HK1222473B - Method for producing an induction component and an induction component - Google Patents

Description

The invention relates to a process for the manufacture of an induction component and an induction component manufactured by that process.

A method for producing an induction component or inductor is already known (KR 10-1044607) whereby a coil core, coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil coil

Another known method (KR 10-1044 608) involves the insertion of a large number of connecting terminals into a first form and a large number of individual coils into a second form.

In another well-known method (KR 10-2011-0100096), the coil core, coil coil coil and coil cover are pressed together with the coil into a mould.

The purpose of the invention is to develop a process for the manufacture of induction components which results in high quality induction components which are easy to manufacture.

To solve this problem, the invention proposes a process with the characteristics mentioned in claim 1.

The method thus involves winding individual coils. These coils can have any shape. The wire used for this can also have any cross section. A block is made of a particularly powdery and/or ferromagnetic substrate, in which the coils are embedded in a predefined orientation. Care is taken that the end of the coil forming the start of the winding is oriented in a certain orientation towards the block. Pre-pressing is then carried out to establish a certain homogeneity within the block and to fix the coils within the block in their spatial orientation.

The prepressed block is placed on a plate with a marking for each coil. The marking is specifically assigned to the start of the winding. The combination of block and plate is pressed. The substrate of the block is solidified and, among other things, produces an impression of the marking on the side of the block assigned to the plate. The marking shows us the orientation of the coil and in particular the position of the start of the winding of the coils. Preferably, the coils and the associated marking are arranged within a pre-determined surface grid.

Pre-pressing can be done isostatically to make the block's substrate as homogeneous as possible and without cracks.

After pressing, the block is released from the support plate and the ends of the coil coils are exposed.

The exposed ends of the coils shall be fitted with connecting contacts.

The block shall be cut to form the induction components, each containing at least one coil or a double coil.

If desired in individual cases, a separation into induction components containing more than one coil may also be carried out.

The further development of the invention may involve the forming of the block of ferromagnetic powder in a pressing process, for example by using an iron powder mixture with an iron content of, for example, 98%.

The coil ends to be contacted may be deflected in the course of the invention so that they are transverse to the coil axis in their endpoint.

In particular, it may be provided that the ends of the coils protrude beyond the outer contour of the coil body.

In further training, the invention may be used to manufacture the coils using insulated wire, in particular lacquer insulated wire.

It is possible and within the scope of the invention that a coil is fitted with a core before being embedded in the block. This core can also be used, for example, to serve as a support for the wire during winding.

It is also within the scope of the invention that the coil is wrapped without a core and embedded in the block without a core.

For the purpose of pre-pressing, it may be provided that the block or substrate, with the coils used, is placed in a moulding press and that the pre-pressing is carried out in this press.

Preferably, the prepressing may be carried out according to a time/pressure profile, which shall be chosen in such a way as not to damage the insulation of the coils' wire or the coils themselves.

It was mentioned at the beginning that the block with the coils inserted is placed on a support plate before the isostatic compression is performed. The side of the block lying on the support plate later forms the top of the induction component, which is opposite the bottom to be mounted on the circuit board. Using a support plate with a low surface roughness ensures that the top of the induction component is also smooth. This improves the possibility of using a suction gripper to treat the induction stream in the pick-and-place process. For example, a support plate with a surface roughness of 0,1 μm or less can be used, which allows very small suction grips to be used.

In the further development of the invention, a layer of material made of an elastic material, e.g. a silicone mat, may be applied to the side of the block on which the coils are wrapped before isostatic pressing is performed, in order to avoid adverse deformation of the underside of the induction components produced during isostatic pressing, particularly in the area of the winding ends and thus the subsequent wire drainage.

In further development of the invention, the unit of the plate, pre-pressed block and layer of elastic material may be gas-tightly evacuated and placed in a liquid-filled pressure vessel where isostatic pressing is performed at a specified pressure and/or temperature, the pressure and/or temperature being subjected to a specified time course.

After the isostatic pressing is completed, the winding ends may be unwound by a mechanical process which not only removes the insulation of the winding ends but also, if necessary, increases the contact area of the wire.

The exposed ends of the coil are then contacted by a known process.

The subsequent cutting of the block containing the large number of coils can be carried out by known methods, for example by a mechanical cutting saw.

Further features, details and advantages of the invention are given in the claims and the summary, both of which are worded by reference to the content of the description, the following description of preferred embodiments of the invention and a drawing showing: Figure 1 a perspective view of a coil;Figure 2 a side view of the coil of Figure 1;Figure 3 a section through the block with coils inserted during prepressing;Figure 4 the process of isostatic pressing;Figure 5 the process step of unwinding the ends of the coils;Figure 6 the result of unwinding the ends;Figure 7 the induction components produced by cutting the block;Figure 8 the perspective view of an induction component of the invention;Figure 9 the partially opened induction component of Figure 8.

The method proposed by the invention is now illustrated by an example.

Figure 1 shows the perspective view of a coil 8 which has at its one axial end, shown in Figure 1 above, the winding ends 6, 7. Both winding ends 6, 7 are deflected so that they run transversely to the axis of the coil 8 and protrude outwards over the outer contour of the coil 8.

Figure 2 shows the side of coil 8 of Figure 1. Here again it is seen that the ends of the coil 6, 7 of the coil forming coil protrude over the outer contour of the coil and are in a common plane.

In the next step, several coils 8 are embedded in a block of a substrate, the substrate being composed of a powder, in particular a mixture of iron powder.

Figure 3 shows the arrangement of block 1 in a moulding press 9, where block 1 may consist of a first substrate powder before the press is closed. When the coils are embedded in block 1, care is taken that the coil ends are oriented towards the side edges of block 1. In layer 10, the coil ends are 6, 7. Block 1 is placed in the moulding press on a support plate 11. The surface 12 of moulding press 9 is pressurised in the direction of arrow 13, with the course of the pressure corresponding to a time/pressure profile. This profile is selected so that the absorbed energy cannot cause any damage to the wire insulation or the pre-pressure.For example, this pressing process of the first substrate powder may apply a pressure of 250 kg/cm2. If necessary, in order to meet the required dimensions of block 1, a second substrate powder may be applied to block 1 after the first pressing process and a second pressing process may be carried out. Block 1 may, if necessary, be coated with a further layer of substrate powder in the form 9 press to achieve the required dimensions of block 1 or the induction components produced from it. The substrate powder may be the same or different from the first substrate powder.The second pressing operation, for example, can apply a pressure of 200 to 270 kg/cm2. After the time corresponding to the profile has elapsed, the pre-pressing of block 1 with coils 8 is completed.

Block 1 is now taken from the moulding press 9 of Fig. 3 and inserted into a pressure vessel 14 as shown in Fig. 4. In the pressure vessel 14 there is a support plate 15 with a surface facing block 1 whose surface quality does not exceed a roughness of 0,1 μm and which can therefore also be called a polished plate. This surface 16 contains a small cone-shaped protrusion 17 for each coil 8 forming a marking. Each of these cones 17 is oriented to the winding ends 6, 7 of the respective coil 8, in particular to the winding beginning. In other words, each of the 8 coils 17 is oriented to the winding beginning of each coil 8.The unit of block 1, plate 15 and layer 18 is then conveniently packaged and evacuated if necessary. The pressure vessel 14 is then filled with liquid, for example water, and pressurised on all sides as indicated by the arrows 19. The silicon layer 18 is intended to prevent damage to the winding loads 6, 7 contained in block 10 during the pressure recovery. The pressure relief creates a complementary depth of 21 K at the bottom of block 3 on page 1.This isostatic pressing has a much higher pressure than the previous pressing processes, for example at at least ten times the pressure, in particular 4500 kg/cm2.

The pressure load can also be applied to the temperature during the pressure load, preferably according to a given time/pressure profile, and the temperature load can also be applied to a given time/temperature profile.

After the isostatic pressing is completed, the block thus produced, which is coated with layer 10, is removed from the pressure vessel 14 and the coils 8 are fully embedded in block 1.

Next, the top of layer 10, still visible at the left end in Figure 5, is removed by a milling machine 22 to the extent that the windings 6, 7 of each coil 8 are released from their insulation and, in particular, are exposed to about half their cross-section, as shown in the right part of Figure 5.

The result is a block 1 (see Fig. 6) in which the windings 6, 7 of all coils 8 are exposed, and these windings 6, 7 can now be fitted with connecting contacts by a familiar process.

The induction components desired as final products are then produced by cutting into parts of block 1, see Figure 7. Figure 7 shows, starting from Figure 6, how individual inductors 24 are produced from the connected block 1 by sawing.

The former underside of block 1 now forms the top of the inductor 24. In this top, a hole 21 is shown, which was created by cone 17 of the support plate 15. On the underside of block 1 forming the former top of block 1 two connecting contacts 25 are attached, each electrically and mechanically connected by a winding end 6 or 7 respectively. This connection of the contact elements 25 to the winding ends 6, 7 is indicated in figure 9, where the substrate actually surrounding the coils 8 is not shown. The top of the inductor is very tightly automatically located, as it is located on the winding hole 15 mm wide, which gives a very small inductor with a maximum aperture of 24 mm.

Claims (15)

1. A method for producing induction components (24), having the following method steps:

   - a multiplicity of individual coils (8) with the two ends (6, 7) of the windings projecting out of the coil body are produced;

   - each coil (8) of the multiplicity of coils (8) is embedded, with predetermined orientation of the winding ends (6, 7), in a block (1) made of an, in particular, pulverulent substrate;

   - the block (1) is positioned on a plate (15) having a marking (17) for each coil (8), wherein the number of markings (17) corresponds to the number of coils (8);

   - the combination made up of block (1) and plate (15) is pressed;

   - subsequently, the block (1) is divided up into individual induction components (24).
2. The method according to claim 1, characterized in that the markings (17) are arranged such that, once the block (1) has been divided up into individual induction components (24), each induction component (24) has an impression of a marking (17) on its upper side, wherein the upper side is located opposite an underside of the induction component (24) with winding ends exposed.
3. The method according to claim 1 or 2, characterized in that the markings (17) are arranged such that the markings (17) end up located in each case within a surface region of the block (1) which is assigned to a respective coil, wherein the surface regions of the block (1) which are assigned to the individual coils do not overlap.
4. The method according to any of the preceding claims, wherein the block (1) is pre-pressed and the pre-pressed block is positioned on the plate (15).
5. The method according to claim 4, wherein the pre-pressing operation takes place in accordance with a time/pressure profile.
6. The method according to any of the preceding claims, wherein the combination made up of block (1) and plate (15) is pressed isostatically.
7. The method according to any of the preceding claims, having the following method steps:

   - following the, in particular isostatic, pressing operation, the ends (6, 7) of the coil windings are exposed;

   - the exposed ends (6, 7) of the coil windings are provided with connection contacts;

   - the block (1) is then divided up to form the individual induction components (24).
8. The method according to at least one of the preceding claims, wherein the operation of exposing the winding ends (6, 7) takes place in a mechanical procedure.
9. The method according to at least one of the preceding claims, wherein the winding ends (6, 7) are bent such that they run transversely to the axis of the coil.
10. The method according to at least one of the preceding claims, wherein the winding ends (6, 7) project beyond the outer contour of the coil body.
11. The method according to at least one of the preceding claims, wherein a coil (8) is provided with a core prior to being embedded in the block (1).
12. The method according to at least one of the preceding claims, wherein use is made of a plate (15) with a low level of surface roughness, in particular R = 0.1 µm or less.
13. The method according to claim 6, wherein, prior to the isostatic pressing operation, a layer made of elastic material is positioned on the side (2) of the block (1), said side being located opposite the plate (15).
14. The method according to claim 6, wherein the isostatic pressing operation is carried out in a liquid-filled pressure vessel (14).
15. An induction component (24) with a coil (8), produced by a method according to at least one of the preceding claims, wherein the induction component (24) has an impression of a marking (17) on its upper side, wherein the upper side is located opposite an underside of the induction component (24) with winding ends exposed, wherein the impression is a hole (21) indicating the orientation of the start of the winding.