TWI643221B - Power inductor and manufacturing method thereof - Google Patents
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Abstract
一種功率電感器包含主體、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。A power inductor includes a body, an isolation layer, an inductor, a first electrode, and a second electrode. The body includes a first end and a second end, the second end being located on an opposite side of the first end. The barrier layer covers at least a surface of the body other than the first end and the second end. The inductive coil is disposed in the body and includes a first extended end extending from the body to the first end and a second extended end extending from the body to the second end. The first electrode is disposed at the first end and is connected to the first extended end. The second electrode is disposed at the second end and connected to the second extended end.
Description
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 present invention relates to an inductor and a method of fabricating the same, and more particularly to a power inductor and a method of fabricating the same.
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 a power supply circuit such as a DC-DC converter in an electronic device, and can also be used to eliminate noise components or form an LC resonance. The components of the circuit. With the development of mobile phones, tablet computers, and digital cameras, power inductor applications are gradually increasing 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. A conventional power inductor includes a body and an inductor. The inductor coil is formed by a wire to form a winding body, which is usually spiral and has a plurality of turns. The winding body is placed in a mold and molded into a mold, preferably a gel-like magnetic hybrid material. The magnetic hybrid material typically comprises a resin and a metallic magnetic material therein. After the magnetic hybrid material is dried, it becomes a bulk. After demolding, an external electrode connected to both ends of the winding body is formed at both ends of the block, that is, a conventional surface-mount type power inductor is obtained.
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, in the conventional power inductor, the main body is exposed to the external environment, and under adverse or unstable temperature or humidity conditions, the metal magnetic material is oxidized and the like, which easily causes appearance oxidation and electrical deviation of the power inductor. In addition, in the conventional manufacturing process, when the main body is cut, the problem that the magnetic material in the cut surface falls to form a hole may occur, and the subsequent connection with the electrode may be affected.
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 manufacturing method thereof, which use an isolation layer to cover a main body of a power inductor to isolate an external environment, thereby preventing the power inductor from being deteriorated 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 that includes a body, an isolation layer, an inductor, a first electrode, and a second electrode. The body includes a first end and a second end, the second end being located on an opposite side of the first end. The barrier layer covers at least a surface of the body other than the first end and the second end. The inductive coil is disposed in the body and includes a first extended end extending from the body to the first end and a second extended end extending from the body to the second end. The first electrode is disposed at the first end and is connected to the first extended end. The second electrode is disposed at the second end and 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 barrier layer is used to isolate oxygen and moisture.
一實施例中，該隔離層的氧滲透率在0.35 cm 3⋅mm/m 2⋅atm⋅day以下。 In one embodiment, the barrier layer has an oxygen permeability of less than 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 body comprises 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), cerium (Si), chromium (Cr), nickel (Ni), 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 barrier layer also covers a portion of the surface of the first end and the second end.
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 to the first end is greater than 75%, and the area ratio of the isolation layer to the second end 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 separator comprises a polymer of cerium oxide, alkane or benzene ring functional groups.
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 isolation layer has an adhesion strength F/T of 0.2 to 3 kg/mm, wherein F is a thrust value applied to the isolation layer, and T is a 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 inductive coil has a transverse plane that is perpendicular and includes an outer portion that is wound from the outside and a lower portion that is wound from the inside to the outside.
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 fabricating a power inductor includes the steps of: (1) fabricating an aggregate comprising a plurality of component bodies, each component body including a body and being disposed in the An inductive coil in the main body, each of the inductive coils has an extended end on both sides, and adjacent or connected extension ends of the adjacent element bodies are laterally arranged in the upper half and the lower half of the aggregate in a laterally spaced manner; Cutting the main body at the corresponding end of the extended end to form a horizontally spaced upper and lower notch; (3) forming an isolation layer to cover the aggregate; (4) cutting the aggregate and the corresponding isolation layer at the notch, and dividing And a plurality of element bodies having the isolation layer on the upper and lower surfaces; and (5) forming a first electrode and a second end on the first end of the element body to form a second electrode.
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 to cover the main body with an isolation layer to block the intrusion of moisture and oxygen, thereby preventing oxidation of materials in the power inductor, thereby avoiding electrical deviation, prolonging the service life and avoiding failure of the power inductor.
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。The above and other technical contents, features and advantages of the present invention will become more apparent from the following description.
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 process of fabricating a power inductor according to an embodiment of the present invention. Referring to Figure 1, an integrator 10 is fabricated by placing an inductive coil 13 in the body 12 using stacking and lamination techniques. The press-fitting can be performed by pressing the main body 12 and the induction coil 13 by hot pressing or cold pressing to form a sheet-like or strip-shaped aggregate 10. In other words, the aggregate 10 includes a plurality of component bodies 11 (each of which is a single component), and each component body 11 includes a body 12 and an inductor 13 disposed in the body 12. The inductor coil 13 is a bobbin formed of a wire, has a spiral shape and has a plurality of turns, and its surface may be covered with an insulating layer. Each of the inductor coils 13 includes extension ends 14 on both sides, and the extension ends 14 of the inductor coils 13 in the adjacent element bodies 11 are connected. In response to the winding structure of the inductor coil 13, the extended end portions 14 of the connection are arranged laterally and sequentially in the upper and lower halves 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, the main body 12 at the connection position of the extended end 14 of the adjacent inductor 13 cuts out a plurality of notches 15, but only the body 12 itself, and does not cut to the extended end 14 of the inductor 13. In other words, the depth of cut needs to have a certain degree of precision. According to the present embodiment, the notches 15 are arranged in the horizontally and sequentially spaced apart manner in the upper half and the lower half of the agglomerate 10, and the notches 15 are arranged in a laterally spaced manner with the openings facing downward and upward. In another embodiment, the extended end 14 between the inductive coils 13 is not necessarily continuous. When the extended end 14 is discontinuous, the similar or identical coil arrangement can still be obtained through the regulation of the entire jig, thereby performing FIG. 2 The half cuts of the upper and lower wheels are shown to form the notches 15. Referring to FIG. 3, a layer 16 is disposed on the surface of the aggregate 10, and the body 12 is entirely covered in the separator 16, thereby isolating the contact of the body 12 with the outside. The spacer layer 16 is filled in the notch 15, which corresponds to the isolation protection at the end of the element body 11. Thereafter, a second cut is made at the corresponding portion of the notch 15, and the joint portion between the respective element bodies 11 is cut, thereby separately separating the individual element bodies 11. Next, the first electrode 17 and the second electrode 18 are formed on the left end of the individual element body 11 by the first end portion 21 and the second end portion 22, respectively, to form a power inductor 40 as shown in FIG. FIG. 5 is a perspective view of the power inductor 40 of FIG. 4. The winding mode and tightness of the inductor coil 13 in the figure are only schematic and are not limited thereto. The surface of the inductor coil 13 may be covered with an insulating layer such as an enameled wire. When the inductor coil 13 is wound, even if the upper and lower rings are in direct contact, there is an insulating layer as isolation therebetween.
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 fabrication of the power inductor 40 generally comprises several steps: (1) press-forming an aggregate 10 comprising a plurality of component bodies 11, each component body 11 comprising a body 12 and being disposed on the body Inductor coil 13 of 11 , each inductor coil 13 includes two extending ends 14 , and the extending ends 14 of the inductor coils 13 are connected to each other in the adjacent element body 11 , and the extending ends 14 of the connecting lines are arranged laterally in sequence The upper and lower halves of the aggregate 10; (2) the main body 12 at the corresponding end of the extended end 14 is formed, forming a horizontally spaced upper and lower notches 15; (3) forming an isolating layer 16 covering the aggregate 10; (4) cutting the aggregate 10 and the spacer layer 16 at the corresponding notch 15 to divide the plurality of surfaces having the spacer layer 16; and (5) respectively for the component body 11 The one end portion 21 forms the first electrode 17 and the second end portion 22 to form the second electrode 18. The production method integrates stacking, pressing, cutting and other technologies, and the 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。Generally speaking, if the isolation layer is formed by dividing into individual components, the isolation layer is usually thought to be applied by immersion or spraying. Therefore, the lead end of the coil of the product end face must be protected first, and then the protective layer is removed after the isolation layer is applied. To avoid contamination, the contact between the inner and outer electrodes is poor, but the application and removal of the protective layer itself is quite troublesome. Therefore, the method of the invention is to cut the half first (without the lead end), and then perform the application of the separating layer, and then cut the connecting portion (secondary cutting), which can save the application of the protective layer. With the removal, save time and materials.
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 to FIGS. 4 and 5, the power inductor 40 includes a body 12, an inductor 13, an isolation layer 16, a first electrode 17, and a second electrode 18. The body 12 includes a first end portion 21 on the left side and a second end portion 22 on the right side, the second end portion 22 being located on the opposite side of the first end portion 21. Inductor coil 13 is disposed in said body 12 and includes a first extended end 14 that extends or is coupled to first end 21, respectively, and a second extended end 14' that extends or is coupled to second end 22. In this embodiment, the isolation layer 16 covers a portion of the main body 12 that is not covered by the first electrode 17 and the second electrode 18, that is, covers a surface of the main body 12 other than the first end portion 21 and the second end portion 22. . In other words, the barrier layer 16 covers the four surfaces other than the first end portion 21 and the second end portion 22 of the body 12, that is, the upper surface, the lower surface, and the two side surfaces of the body 12. In addition, the isolation layer 16 also covers most of the first end portion 21 and the second end portion 22, only the first extended end 14 is adjacent to the portion of the first end portion 21 and the second extended end 14' is connected to the second end portion. There is no isolation layer 16 covered near the portion of 22. In one embodiment, the ratio of the area of the isolation layer 16 to the first end surface 21 is greater than 75%, or 85%, and the ratio of the area of the isolation layer 16 to the second end surface 22 is also greater than 75%, or 85%. The first electrode 17 is disposed at the first end portion 21 and is connected to the first extended end 14 of the first end portion 21 of the inductor coil 13 . The second electrode 18 is disposed at the second end 22 and is coupled to the second extended end 14' of the second end portion 22 of the inductive coil 13. The body 12 contains a polymer and a metallic magnetic filler dispersed in the polymer. The metal magnetic filler contains an alloy of Fe, Si, Cr, Ni, and Co. The metal magnetic material accounts for 10 to 95% by weight of the main body 12. Conventionally, the end portion where the electrode is formed is usually a cut surface, and the metal magnetic filler in the main body often forms a hole by dropping due to the cutting action. The first electrode 17 and the second electrode 18 of the present invention have a large area directly contacting the isolation layer 16, and only a small portion contacts the body 12 containing the metal magnetic filler, so that the first electrode 17 and the second electrode 18 are substantially free of the cut surface. The metal magnetic filler is dropped to cause the influence of holes.
一實施例中，該隔離層16的材質包含氧化矽類((SiO 2) n)、烷類(C nH 2n+1)或苯環類(C 6H 6) n(n≧1)官能基的聚合物。該隔離層16的氧滲透率在0.35 cm 3⋅mm/m 2⋅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、23 oC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。 In one embodiment, the material of the isolation layer 16 comprises cerium oxide ((SiO 2 ) n ), alkane (C n H 2n+1 ) or benzene ring (C 6 H 6 ) n (n≧1) functional Base polymer. The separator 16 has an oxygen permeability of 0.35 cm 3 ⋅mm/m 2 ⋅atm⋅day or less, providing an excellent oxygen barrier effect. The barrier layer 16 is an oxygen permeability measured in cubic centimeters of oxygen having a thickness of one millimeter across an area of one square meter, at 0% relative humidity, 23 o C over a 24 hour period. The permeability was measured at a partial pressure difference of 1 atm. Oxygen permeability can be measured according to ASTM F1927 specifications. The thickness of the barrier layer 16 is preferably less than 1 mm or especially less than 0.5 mm in view of the aforementioned oxygen permeability.
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, depending on the different sensed values, the inductor coil can be made in a variety of winding modes. Figure 6 shows another embodiment of the inductor power inductor in a vertical winding, that is, the cross-section of the inductor is vertical. The power inductor 60 includes a body 62, an inductor 63, an isolation layer 66, a first electrode 67, and a second electrode 68. The body 62 includes a first end 71 on the left side and a second end 72 on the right side, the second end 72 being located on the opposite side of the first end 71. An inductive coil 63 is disposed in the body 62 and includes a first extended end 64 that extends or is coupled to the first end 71, respectively, and a second extended end 64' that extends or is coupled to the second end 72. In the present 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, covers the surface of the main body 62 other than the first end portion 71 and the second end portion 72. . In other words, the isolation layer 66 covers the 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, only the first extended end 64 is adjacent to the portion of the first end portion 71 and the second extended end 64' is connected to the second end portion. There is no isolation layer 66 in the vicinity of the portion of 72. In one embodiment, the ratio of the area of the isolation layer 66 to the first end surface 71 is greater than 75%, or 85%, and the ratio of the area of the isolation layer 66 to the second end surface 72 is also greater than 75%, or 85%. The first electrode 67 is disposed at the first end portion 71 and is connected to the first extended end 64 of the first end portion 71 of the inductor 63. The second electrode 68 is disposed at the second end portion 72 and is coupled to the second extended end 64' of the second end portion 72 of the inductive coil 63. The inductor coil 63 is vertically wound, so that the transverse direction of the inductor coil 63 is vertical, and the first extending end 64 extends from the first end portion 71 into the main body 62 and is wound from the outside to the inside to form an upper winding, and then extends to the lower side. The inner and outer windings form a lower winding which then extends from the second extended end 64' to the second end 72. Similarly, body 62 comprises a polymer and a metallic magnetic filler dispersed in the polymer. The power inductor 60 can be fabricated using a process similar to that shown in Figures 1-3.
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10 3~10 7Ω，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. First, the main body is cut into long and short sides to form components with length, width and thickness of 2.15mm, 1.42mm and 1.0mm respectively. After that, the coating is soaked and baked to cure. The power inductor is made of an isolation layer and has a thickness and a thickness of about 2.6 mm, 1.9 mm, and 1.5 mm after curing. Thereafter, a rust proof test was conducted for 48 hours in a salt spray having a temperature of 37 ° C and a salt content of 5 wt%. After the test, the resistance of the power inductor is measured to be 10 3 ~ 10 7 Ω, which shows that it still has good insulation, and has 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。In the following, the power inductor is tested for different thickness of the isolation layer, wherein the main body is made to have a length and a width of 1 cm, 0.5 cm and 0.5 cm, respectively, and then the separation layer colloid is formed on the side of the main body and passes through the universal tensile machine. The thrust is applied to the isolation layer from top to bottom at a constant speed, and the thrust value F fed back on the tensile machine is recorded. This thrust value F is the shear strength of the isolation layer attached to the main body. A total of 4 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 T of the isolation layer. The adhesion strength value F/T is 0.2~3kg/mm, and sufficient adhesion strength can resist the subsequent process and provide good anti-oxidation protection.
表1 <TABLE border="1" borderColor="#000000" width="85%"><TBODY><tr><td> 組別 </td><td> A </td><td> B </td><td> C </td><td> D </td></tr><tr><td> 隔離層厚度T (mm) </td><td> 0.25~0.76 </td><td> 0.24~0.67 </td><td> 0.19~0.61 </td><td> 0.25~0.81 </td></tr><tr><td> 推力F (kg) </td><td> 0.2~0.5 </td><td> 0.3~0.6 </td><td> 0.1~0.5 </td><td> 0.4~0.7 </td></tr><tr><td> F/T(kg/mm) </td><td> 0.5~2.4 </td><td> 0.4~2.9 </td><td> 0.3~2.6 </td><td> 0.5~3 </td></tr></TBODY></TABLE>Table 1 <TABLE border="1" borderColor="#000000" width="85%"><TBODY><tr><td> Groups</td><td> A </td><td> B </td ><td> C </td><td> D </td></tr><tr><td> Isolation layer thickness T (mm) </td><td> 0.25~0.76 </td><td > 0.24~0.67 </td><td> 0.19~0.61 </td><td> 0.25~0.81 </td></tr><tr><td> Thrust F (kg) </td><td> 0.2~0.5 </td><td> 0.3~0.6 </td><td> 0.1~0.5 </td><td> 0.4~0.7 </td></tr><tr><td> F/T (kg/mm) </td><td> 0.5~2.4 </td><td> 0.4~2.9 </td><td> 0.3~2.6 </td><td> 0.5~3 </td>< /tr></TBODY></TABLE>
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, can effectively block oxygen and moisture, eliminates its influence on materials, and maintains long-term electrical stability, and the barrier layer has good end face adhesion strength. The technical characteristics of the present invention are inferior to conventional power inductors, and have substantial features and outstanding advancements.
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 contents and technical features of the present invention have been disclosed as above, and those skilled in the art can still make various substitutions and modifications without departing from the spirit and scope of the invention. Therefore, the scope of the present invention should be construed as being limited by the scope of the appended claims
10‧‧‧聚集體10‧‧‧ aggregates
11‧‧‧元件體 11‧‧‧Component body
12、62‧‧‧主體 12.62‧‧‧ Subject
13、63‧‧‧電感線圈 13, 63‧‧‧Inductance coil
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 layer
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 of fabricating the power inductor of the present invention; Fig. 5 is a perspective view showing the power inductor of Fig. 4; and Fig. 6 is a view showing a power inductor according to another embodiment of the present invention.
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| US20170372833A1 (en) * | 2016-06-24 | 2017-12-28 | Samsung Electro-Mechanics Co., Ltd. | Power inductor with a chip structure |
| TW201812805A (en) * | 2016-09-08 | 2018-04-01 | 摩達伊諾琴股份有限公司 | Power inductor |
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| US20170372833A1 (en) * | 2016-06-24 | 2017-12-28 | Samsung Electro-Mechanics Co., Ltd. | Power inductor with a chip structure |
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