Method For Producing An Induction Component, And Induction Component

• US 20170053741A1
• Filed: 04/09/2015
• Published: 02/23/2017
• Est. Priority Date: 04/23/2014
• Status: Active Grant

• Current Assignee: Wurth elektronik eisos gmbh & co. kg
• Original Assignee: Wurth elektronik eisos gmbh & co. kg
• Inventors: STARK, Markus, RICHTER, Klaus, DEGEN, Dorian
• Granted Patent: US 10,319,519 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 27/292 Surface mounted devices
• 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 41/06 Coil winding
• CPC Class Codes: H01F 41/127 Encapsulating or impregnating encapsulating coil and core H01F41/005

Abstract

The invention proposes a method of producing induction components each containing a coil, wherein the coils are wound on a wire-winding plate, containing a multiplicity of wire-winding stubs arranged in rows and columns, using a wire which is continuous for a plurality of coils. The template provided with the coils is then pressed in a moulding press with ferromagnetic substrate powder, which embeds the coils. Once the template has been removed, the interiors of the coils are provided with substrate powder, and pressed, once again in a moulding press. Electrical contact is then made with the connections and the block is divided up into individual induction components each containing a coil.

Claims

1. Method of producing induction components (15), having the following method steps:

a winding operation is carried out for a multiplicity of coils (5) arranged one beside the other and having parallel coil axes;

the coils (5) are embedded at intervals in a block (8) made of pressed substrate;

the interior of the coils (5) in the block (8) is filled with the substrate, which is present in powder form;

the substrate powder is pressed;

the two ends of the winding of all the coils (5) are exposed;

the exposed ends of the coil windings are provided with connection contacts (14);

the block (8) is then divided up to form the individual induction components (15) each containing at least one coil (5).

2. Method according to claim 1, wherein the block (8) is formed by virtue of the substrate powder being pressed around the coils arranged therein.

3. Method according to claim 1, wherein the block (8) is produced with a respective cavity, which corresponds in shape and size at least to one coil (13) of the multiplicity of coils (5), and the coils (5) are inserted into the respective cavity.

4. Method according to claim 1, wherein, in order to produce the coils (5), use is made of a template (1) with a multiplicity of stubs (3), which are arranged one beside the other and run parallel to one another and around which a wire (4) is wound.

5. Method according to claim 4, wherein the template with the coils (5) wound on its stubs (3), is incorporated in a moulding press (6), and then the substrate powder is applied to the template (1) and pressed in the moulding press (6).

6. Method according to claim 5, wherein, once the substrate powder has been pressed, the template (1) is removed from the block (8) generated by virtue of the substrate powder being pressed, the block (8) is incorporated in a moulding press (10), and then substrate is filled up into the moulding press (10), in order to fill the interior of the coils (5), and pressed.

7. Method according to claim 6, characterized in that the interior of the coils is filled up, at least in part, with a prefabricated core.

8. Method according to claim 1, wherein, prior to the connection contacts (14) being applied, incisions are cut into the upper side of the block (8), between the individual regions containing the coils (5), part of the way along the height of the block, and the connection contacts (14) are also applied to the walls of the incisions (13).

9. Method according to claim 8, wherein the incisions (13) are made at the location where the block (8) is later divided up to form the individual induction components (15).

10. Method according to claim 1, wherein the coils (5) are arranged in a matrix-like arrangement, in rows and columns, in the block (8).

11. Method according to claim 1, wherein, once the ends of the winding of all the coils (5) have been exposed, strip-like masking (12) takes place.

12. Method according to claim 1, characterized in that the block (8) is pressed isostatically, in particular in a liquid-filled pressure vessel.

13. Method according to claim 1, characterized in that the operation of exposing the ends of the coil windings takes place by means of mechanical removal.

14. Induction component, capable of being produced by a method according to claim 1.