METHOD OF MANUFACTURING MAGENTIC BODY

• US 20100158743A1
• Filed: 06/27/2008
• Published: 06/24/2010
• Est. Priority Date: 06/27/2007
• Status: Abandoned Application

• Current Assignee: Shindengen Electric Manufacturing Company Limited
• Original Assignee: Shindengen Electric Manufacturing Company Limited
• Inventors: Funakoshi, Shichio, Ikeda, Katsuya, Song, Man Ho, Ohshima, Masaki
• Application Number:
  US12/665,659
• Publication Number:
  US 20100158743A1
• Time in Patent Office: Days
• US Class Current: 419/66
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• 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: H05K 1/0373 containing additives, e.g. fillers H05K1/036 takes precedence
• CPC Class Codes: H05K 1/165 incorporating printed inductors
• CPC Class Codes: H05K 2201/0215 Metallic fillers
• CPC Class Codes: H05K 2201/083 Magnetic materials
• CPC Class Codes: H05K 2201/09118 Moulded substrate
• CPC Class Codes: H05K 2201/10265 Metallic coils or springs, e.g. as part of a connection element
• CPC Class Codes: H05K 2201/10287 Metal wires as connectors or conductors
• CPC Class Codes: H05K 3/103 by bonding or embedding conductive wires or strips
• CPC Class Codes: H05K 3/20 by affixing prefabricated conductor pattern H05K1/187, H05K3/046, H05K3/4658, H05K3/4682 takes precedence

Abstract

A method of manufacturing a magnetic body in which insulating magnetic powder particles are stacked and press-molded in a molding space, and wiring is formed on a surface of the insulating magnetic powder particles solidified by press molding is provided according to the present invention. The method includes: a first step S10 of preparing a wiring plate which includes a sheet-shaped base plate and the wiring which is formed on the base plate and is removable from the base plate; a second step S20 of stacking the insulating magnetic powder particles in the molding space, arranging the wiring plate on a surface of the insulating magnetic powder particles in a state that the wiring faces the surface of the insulating magnetic powder particles in an opposed manner, and press-molding the insulating magnetic powder particles and the wiring plate; and a third step S30 of removing the base plate from the surface of the solidified insulating magnetic powder particles while leaving the wiring on the insulating magnetic powder particles in this order. According to the method of manufacturing a magnetic body of the present invention, it is possible to prevent the corrosion of the insulating magnetic powder particles thus realizing the manufacture of a highly reliable magnetic body.

Claims

1. A method of manufacturing a magnetic body in which insulating magnetic powder particles are stacked in a molding space and are press-molded, and wiring is formed on a surface of the insulating magnetic powder particles solidified by press molding, the method comprising:

a first step of preparing a wiring plate which includes a sheet-shaped base plate and the wiring which is formed on the base plate and is removable from the base plate;

a second step of stacking the insulating magnetic powder particles in the molding space, arranging the wiring plate on a surface of the insulating magnetic powder particles in a state that the wiring faces the surface of the insulating magnetic powder particles in an opposed manner, and press-molding the insulating magnetic powder particles and the wiring plate; and

a third step of removing the base plate from the surface of the solidified insulating magnetic powder particles while leaving the wiring on the surface of the solidified insulating magnetic powder particles in this order.

2. A method of manufacturing a magnetic body according to claim 1, wherein the wiring plate is a wiring plate which is formed in such a manner that an electric conductive film is formed on the base plate, and etching with a desired pattern is applied to the electric conductive film thus forming the wiring.

3. A method of manufacturing a magnetic body according to claim 1, wherein average surface roughness of the wiring is larger than an average particle size of the insulating magnetic powder particles.

4. A method of manufacturing a magnetic body according claim 1, wherein the wiring is formed of a metal foil.

5. A method of manufacturing a magnetic body according to claim 4, wherein the metal foil is a copper foil.

6. A method of manufacturing a magnetic body according to claim 1, wherein the base plate is made of a resin.

7. A method of manufacturing a magnetic body according to claim 1, wherein the second step includes:

a pre-pressing step of stacking the insulating magnetic powder particles in the molding space, and applying pre-press molding to the insulating magnetic powder particles in such a stacked state for leveling the surface of the insulating magnetic powder particles; and

a main pressing step of press-molding the insulating magnetic powder particles at a pressing pressure higher than a pressing pressure in the pre-press molding in a state where the wiring plate is arranged on a surface of the insulating magnetic powder particles such that the wiring faces the surface of the insulating magnetic powder particles in an opposed manner in this order.