MANUFACTURING METHOD OF COIL COMPONENT AND COIL COMPONENT

• US 20160075058A1
• Filed: 09/04/2015
• Published: 03/17/2016
• Est. Priority Date: 09/11/2014
• Status: Active Grant

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: Kajiyama, Tomohiro, Tanaka, Teruaki, Sakamoto, Shinichi, Oki, Juichi, Kawarai, Mitsugu, Otsuka, Tsutomu, Takahashi, Motomi
• Granted Patent: US 10,786,932 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B22F 1/08 Metallic powder characterised by particles having an amorphous microstructure
• CPC Class Codes: B22F 1/10 Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
• CPC Class Codes: B22F 3/12 Both compacting and sintering by forging B22F3/17
• CPC Class Codes: B29C 2043/181 encapsulated
• CPC Class Codes: B29C 43/00 Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor by liberation of internal stresses B29C61/006
• CPC Class Codes: B29C 43/003 characterised by the choice of material
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 43/52 Heating or cooling
• CPC Class Codes: B29K 2083/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2505/00 Use of metals, their alloys or their compounds, as filler
• CPC Class Codes: B29K 2995/0008 Magnetic or paramagnetic
• CPC Class Codes: B29L 2031/34 Electrical apparatus, e.g. sparking plugs or parts thereof
• CPC Class Codes: H01F 17/045 with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
• CPC Class Codes: H01F 2017/046 helical coil made of flat wire, e.g. with smaller extension of wire cross section in the direction of the longitudinal axis
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2852 Construction of conductive connections, of leads
• CPC Class Codes: H01F 27/292 Surface mounted devices
• 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 41/061 : Winding flat conductive wires or sheets
• CPC Class Codes: H01F 41/076 : Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire

Abstract

A manufacturing method of a coil component comprising the steps of: preparing a coil assembly body in which a coil is attached on a magnetic core and a mold body which is formed with a cavity portion in the inside thereof and which includes at least one opening portion, putting a viscous admixture including magnetic powders and thermosetting resin and the coil assembly body in the cavity portion, pushing the put-in viscous admixture in the mold body, and thermally-curing the pushed-in viscous admixture and forming a magnetic exterior body which covers the coil assembly body.

Claims

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

preparing a coil assembly body in which a coil is attached on a magnetic core and a mold body which is formed with a cavity portion in the inside thereof and which includes at least one opening portion,

putting a viscous admixture including magnetic powders and thermosetting resin and the coil assembly body in the cavity portion,

pushing the put-in viscous admixture in the mold body, and

thermally-curing the pushed-in viscous admixture and forming a magnetic exterior body which covers the coil assembly body.

2. The manufacturing method of a coil component according to claim 1, wherein a press body is pressed against the viscous admixture in the step of pushing.

3. The manufacturing method of a coil component according to claim 2, wherein in the step of pushing, the press body is pressed against a swelling portion which is a part of the viscous admixture and which overflows from the opening portion for the planarization thereof.

4. The manufacturing method of a coil component according to claim 3, wherein the swelling portion is rubbed and cut by separating the press body which is pressed against the swelling portion from the viscous admixture while rotating it in the in-plane direction of the opening portion.

5. The manufacturing method of a coil component according to claim 3, wherein the press body is pressed against the swelling portion while rotating it in the in-plane direction of the opening portion.

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

the viscous admixture put in the cavity portion is covered by a lid member having excellent mold-releasable property, and

in the step of pushing, the viscous admixture is pushed-in by pressing the press body against the lid member.

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

in the step of putting, the viscous admixture is put as far as a lower position compared with the opening portion,

there is provided the lid member having approximately the same shape as the opening portion inside the opening portion, and

in the step of pushing, the press body having a thin diameter compared with the opening portion is pressed against the lid member.

8. The manufacturing method of a coil component according to claim 6, wherein the viscous admixture which is pushed-in by being covered by the lid member is taken out from the mold body together with the coil assembly body, and the magnetic exterior body is formed by thermally-curing the taken-out viscous admixture.

9. The manufacturing method of a coil component according to claims 1, wherein in the step of forming, the viscous admixture is thermally-cured inside the mold body and the magnetic exterior body is formed.

10. The manufacturing method of a coil component according to claim 1, wherein the viscous admixture is thermally-cured inside the mold body by a first temperature, the semi-cured viscous admixture is taken out from the mold body together with the coil assembly body, and the taken-out viscous admixture is thermally-cured by a second temperature which is a higher temperature than the first temperature.

11. The manufacturing method of a coil component according to claim 1, wherein the mold body is formed by a resin material having an excellent mold-releasable property.

12. The manufacturing method of a coil component according to claim 11, wherein

the mold body has flexibility and also includes the aligned plurality of cavity portions,

in the step of putting, the viscous admixtures and the coil assembly bodies are put in the plurality of cavity portions respectively,

in the step of forming, the viscous admixtures are thermally-cured inside the mold body respectively and the plurality of magnetic exterior bodies are formed, and

the formed plurality of magnetic exterior bodies are taken out from the cavity portions by bending the mold body such that the mold body is bent backward toward the alignment direction of the cavity portions.

13. The manufacturing method of a coil component according to claim 1, wherein the mold body includes a plurality of split-molds which define the cavity portions by being mutually combined.

14. The manufacturing method of a coil component according to claim 13, wherein the split-molds are removed from the viscous admixture which was pushed-in the step of pushing by mutually separating the plurality of split-molds and the magnetic exterior body is formed by thermally-curing the viscous admixture from which the split-molds were removed.

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

in the step of putting, the coil assembly body is attached to the bottom portion of the cavity portion and thereafter, the coil assembly body is buried by putting the viscous admixture, and

in the step of pushing, the viscous admixture facing the opening portion is pressed toward the coil assembly body.

16. The manufacturing method of a coil component according to claim 15, wherein

the coil assembly body includes a terminal portion which is connected to the coil and which is exposed from the magnetic core, and

at the bottom portion of the cavity portion, there is provided a concave portion which houses the terminal portion and which separates the terminal portion and the viscous admixture.

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

the coil assembly body includes a terminal portion which is connected to the coil and which is exposed from the magnetic core,

in the step of putting, the viscous admixture is put in the cavity portion and thereafter, the coil assembly body is placed on the viscous admixture such that the terminal portion is exposed from the viscous admixture, and

in the step of pushing, the placed coil assembly body is pressed toward the viscous admixture in the pushing-in direction.

18. The manufacturing method of a coil component according to claim 1, wherein a thermosetting-resin coated-layer is formed on the surface of the formed magnetic exterior body.