201236035 六、發明說明： [0001] [0002] Ο 〇 [0003] 【發明所屬之技術領域】 本發明係有關於一種電感器製造方法，尤其是指一 種於電感器之製作上能更為簡易、便利，更不會對包覆 在線圈外的塑料造成損壞，而在其整體製作施行過程中 更增實用功效特性之電感器製造方法創新設計者。 [先前技術] 按，於許多電路板、電子產品上，常可見到設置有 各種電感器、變壓器；其中，如9 4年9月1 6曰公開 編號20053109 6號之「新穎線圈及其製造方法 」，其即為常見之一種線圈的製造方法，該線圈係以金 屬扁平線和或圓形線材經繞線機形;成連續導電性螺旋線 圈本體’且使圓形線材構成之線圈本體兩端部形成扁平 後’置入於内部填充磁性粉末，以將線圈完全包覆使之 不具氣隙之模具中，予以壓製成形，而線圈兩端延伸出 模具的扁平部份乃成為電極部，又將該電極部沿著線圈 包覆表面彎折，即構成電極部與線圈為一體成型，體積 更小’製造更為簡單，成本更低之斯穎線圈》 及公告第1 256063號「一種抗流線圈之製造 方法j，包括：螺旋線圈成型步驟：將金屬線材繞線形 成螺旋線圈；模塑成型步驟：將繞線完成之螺旋線圈置 入模具中，使螺旋線圈的兩末端延伸出模具之外，然後 予以模塑成型；製備電極部步驟：以模塑成型後露在包 覆體外部的螺旋線圈末端做為電極部；其特徵在於：所 述之螺旋線圈成型步驟，在對金屬線材進行螺旋繞線前 100106247 表單編號A0101 第3頁/共14頁 1002010637-0 201236035 ’係先將金屬線材至少分成上 '下截，然後將上截金屬 線材與下截金屬線材分別依分段處往不同方向作螺旋環 繞’使繞線完成的螺旋線圈雜㈣兩末料直接位於 螺方疋線圈的外侧，而可直接連線使用者。 [0004] [0005] 然而，上述「新穎線圈及其製造方法」及「一種抗 流線圈之製造方法」雖可達到令電感器於製造上更為簡 單、成本更低、體積更小之預期功效，但於其整體實際 施行製造過程巾卻發現，該方法如第_〜三圖所示於 線圈（5)捲繞後，以磁性粉末（6 i)形成之包覆體 (6)包覆成形後，需將鍊圈（5)兩端延伸出模具（ 7)之電極部（5 1 )沿著線圈（5)包覆體（6)表 面弯-折’使其貼覆在包覆體（6 )表面上，而此令電極 邛（5 1 )彎折壓貼於包覆體（6)表面之過程卻極易 因操作不慎、施力過當，對該包覆體（6)表面造成損 傷，甚至疋將該包覆趙（6)壓裂破損，尤其是在電子 製品日漸微小型化後，内部電子元件亦相對微小化，致 包覆體（6)包覆厚度變薄，此種將包覆體（6)壓裂 破損的情形日趨嚴重，導致廠商極大的損失，而在其製 造過程中仍存有尚待改進之處者。 緣是，發明人即是鑒於上述現有結構在實際實施上 所具之缺點，乃於先前申請公開第2〇〇832462 號一種線圈製造方法，其步驟：（3)捲繞成形—將金 屬線材利用繞線機予以捲繞形成螺旋狀線圈；（b)塑 料混合一將金屬粉末添加樹脂及硬化劑進行攪拌，使塑 料形成具磁性之可塑性的軟質塑料；（c)模塑成形一 100106247 表單編號A0101 第4頁/共14頁 1002010637-0 201236035 [0006]201236035 VI. Description of the invention: [0001] [0002] [0002] [Technical Field] The present invention relates to a method of manufacturing an inductor, and more particularly to an inductor that can be fabricated more easily. Convenient, and will not cause damage to the plastic coated on the outside of the coil, and an innovative designer of the inductor manufacturing method that has more practical and effective characteristics in its overall manufacturing process. [Prior Art] According to many circuit boards and electronic products, various inductors and transformers are often found. Among them, the novel coil and its manufacturing method are disclosed in the publication No. 20053109 No. 2005. It is a common method for manufacturing a coil which is formed by winding a metal flat wire and a round wire; forming a continuous conductive spiral coil body and forming a circular wire to form both ends of the coil body After the flat portion is formed into a flat shape, the magnetic powder is placed in the mold to completely coat the coil so as to have no air gap, and the flat portion of the coil extending beyond the mold becomes the electrode portion, and The electrode portion is bent along the coil covering surface, that is, the electrode portion and the coil are integrally formed, and the volume is smaller, the manufacturing is simpler and the cost is lower, and the coil is not less than the first one. The manufacturing method j includes: a spiral coil forming step: winding a metal wire into a spiral coil; and a molding step: inserting the wound spiral coil into the mold to make the spiral The two ends of the ring extend out of the mold and then are molded; the electrode portion is prepared: the end of the spiral coil exposed on the outside of the covering body after molding is used as an electrode portion; and the spiral coil is described Molding step, before spiral winding of metal wire 100106247 Form No. A0101 Page 3 / Total 14 Page 1002010637-0 201236035 'Before dividing the metal wire into at least 'lower cut', then the upper cut metal wire and the lower cut metal The wires are spirally wound in different directions according to the segments. The spiral coils (four) and the two ends of the windings are directly located outside the spiral coils, and can be directly connected to the user. [0004] [0005] However, The above-mentioned "new coil and its manufacturing method" and "manufacturing method of a current-resistant coil" can achieve the expected effect of making the inductor simpler, lower in cost and smaller in size, but it is actually manufactured in its entirety. The process towel found that the method is as shown in the figure _~3, after the coil (5) is wound, and the coated body (6) formed of the magnetic powder (6 i) is overmolded, and the chain ring (5) is required. ) The electrode portion (5 1 ) extending from the end of the mold (7) is bent-folded along the surface of the coil (5) covering body (6) so as to be attached to the surface of the covering body (6), and the electrode 邛(5 1 ) The process of bending and pressing on the surface of the covering body (6) is extremely easy to cause damage to the surface of the covering body (6) due to inadvertent operation and excessive force, and even the coating is applied to Zhao ( 6) Fracture damage, especially after the electronic products are increasingly miniaturized, the internal electronic components are also relatively miniaturized, so that the thickness of the coating body (6) is thinned, and the coating body (6) is fractured and broken. The situation has become increasingly serious, leading to great losses for manufacturers, and there are still areas for improvement in the manufacturing process. The inventor is in view of the shortcomings of the prior art in the actual implementation, and is a method for manufacturing a coil according to the prior application, the steps of which: (3) winding forming - utilizing metal wires The winding machine is wound to form a spiral coil; (b) the plastic is mixed, the metal powder is added with a resin and a hardener to stir, and the plastic is formed into a soft plastic plastic; (c) Molding a 100106247 Form No. A0101 Page 4 of 14 1002010637-0 201236035 [0006]
[0007] 〇 t〇〇〇8] [0009] 100106247 將線圈置入一模具内，再添入軟質塑料；（d)加熱定 型一將填入模具之具磁性之可塑性的軟質塑料進行溫度 的加熱作用，使其固化成形；（e )製備電極部：以模 塑、加熱成形後外露在塑料外部的螺旋線圈末端折彎作 為電極部，即為成品者。 而本發明人藉由上述製程方法實質改善前述習知技 術的缺失，而在本發明人多年實務經驗與不斷實驗測試 之下，獲得更精確與確實的實驗數據及製程步驟，而針 對改善本發明人先前案件不明確之處，特再提供一種電 感器製造方法的設計，以增加使用上的優點，讓整體製 作施行過程中更增實用功效特性者。 【發明内容】 本發明之主要目的為提供一種電感器製造方法，尤 其是指一種讓電感器之製作上能更為簡易、便利，且不 會對包覆在線圈外的塑料造成損壞，而在其整體製作施 行過程中更增實用功效特性之線圈製造為發明目的者。 本發明電感器製造方法的目的與功效係由以下之技 術所實現： 其主要係於將金屬線材經繞線機捲繞形成螺旋狀線 圈後，再予以將具有兩相對應延伸段之螺旋線圈置於模 具内，藉以由金屬粉末、樹脂及硬化劑所混合而成之塑 料包覆，再經模具加熱成型，爾後，再將該線圈兩端延 伸段折彎成型為電極部者；藉由，以塑料受熱包覆所具 之強度，能避免於將電極部折彎成型之過程中，產生塑 料壓裂損傷之情況，而在其整體實際操作製造過程中更 表單編號A0101 第5頁/共14頁 1002010637-0 201236035 [0010] [0011] [0012] [0013] [0014] [0015] [0016] 100106247 具便利性、更增實用功效特性者。 本發明感H製造方法之㈣成份巾的金屬粉 末採用鐵粉，而其樹脂為環氧樹脂或聚乙烯（pE)者 ’且塑料混合之比例為金屬粉末8卜9 Q%、樹脂為 9〜1 8%，而硬化劑為1〜2%者。 本％明-種電感$製造方法的加熱定形過程中係 將模具加熱到6 0〜2 OOt的範圍内’使其塑料固化 成形者。 【實施方式】 為令本發明所運用之技術内容、發明目的及其達成 之功效有更完整且清楚的揭露，兹於下詳細說明之並 請一併參閱所揭之圖式及圖號： 首先’請參閲第四圖所示，係本發明之流程示意圖 ’及-併參閱第五〜六圖之電感器外觀示意圖，其電感器 製造方法（一）步驟如下： :” (a )捲繞成形-將金屬線材〔如：扁平形線材或圓形 線材……等〕利用繞線機予以捲繞形成螺旋狀線圈（1 )，且線圈（1 )兩端具有起始的延伸段； (b) 塑料混合一將80〜9〇%金屬粉末〔 如：鐵粉〕添加9〜1 8 %樹脂（3 2)〔如：環氧樹 脂或聚乙烯〕及1〜2%硬化劑（3 3 )進行㈣，使 塑料（3)形成具磁性及可塑性的顆粒軟質塑料（3 〔一併參閱第六圖所示〕； (c) 模塑定型-將線圈（1)置入—模具（ 表早編號A0101 第6頁/共14頁 1002010637-0 201236035 [0017] [0018] Ο[0007] 0007t〇〇〇8] [0009] 100106247 The coil is placed in a mold and then added to the soft plastic; (d) heating and shaping a magnetic plastic soft plastic filled into the mold for temperature heating The action is to form the electrode; (e) preparing the electrode portion: the end of the spiral coil exposed to the outside of the plastic after molding and heat forming is bent as the electrode portion, that is, the finished product. The inventors have substantially improved the lack of the prior art by the above-described process method, and obtained more accurate and accurate experimental data and process steps under the inventor's many years of practical experience and continuous experimental testing, and aimed at improving the present invention. In the case of unclear previous cases, the design of an inductor manufacturing method is further provided to increase the advantages of use and to make the utility model more practical and effective in the execution process. SUMMARY OF THE INVENTION The main object of the present invention is to provide a method for manufacturing an inductor, in particular to make the inductor more convenient and convenient to manufacture, and does not cause damage to the plastic coated outside the coil. The coil which is more practical and effective in the overall production process is manufactured for the purpose of the invention. The purpose and function of the inductor manufacturing method of the present invention are achieved by the following techniques: Mainly after winding a metal wire through a winding machine to form a spiral coil, and then placing a spiral coil having two corresponding extensions In the mold, by a plastic powder mixed with metal powder, a resin and a hardener, and then heated by a mold, and then the end extension of the coil is bent into an electrode portion; The strength of the plastic coated by heat can avoid the occurrence of plastic fracturing damage during the process of bending the electrode part, and in the whole actual manufacturing process, the form number A0101 is 5/14 [0010] [0016] [0016] [0016] [0016] 100106247 Convenience, more utility features. The metal powder of the (4) component towel of the invention is manufactured by using iron powder, and the resin thereof is epoxy resin or polyethylene (pE), and the ratio of plastic mixing is metal powder 8 9 9%, resin is 9~ 1 8%, and the hardener is 1 to 2%. In the heating and setting process of the manufacturing method of the present invention, the mold is heated to a range of 60 to 2,000 tons to cure the plastic. [Embodiment] For a more complete and clear disclosure of the technical content, the purpose of the invention, and the effects thereof achieved by the present invention, the following detailed description is provided, and the drawings and drawings are disclosed. 'Please refer to the fourth diagram, which is a schematic diagram of the process of the present invention' and - and referring to the appearance of the inductors of the fifth to sixth embodiments, the steps of the inductor manufacturing method (1) are as follows: "(a) Winding Forming - winding a metal wire (such as a flat wire or a round wire, etc.) into a spiral coil (1) by a winding machine, and having a starting extension at both ends of the coil (1); Plastic mixing: Add 80~9〇% metal powder (such as iron powder) to 9~18% resin (3 2) [such as epoxy resin or polyethylene] and 1~2% hardener (3 3 ) Carry out (4) to make the plastic (3) form a soft plastic with magnetic and plasticity (3 [see also Figure 6]; (c) Molding and setting - placing the coil (1) into the mold (table early) A0101 Page 6 of 14 1002010637-0 201236035 [0017] [0018] Ο
Q 而模具内保持溫度6 〇〜2 ο crc之間，添入軟質塑料 (3)，以模壓配合溫度的作用，使其加速固化成形； (d)製備電極部：以模塑定型後外露在塑料（3 )外 部之螺旋線圈起始端的延伸段經折彎成形為電極部（工 1)，即達電感器成品（12)者〔一併參閱第七圖所 示〕。 δ月再一併參閱第四圖至第七圖所示，於製作時，首 先，將扁平形線材或圓形線材……等金屬線材，利用繞 線機予以捲繞形成螺旋狀線圈（丄），而線圈（i )之 兩端具有起始的延伸段，爾後，把線圈（1)置入一預 定的模具（2 )内，於該模具（2)内填入塑料（3 ) ，而該塑料（3)係以金屬粉末（3 1)添加樹脂（3 2)及硬化劑（3 3)進行攪拌，而其|屬粉末（3工 )主要以鐵粉為主，亦可添加其他金屬材質的粉末物質 ，而比例採8 0〜9 0%，接著，樹脂（32)以環氧 樹脂或聚乙烯為之，其比例佔9^ 8%，而硬化劑（ 3 3)的比例則為3[〜2%，將上述材料混合授拌，使 其形成具磁性及可塑性的軟質塑料（3)物質，而模具 (2 )加熱保持溫度約6 〇〜2 〇 〇 °c之間，其模具（ 2)加熱主要為在模具（2)内設有加熱的設備，一般 為加熱管或加熱器等，而軟質塑料（3)藉由模壓與溫 度的作用，同時擠壓與固化成形，如此，該塑料（3 ) 達到較尚強度的效果；接續，當完成模塑定型後，該線 圈（1)包覆於該塑料（3)内，再將該螺旋狀線圈（ 1)兩端予以折彎成電極部（11)，即為電感器成品 100106247 表單編號A0101 第7頁/共14頁 1002010637-0 201236035 (1 2 )者。 [0019] 藉由以上所述，本發明之製作方法與現有方法相較 之下可知，由於本發明係先將線圈（1 )彎折定位後， 再以具磁性及可塑性的軟質塑料（3 )包覆加熱固化成 型，讓塑料（3 )受熱包覆之強度，能避免於電極部（ 1 1 )折彎成型之過程中將該塑料（3 )壓裂損傷，而 在其整體實際操作製造過程中更具便利性、更增實用功 效特性者。 [0020] 前述之實施例或圖示並非限定本發明之結構樣態或 尺寸，任何所屬技術領域中具有通常知識者之適當變化 或修飾，皆應視為不脫離本發明之專利範疇。 [0021] 藉由上述可知，本發明之組成與使用實施說明相較 於一般現有類似技術，我們可以知道線圈製造方法，具 有下列幾項優點，如下： [0022] 1、本發明之電感器製造方法，利用金屬粉末添加樹脂 及硬化劑進行攪拌，使塑料形成具磁性及可塑性的軟質 塑料，再加熱固化，如此，可降低製作的成本，達到符 合經濟效益的製程者。 [0023] 2、本發明之電感器製造方法，利用將塑料混合物加熱 固化後，係可加強其於塑料的強度，讓線圈折彎電極部 時塑料表面不會造成損傷，甚至破損的缺失產生，為一 現有缺點之優良發明者。 [0024] 綜上所述，本發明實施例確能達到所預期之使用功 效，又其所揭露之具體構造，不僅未曾見諸於同類產品 100106247 表單編號A0101 第8頁/共14頁 1002010637-0 201236035 中，亦未曾公開於申請前，誠已完全符合專利法之規定 與要求，爰依法提出發明專利之申請，懇請惠予審查， 並賜准專利，則實感德便。 【圖式簡單說明】 [0025] 第一圖：現有結構之線圈外觀示意圖 [0026] 第二圖：現有結構之加工過程示意圖一 [0027] 第三圖：現有結構之加工過程示意圖一 [0028] 第四圖：本發明之流程示意圖 [0029] 第五圖：本發明之線圈外觀示意圖 [0030] 第六圖：本發明之加工過程示意圖 [0031] 第七圖：本發明之電感器成品示意圖 【主要元件符號說明】 [0032] <本發明> (1 ) 線圈 （1 1 ) 電極部 [0033] (12) 電感器成品（2 ) 模具 [0034] (3) 塑料 （3 1) 金屬粉末 [〇〇35] (32) 樹脂 （33) 硬化劑 [0036] <現有技術> [0037] (5 ) 線圈 (51) 電極部 [0038] (6 ) 包覆體 (61) 磁性粉末 [0039] (7 ) 模具 表單編號A0101 第9頁/共14頁 100106247 1002010637-0Q, while maintaining a temperature of 6 〇~2 ο crc in the mold, add soft plastic (3), and press the temperature to accelerate the curing; (d) Prepare the electrode part: expose it after molding. The extension of the starting end of the outer spiral coil of the plastic (3) is bent into an electrode portion (work 1), that is, the inductor finished product (12) (see also the seventh figure). In addition, as shown in the fourth to seventh figures, in the production, first, a metal wire such as a flat wire or a round wire is wound by a winding machine to form a spiral coil (丄). And the coil (i) has an initial extension at both ends, and then the coil (1) is placed in a predetermined mold (2), and the mold (2) is filled with plastic (3), and The plastic (3) is stirred by adding the metal powder (3 1) resin (3 2) and the hardener (3 3), and the powder (3 work) is mainly composed of iron powder, and other metal materials may be added. Powder material, and the ratio is 80 to 90%, then the resin (32) is epoxy resin or polyethylene, the proportion of which is 9^8%, and the ratio of hardener (3 3) is 3. [~2%, the above materials are mixed and mixed to form a soft plastic (3) material with magnetic and plasticity, while the mold (2) is heated to maintain a temperature between about 6 〇~2 〇〇°c, the mold ( 2) Heating is mainly provided with heating equipment in the mold (2), generally a heating tube or a heater, etc., while the soft plastic (3) is molded and temperature Simultaneously pressing and solidifying, so that the plastic (3) achieves a stronger strength effect; subsequently, after the molding is completed, the coil (1) is wrapped in the plastic (3), and then the The spiral coil (1) is bent at both ends into an electrode portion (11), which is the finished inductor 100106247 Form No. A0101 Page 7 / 14 pages 1002010637-0 201236035 (1 2 ). [0019] From the above, the manufacturing method of the present invention is compared with the prior art method. Since the present invention firstly bends the coil (1), the flexible plastic with magnetic and plasticity (3) is used. The coating is heated and solidified to allow the plastic (3) to be heat-coated, so as to prevent the plastic (3) from being fractured during the bending process of the electrode portion (1 1 ), and the manufacturing process is actually carried out in the whole process. More convenient and more practical features. [0020] The foregoing embodiments or illustrations are not intended to limit the scope of the invention, and any suitable variations or modifications may be made without departing from the scope of the invention. [0021] From the above, it can be seen that the composition of the present invention and the implementation description are similar to the conventional prior art, and we can know the coil manufacturing method, which has the following advantages, as follows: [0022] 1. Inductor manufacturing of the present invention The method uses a metal powder to add a resin and a hardener to stir, so that the plastic forms a soft plastic having magnetic properties and plasticity, and then heats and solidifies, thereby reducing the manufacturing cost and achieving a cost-effective process. [0023] 2. The inductor manufacturing method of the present invention, by heating and solidifying the plastic mixture, can strengthen the strength of the plastic, so that the plastic surface of the coil is not damaged when the electrode is bent, and even the loss of damage occurs. An excellent inventor of an existing disadvantage. [0024] In summary, the embodiments of the present invention can achieve the expected use efficiency, and the specific structure disclosed therein has not only been seen in the similar products 100106247 Form No. A0101 Page 8 / Total 14 Pages 1002010637-0 In 201236035, it has not been disclosed before the application. Cheng has fully complied with the requirements and requirements of the Patent Law. If you file an application for an invention patent in accordance with the law, you are welcome to review it and grant a patent. BRIEF DESCRIPTION OF THE DRAWINGS [0025] First figure: Schematic diagram of the appearance of the coil of the prior art [0026] Second diagram: Schematic diagram of the processing of the existing structure [0027] Third: Schematic diagram of the processing of the existing structure [0028] Figure 4: Schematic diagram of the flow of the present invention [0029] Figure 5: Schematic diagram of the appearance of the coil of the present invention [0030] Figure 6: Schematic diagram of the processing of the present invention [0031] Figure 7: Schematic diagram of the finished inductor of the present invention [ Description of main component symbols [0032] <The present invention> (1) Coil (1 1 ) Electrode portion [0033] (12) Inductor finished product (2) Mold [0034] (3) Plastic (3 1) Metal powder [〇〇35] (32) Resin (33) Hardener [0036] <Prior Art> [0037] (5) Coil (51) Electrode portion [0038] (6) Wrap (61) Magnetic powder [ 0039] (7) Mold form number A0101 Page 9 of 14 100106247 1002010637-0