔離層16, 66‧‧‧ Isolation
17、67‧‧‧第一電極17, 67‧‧‧ first electrode
18、68‧‧‧第二電極18, 68‧‧‧Second electrode
21、71‧‧‧第一端部21, 71‧‧‧ first end
22、72‧‧‧第二端部22, 72‧‧‧ second end
40、60‧‧‧功率電感器40, 60‧‧‧ Power Inductors
圖1至圖4顯示本發明之功率電感器的製作方法； 圖5顯示圖4之功率電感器的立體示意圖；以及 圖6顯示本發明另一實施例的功率電感器示意圖。1 to 4 show a method for manufacturing a power inductor of the present invention; FIG. 5 shows a schematic perspective view of the power inductor of FIG. 4; and FIG. 6 shows a schematic diagram of a power inductor according to another embodiment of the present invention.
Claims (13)
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