Method of manufacturing magentic body

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 S 10 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 S 20 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 S 30 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.

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.