Manufacturing method of coil component and mold apparatus for manufacturing the coil component

• US 10,032,558 B2
• Filed: 08/17/2016
• Issued: 07/24/2018
• Est. Priority Date: 08/19/2015
• Status: Active Grant

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: Oki, Juichi, Kajiyama, Tomohiro
• Primary Examiner(s): Sanders, James
• Application Number:
  US15/238,843
• Publication Number:
  US 20170053739A1
• Time in Patent Office: 706 Days
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 41/005 Impregnating or encapsulating insulating of windings H01F41/12
• CPC Class Codes: H01F 41/0246 Manufacturing of magnetic circuits by moulding or by pressing powder magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36
• CPC Class Codes: H01F 41/04 for manufacturing coils coils for transformer or inductances H01F27/28

Abstract

A manufacturing method of a coil component including the steps of: assembling and forming a coil assembly body in which a coil is attached to a magnetic-body core; and inputting the coil assembly body and a putty-like admixture including magnetic powders and a thermosetting resin into an inner cylindrical portion of a die, further including the steps of: pressing the admixture which is inputted into the inner cylindrical portion, applying vibration for giving shear force with respect to the admixture which is inputted into the inner cylindrical portion for decreasing the viscosity of the aforesaid admixture, and thermosetting and forming a magnetic cover portion by heating an integrated object comprised of the admixture which was applied with the vibration and the coil assembly body and by thermally-curing the thermosetting resin included in the admixture.

Claims

1. A manufacturing method of a coil component comprising the steps of:

assembling and forming a coil assembly body in which a coil is attached to a magnetic-body core; and

inputting the coil assembly body and a putty state admixture including magnetic powders and a thermosetting resin into an inner cylindrical portion of a die, further comprising the steps of;

pressing the admixture which is within the inner cylindrical portion,

applying vibration for giving shear force with respect to the admixture which is within the inner cylindrical portion for decreasing the viscosity of the aforesaid admixture, and

thermosetting and forming a magnetic cover portion by heating an integrated object comprised of the admixture which was applied with the vibration and the coil assembly body and by thermally-curing the thermosetting resin included in the admixture.

2. The manufacturing method of a coil component according to claim 1, wherein

in the step of applying vibration, the vibration is applied to the admixture by an operation of a vibration generating mechanism which applies vibration to the die directly or indirectly.

3. The manufacturing method of a coil component according to claim 1, wherein

in the step of applying vibration, the vibration is applied to the admixture by an operation of a percussion mechanism which applies periodic impact to the admixture.

4. The manufacturing method of a coil component according to any one of claim 1, wherein

the step of pressing is carried out earlier than the step of applying vibration, and concurrently,

the step of pressing is carried out concurrently also in the step of applying vibration.

5. The manufacturing method of a coil component according to claim 3, wherein

in the step of applying vibration, the vibration is applied to the admixture by the operation of the vibration generating mechanism which applies vibration to the die directly or indirectly, and concurrently,

before or after the vibration application to the admixture by the vibration generating mechanism, the vibration is applied to the admixture by the operation of the percussion mechanism which applies periodic impact to the admixture.

6. The manufacturing method of a coil component according to claim 1, wherein

after the step of inputting, a lid member is placed at an upper portion of the admixture, further, a press member is placed at an upper portion of the lid member,

in the step of pressing, the admixture is pressurized by operating a pressurizing mechanism which pressurizes the press member, and concurrently,

prior to the step of thermosetting and forming, there is carried out a step of ejecting the integrated object from the inner cylindrical portion while maintaining the state in which the upper surface of the integrated object is in close contact with the lid member.