CN1875441B - Coil device - Google Patents

Coil device Download PDF

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Publication number
CN1875441B
CN1875441B CN2004800323568A CN200480032356A CN1875441B CN 1875441 B CN1875441 B CN 1875441B CN 2004800323568 A CN2004800323568 A CN 2004800323568A CN 200480032356 A CN200480032356 A CN 200480032356A CN 1875441 B CN1875441 B CN 1875441B
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China
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mentioned
coil
magnetic core
coil device
coiling
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CN2004800323568A
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CN1875441A (en
Inventor
山下充弘
长坂孝
三浦英树
松川泰弘
佐藤和男
佐藤玲
佐藤广宣
伊东孝之
北岛保彦
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TDK Corp
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TDK Corp
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Priority claimed from JP2004244279A external-priority patent/JP2006066469A/en
Priority claimed from JP2004244278A external-priority patent/JP4757466B2/en
Priority claimed from JP2004244280A external-priority patent/JP2006066470A/en
Priority claimed from JP2004245723A external-priority patent/JP4131515B2/en
Application filed by TDK Corp filed Critical TDK Corp
Priority claimed from PCT/JP2004/016425 external-priority patent/WO2005045858A1/en
Publication of CN1875441A publication Critical patent/CN1875441A/en
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Abstract

A coil device in a part-winding form and a method for manufacturing a coil device are disclosed. The size of the core is small, and the windings do not collapse even though the form is simple. The coil device (501) comprises a ferrite core (503) and a coil (505) provided around the core. The coil (505) has at least a first coil portion (551) and a second coil portion (553). The boundary end surface (CF1), on the second coil side, of the first coil is so inclined that the inner circumferential side is nearer the second coil portion than the outer circumferential side. The boundary end surface (CF2), on the first coil side, of the second coil portion is so inclined that the outer circumferential side is nearer the first coil portion than the inner circumferential side.

Description

Coil device
Technical field
The present invention relates to a kind of FERRITE CORE and use the coil device of this FERRITE CORE.
Coil device involved in the present invention comprises: be applicable to the antenna of vehicle-mounted transponder etc., perhaps be used for the inductor of communication equipment or choke etc.
Background technology
The coil device of various kinds had been proposed in the past, and practicability.As one of them, recently, the applicable coil device of making car antenna or transponder has been proposed.Be applicable to the coil device of this purposes, not only require miniaturization, and require in the service band that client wishes, to keep inductance stabilization.Therefore, also designed a kind of will the coil portion that radial layer lap wound line forms cut apart about the axis direction of magnetic core and form cut apart the coiling form.
That is, between adjacent windings portion, be provided with and the integrally formed flange of magnetic core 1 described cutting apart in the coiling form of above-mentioned patent documentation, still,, then can further realize the reduction of miniaturization and magnetic core manufacturing cost if can save this flange, more suitable.
But, at this, to adopt wanting flange is not set and to cut apart the coiling form, and form successively under the situation of a plurality of coil portions, the coiling of the coil portion that forms earlier may be lost shape in forming next coil portion process.
In addition, be applicable in the coil device of car antenna or transponder (transponder) and so on purposes, use the good FERRITE CORE of high frequency characteristics usually.In addition, can obtain following structure, that is, and the coil of the necessary number of turns of on this FERRITE CORE, reeling, and coil end is connected on the metal terminal that two ends had of length direction of FERRITE CORE, and covers its integral body by heat-curing resins such as epoxy resin.
As FERRITE CORE, use the desired inductance value of this coil device, Q value and the self-resonant frequency characteristic etc. should the value of meeting the demands usually, and from the long elongated magnetic core of the wireline reel direction of coil.
But FERRITE CORE is the fragility sintered body, original just not shock-resistant and vibration.And, for the above reasons, have to make elongated shape not shock-resistant and vibration.Therefore, under the situation of the vehicle-mounted coil device that is often impacted and vibrate, how to realize that the structure of resistance to impact and vibration resistance is particularly important.
And, be not limited to the situation of vehicle-mounted coil device, in coil device, seek the simplification of miniaturization, structure and cost degradation etc. usually with inductor that acts on communication equipment or choke, therefore, how satisfying these requirements also is important problem.
If inquire into known technology according to this viewpoint, then, for example, patent documentation 2 discloses following structure, that is, on the terminal installation portion that is had at the length direction both ends of FERRITE CORE, the synthetic resin matrix that forms by injection moulding is installed, and the metal electrode terminal being installed in the periphery of synthetic resin matrix, this metal electrode terminal is to install by the spring action of itself.But these prior aries are difficult to meet requirements such as the simplification of miniaturization, structure and cost degradation.
As the solution of the problems referred to above, disclose a kind ofly in the patent documentation 1, concentrated studying intensively improved the coil device of frequency characteristic, resistance to impact and vibration resistance at aspects such as the shape of FERRITE CORE and terminal structures.
According to the prior art, even in the purposes of environment for use strictnesses such as vehicle-mounted coil device (complicated, arduous), also can expect the result that it is quite feasible.
In addition, in the coil device of the purposes that is applicable to car antenna or transponder and so on, use the coil device of surface installing type, require miniaturization, slimming and resistance to impact, vibration resistance and thermal endurance etc., but, at present in the coil device of surface installing type, the structure that coats the insulation crust body of magnetic core and coil is, the section shape of itself and coil spool direction quadrature is a quadrangle.In addition, even being contained in inner magnetic core, according to the viewpoint on the characteristic of coil, also majority constitutes quadrangle with the coordinated insulation shell body with its section shape.
But the section shape of magnetic core is in the tetragonal coil, can find crackle on the insulation crust body by detecting operation.This is because the coiling of thermal conductance induced coil when the insulation crust phantom is molded is expanded, and especially covers the stress that takes place to be caused by expansion on the part of insulation crust body in tetragonal bight of magnetic core and concentrates, and thinks can crack on the outer axial face of insulation crust body.
To this, consider that section shape with magnetic core makes to be not easy to take place the circle that stress is concentrated.But, adopt and the situation of the circular section of original four angle sections shape inscribes under, can not obtain the sectional area of magnetic core, neither be preferred aspect characteristic.On the other hand, if be chosen to be such as the circle of the above inscribe the section shape of magnetic core big, then, can not guarantee the suitable thickness in the insulation crust body, perhaps preferably guarantee thickness and make that coil device is whole to maximize because the section shape of insulation crust body is a quadrangle.
In addition, be not limited to the situation of vehicle-mounted coil device, in the coil device with inductor that acts on communication equipment or choke, electrical characteristics also depend on the magnetic core size greatly.Usually, the magnetic core size is big more, and the electrical characteristics that obtain are good more.
But, the overall dimension of coil device limits according to its purposes, therefore, in confined overall dimension, when the magnetic core size is big, the thickness of the insulation nappe that is made of heat-curing resins such as epoxy resin is less relatively, and magnetic core and coil integral body or a part are exposed to the outside, can not guarantee the resistance to impact, vibration resistance, durability of the purpose that covers as insulation etc.In contrast, increase the thickness of insulation nappe, when guaranteeing resistance to impact, vibration resistance, durability etc., specifically, the magnetic core size decreases has been sacrificed electrical characteristics.That is, in this coil device, how harmless resistance to impact, vibration resistance and the durability of being brought by the insulation covering increases the magnetic core size, guarantees that high electrical characteristics become major issue.
And, consider the insulation nappe to the influence of magnetic core, must employing can not make the structure of the deterioration in characteristics of magnetic core.
According to this viewpoint known technology is inquired into, for example, above-mentioned patent documentation 2 discloses following structure, promptly, on the flange part that has on the both ends of the length direction of magnetic core, the synthetic resin matrix that forms by injection moulding is installed, and in the periphery of synthetic resin matrix the metal electrode terminal is installed, this metal electrode terminal is to install by the spring action of himself.But the prior art does not disclose result of the above problems.
Secondly, patent documentation 3 discloses by sheathing materials such as resins and has carried out the whole structure that covers, and still, does not mention the resin material that constitutes sheathing material,, does not have openly result of the above problems that is.
And, known technology is inquired into, for example, above-mentioned patent documentation 3 discloses the coil device that carries out whole covering by resin moulded.
In addition, above-mentioned patent documentation 1 discloses a kind of coil device, and its integral body is covered by insulating resin, and, by concentrated studying intensively, improved resistance to impact and vibration resistance at aspects such as the shape of FERRITE CORE and terminal structures.
In the prior art, especially,,, also can expect the result that it is quite feasible even in the purposes of environment for use strictnesses such as vehicle-mounted coil device according to patent documentation 1.
Patent documentation 1: TOHKEMY 2003-318030 communique
Patent documentation 2: TOHKEMY 2001-339224 communique
Patent documentation 3: Japanese kokai publication hei 7-130556 communique
Summary of the invention
The invention provides a kind of miniaturization that can realize magnetic core, form is simplified and prevent to wind the line the coil device of cutting apart the coiling form that loses shape and the manufacture method of coil device.
The invention provides a kind of except above-mentioned prior art is further improved, especially increased the mechanical strength of portion of terminal, even and in the purposes of environment for use strictnesses such as vehicle-mounted coil device, also can guarantee the coil device of sufficient resistance to impact and vibration resistance.
The present invention finishes in view of the above problems, and its purpose is to provide a kind of coil device that can satisfy the requirement of miniaturization, slimming and prevent to crack on the insulation crust body.
The present invention further provides a kind ofly without detriment to the resistance to impact that cover to realize by insulation, vibration resistance, durability and the magnetic core size that increases, improve the coil device of electrical characteristics.
The present invention further provides a kind of coil device that reduces the variable quantity of the inductance value that causes by temperature change.
In addition, the invention provides a kind of coil device, except above-mentioned prior art is further improved, especially improve thermal diffusivity, improve the stability of the heat of characteristic, even in the purposes of environment for use strictnesses such as vehicle-mounted coil device, also can guarantee sufficient thermal stability, resistance to impact and vibration resistance.
(the 1st mode of the present invention)
Coil device among the present invention, it is drawn together magnetic core and is arranged on this magnetic core coil on every side, wherein, above-mentioned coil has the 1st coil portion and the 2nd coil portion at least, the border end face of above-mentioned the 2nd coil portion side of above-mentioned the 1st coil portion, more tilt than outer circumferential side with all sides in it near the mode of the 2nd coil portion, coil device of the present invention, also comprise the insulation crust body that covers above-mentioned magnetic core and coil, above-mentioned magnetic core has the volume core of the coiling of the above-mentioned coil that is used to reel, and the pair of flanges portion that forms at the two ends of this volume core, the section with coil wireline reel direction quadrature of above-mentioned volume core has following shape: the section that bulge is arranged at tetragonal relative a pair of mask.
In addition, the border end face of above-mentioned the 1st coil portion side of above-mentioned the 2nd coil portion preferably more tilts near the mode of the 1st coil portion than interior all sides with its outer circumferential side.
And, the invention provides a kind of manufacture method of coil device.Promptly, the manufacture method of coil device of the present invention, be used for around magnetic core, forming the coil that has the 1st coil portion and the 2nd coil portion at least, when forming above-mentioned the 1st coil portion, the border end face of above-mentioned the 2nd coil sides is formed with all sides in it more to tilt near the mode of the 2nd coil portion than outer circumferential side, after forming above-mentioned the 1st coil portion, form above-mentioned the 2nd coil portion.
In addition, preferably, the border end face of above-mentioned the 1st coil portion side of above-mentioned the 2nd coil portion is formed on the border end face that is positioned in the 2nd coil portion.
By coil device of the present invention and manufacture method thereof,, flange is not set on magnetic core can prevents that coiling from losing shape yet when cutting apart the coiling form and form coil.Thereby, owing to omitted flange, can realize the miniaturization of magnetic core and the reduction that form is simplified the manufacturing cost of bringing.
In addition, the border end face of the 1st coil portion side in the 2nd coiler part forms under the situation about more tilting near the mode of the 1st coil portion than interior all sides with its outer circumferential side, can effectively guarantee the wrapping range that winds the line.The border end face of the 1st coil portion side in the 2nd coil portion forms under the situation on the border end face that is positioned in the 2nd coil portion, and is like this too.
(the 2nd mode of the present invention)
Coil device of the present invention except the technical characterictic of above-mentioned the 1st mode, can also have following technical characterictic.
That is, coil device of the present invention also has terminal.Above-mentioned magnetic core has the terminal installation portion at relative two ends, and has the winding section at pars intermedia.Above-mentioned coil is made of the coiling that is wound in the above-mentioned coiling portion, and above-mentioned terminal is the part that connects the end of above-mentioned coiling, is made of a slice metallic plate, comprises installation portion, pars intermedia and bottom.
Above-mentioned installation portion, one end are fixed on the above-mentioned terminal installation portion of above-mentioned magnetic core.Above-mentioned pars intermedia, the one end is connected with the other end of above-mentioned installation portion by kink.Above-mentioned bottom, the one end is connected with the other end of above-mentioned pars intermedia by kink, and relative with above-mentioned installation portion, and its other end is a free end.
And above-mentioned pars intermedia is porose in face, above-mentioned hole be arcuation at two relative inward flanges of direction at least.
As mentioned above, the terminal that connects the end of coiling is made of a slice metallic plate, and comprises installation portion, pars intermedia and bottom.Installation portion, one end are fixed on the terminal installation portion of magnetic core.Pars intermedia, the one end is connected with the other end of above-mentioned installation portion by kink.The bottom, the one end is connected with the other end of pars intermedia by kink, and relative with installation portion.
By this structure, can guarantee elasticity based on two kinks, absorb and impact and vibration, therefore, can realize the coil device that resistance to impact and vibration resistance are good.
Pars intermedia is the part of facing mutually with the end face of magnetic core, and the plate face is in and by flowing through the magnetic flux quadrature that electric current produced of coiling or the relation of intersection.Therefore, become the obstruction part of the smooth circulation that hinders magnetic flux, can make frequency-inductance characteristic and frequency-Q characteristic variation.Therefore, among the present invention, in the face of pars intermedia, the hole is set.
Because the existence in above-mentioned hole, become the sectional area structure littler of pars intermedia than the sectional area of installation portion and bottom, therefore, the obstruction of the smooth circulation of magnetic flux is diminished, can blanketing frequency-inductance characteristic and frequency-Q characteristic variation.
As mentioned above, because the hole is set on pars intermedia, the mechanical strength of pars intermedia reduces, and therefore, the degree of its reduction must be inhibited.Otherwise, can not guarantee desired resistance to impact and vibration resistance in the purposes of environment for use strictnesses such as vehicle-mounted coil device.
As its method, among the present invention, the shape in hole is that at least in one direction, two relative inward flanges are curved.According to the shape in above-mentioned hole, for example different with four jiaos of holes with acutangulate interior angle, can guarantee sufficient mechanical, fully satisfy desired resistance to impact and vibration resistance in the purposes of environment for use strictnesses such as vehicle-mounted coil device.
Hole in that pars intermedia is provided with as long as satisfy above-mentioned condition, can obtain various forms.Its example is as described below.
(a) hole is set to be partial to the direction of installation portion.According to this structure is set, downside and sidepiece in the hole can increase leg (fillet) and form with the interval.
(b) representative in hole is shaped as circle, but also can be non-circular.
(c), can enumerate and have minor axis and major diameter, the direction of minor axis and the consistent example of direction from installation portion towards the bottom as non-circular hole.
(d), can enumerate and have minor axis and major diameter, the direction of major diameter and the consistent type of direction from installation portion towards the bottom as another example in non-circular hole.
(e) as an example again in non-circular hole, also can be to have the shape of the arcuation part at its two ends by the straight line portion connection, promptly so-called run-track shaped.
(f), also can be oval as an example again in non-circular hole.
In addition, above-mentioned terminal preferably between from the pars intermedia to the bottom, has towards the extended widening portion of its width of the direction from the pars intermedia to the bottom.The effect of this structure is, can increase leg and form and use the space, and fully satisfy desired resistance to impact and vibration resistance in the purposes of environment for use strictnesses such as vehicle-mounted coil device.
(the 3rd mode of the present invention)
Coil device of the present invention except the technical characterictic of above-mentioned the 1st mode, can also have following technical characterictic.
Preferably, the bulge of above-mentioned volume core is made of curve at the section with coil wireline reel direction quadrature.
In addition, preferably, form at least one coiling at above-mentioned volume core and keep out of the way portion, the above-mentioned coiling portion of keeping out of the way forms, and from the cross section of above-mentioned volume core, is connected with above-mentioned bulge, and the arcuation line that connects than the above-mentioned quadrangle bight with these bulge both sides caves in more to the inside.
Preferably, above-mentioned volume core has the par in the both sides of above-mentioned bulge, and above-mentioned par is formed in the above-mentioned quadrangle another between the face and above-mentioned bulge faced mutually.
Preferably, passed through R processing or tapering processing between the face of this volume core side of the outer peripheral face of above-mentioned volume core and above-mentioned flange part, and/or, R processing passed through between the face of the above-mentioned volume core side of above-mentioned flange part and the outer peripheral face of radial outside.
According to coil device of the present invention, during the coiling of coiling coil, this coiling is compared with the situation that does not possess bulge, from the cross section, is wound into the shape of more approaching circle on the volume core.Thereby, even the heat when the insulation crust phantom is molded makes coil expand, also can relax the stress that produces on the part of insulation crust body of the coiling that covers the bight in the volume core and concentrate, prevent from this part, to crack.And bulge is formed in the cross section shape of volume core on the opposite of facing mutually in the quadrangle, therefore, as mentioned above, can prevent to crack on the insulation crust body, and can satisfy the requirement of coil device miniaturization.
In addition, under the situation that bulge is made of curve in cross section shape, can avoid producing new stress and concentrate by bulge is set.
In addition, forming coiling in the volume core keeps out of the way under the situation of portion, when coil expands, the part of coiling can enter coiling keeps out of the way in the portion, thereby, like this, the ratio of the expansive force of the insulation crust body outside the coiling of expanding imposes on reduces, especially, even the corner periphery of the insulation crust body that can have problems at crackle also can effectively prevent the generation of crackle.
In addition, the both sides of bulge form under the situation of par, when making the volume core by the compression forming of powder, can prevent from acting on bigger compression counter-force on the end of mould.Thereby, can apply adequate compressive forces, and prevent that mould from damaging at short notice.
In addition, the connecting portion of volume core and flange part, and/or, on the connecting portion of outer peripheral face in the flange part and volume core side, carry out going up under the situation of the bigger R processing of spontaneous form than processing, can prevent from the border of volume core and flange part, to crack, perhaps on flange part, produce crack or shortcoming.
(the 4th mode of the present invention)
Coil device of the present invention except the technical characterictic of above-mentioned the 1st mode, can also have following technical characterictic.
That is, coil device of the present invention also comprises the insulation nappe.Above-mentioned magnetic core comprises coil coiling portion, and above-mentioned coil coiling portion extends at length direction.Above-mentioned insulation nappe is made of the thermoplastic insulating resin, is used to cover above-mentioned magnetic core and above-mentioned coil.Above-mentioned magnetic core and above-mentioned coil are positioned in the substantial middle portion of above-mentioned insulation nappe.
As mentioned above, coil device of the present invention comprises the insulation nappe, and the insulation nappe covers above-mentioned magnetic core and above-mentioned coil.According to this structure, cover magnetic core and coil by the insulation nappe, can realize the coil device that reliability is good.
Among the present invention, one of emphasis is that magnetic core and coil location are in the substantial middle portion of insulation nappe.By this structure, magnetic core and coil are sealed in the inside of insulation nappe, and prevent that the whole of magnetic core and coil or part from exposing, and can realize the coil device of the high reliability that resistance to impact and vibration resistance are good.And the thickness of insulation nappe can be set at necessary minimum value, therefore, with respect to the overall dimension of the coil device that is determined, sets the magnetic core of inside and the overall dimension of coil relatively large, can obtain good electrical characteristics.
Among the present invention, another emphasis is that the insulation nappe is made of the thermoplastic insulating resin.When the insulation nappe is made of the thermoplastic insulating resin, compare with situation about being made of the Thermocurable insulating resin, the variable quantity of the inductance value that temperature change causes diminishes.By inference, this is because the insulation nappe is when being made of the thermoplastic insulating resin, compare with situation about constituting by heat-curing resin, thermal expansion, the contraction of insulation nappe are littler for the influence of magnetic core, and the thermal stress of magnetic core reduces, and can bring into play the intrinsic magnetic characteristic of magnetic core.The insulation nappe preferably is made of liquid crystal polymer.
(the 5th mode of the present invention)
Coil device of the present invention except the technical characterictic of above-mentioned the 1st mode, can also have following technical characterictic.
That is, coil device of the present invention also comprises insulating resin shell body and terminal.Above-mentioned magnetic core is the clava that extends in a direction, has the winding section at pars intermedia.Above-mentioned coil is made of the coiling that is wound on the above-mentioned winding section.Above-mentioned insulating resin shell body covers at least a portion of above-mentioned coiling.Above-mentioned terminal is the part that connects the end of above-mentioned coiling, it is made of a slice metallic plate, the one end is fixed on the above-mentioned terminal installation portion of above-mentioned magnetic core, has kink between an above-mentioned end and the other end, and above-mentioned bending part is in the outside of above-mentioned insulating resin shell body.And at least a portion on the surface of above-mentioned insulating resin shell body is roughened.
As mentioned above, the insulating resin shell body covers at least a portion of coiling, therefore, by insulating resin shell body protection coiling, can realize good coil devices such as resistance to impact and vibration resistance.The part that is not limited to wind the line that the insulating resin shell body is covered also can be that they are whole, even part or all of magnetic core.Coverage mode can be according to application target, environment for use and suitably decision.
In addition, the terminal that connects the end of above-mentioned coiling is made of a slice metallic plate, the one end is fixed on the terminal installation portion of magnetic core, has kink between one end and the other end, therefore bending part, has been installed in this coil device under the situation on substrate etc. in the outside of insulating resin shell body, can guarantee the elasticity of kink, can absorb and impact and vibration.Therefore, can realize the coil device that resistance to impact and vibration resistance are good.
As mentioned above, coiling is covered by the insulating resin shell body, therefore, can improve resistance to impact and vibration resistance etc., and still, the insulating resin shell body can hinder the heat radiation of the coiling heat that produces.The resistance value of coiling has temperature dependency, and therefore, if do not promote heat radiation, characteristic will change.About magnetic core, also can see the characteristic variations that causes by temperature.
Therefore, as the means that address this problem, among the present invention, with at least a portion roughening on insulating resin shell body surface.The typical example of roughening is so-called " texture processing (Texturing) ".
As mentioned above, during the surface roughening of insulating resin shell body, according to the character of the surface area of roughening, roughening and state etc., the surface area of insulating resin shell body increases.Therefore, in fact enlarged area of dissipation, promoted heat radiation, therefore, the thermal stability of characteristic improves.It is desirable to the whole surface roughening with the insulating resin shell body, still, the part roughening also can.
Coil device of the present invention can be used for many aspects.As its concrete purposes example, can enumerate the inductor of antenna that antenna, especially car-mounted device use, transponder, electronic equipment or choke etc.
The invention effect
As mentioned above, the present invention can obtain following effect.
(a) can provide a kind of and can realize the miniaturization of magnetic core, the coil device of cutting apart the coiling form that form is simplified and prevented to wind the line and lose shape.
(b) can provide a kind of mechanical strength that increases portion of terminal, even and in the purposes of environment for use strictnesses such as vehicle-mounted coil device, also can guarantee the coil device of sufficient resistance to impact and vibration resistance.
(c) can provide a kind of coil device that satisfies the requirement of miniaturization, slimming and prevent to crack on the insulation crust body.
(d) can provide a kind of without detriment to the resistance to impact that cover to realize by insulation, vibration resistance, durability and the magnetic core size that increases, improve the coil device of electrical characteristics.
(e) can provide a kind of coil device that reduces the variable quantity of the inductance value that causes by temperature change.
(f) can provide a kind of coil device, it can improve thermal diffusivity, improves the stability of the heat of characteristic, even and in the purposes of environment for use strictnesses such as vehicle-mounted coil device, also can guarantee sufficient thermal stability, resistance to impact and vibration resistance.
Description of drawings
Fig. 1 is the longitudinal section of the coil device of expression embodiment of the present invention;
Fig. 2 is the stereogram of the FERRITE CORE in the expression coil device;
Fig. 3 is the end view of the FERRITE CORE in the expression coil device;
Fig. 4 is the figure of the loop construction in the expression coil device;
Fig. 5 is the figure of coiling form of the coiling of expression coil;
Fig. 6 is the figure of the loop construction of expression another embodiment of the present invention;
Fig. 7 is the stereogram of the coil device of expression another embodiment of the present invention;
Fig. 8 is the front section view of expression coil device shown in Figure 7;
Fig. 9 is that the part of presentation graphs 7 and coil device shown in Figure 8 enlarges stereogram;
Figure 10 is the figure of the user mode of presentation graphs 7～coil device shown in Figure 9;
Figure 11 is the stereogram of the another way of the used terminal of expression coil device of the present invention;
Figure 12 is the stereogram of the another way of the used terminal of expression coil device of the present invention;
Figure 13 is the stereogram of the another way of the used terminal of expression coil device of the present invention;
Figure 14 is the stereogram of the another way of the used terminal of expression coil device of the present invention;
Figure 15 is the stereogram of the another way of the used terminal of expression coil device of the present invention;
Figure 16 is the expanded view of expression Figure 14 and terminal shown in Figure 15;
Figure 17 is the cutaway view of the coil device of expression another embodiment of the present invention;
Figure 18 is the longitudinal section of the coil device of expression another embodiment of the present invention;
Figure 19 is the stereogram of the FERRITE CORE in the expression coil device;
Figure 20 is the end view of the FERRITE CORE in the expression coil device;
Figure 21 is the cutaway view of expression along the 21-21 line of Figure 20;
Figure 22 is the cutaway view of the coil device of expression another embodiment of the present invention;
Figure 23 is in the expression coil device shown in Figure 22, the stereogram of the state before the terminal bending;
Figure 24 is the figure of the molding process of the insulation nappe that is made of thermoplastic resin of expression;
Figure 25 is the figure of expression temperature-L rate of change performance data;
Figure 26 is the stereoscopic figure of the coil device of expression another embodiment of the present invention;
Figure 27 represents for the internal structure of coil device shown in the presentation graphs 26 insulating resin shell body abridged stereogram;
Figure 28 is the front section view of expression Figure 26 and coil device shown in Figure 27;
Figure 29 is the figure of the user mode of expression Figure 26～coil device shown in Figure 28;
Figure 30 is the cutaway view of the coil device of expression another embodiment of the present invention.
The drawing reference numeral explanation
501 coil devices, 503 FERRITE CORE, 505 coils
551 the 1st coil portions 553 the 2nd coil portion CF 1, CF 2The border end face
Embodiment
Below, with reference to accompanying drawing the 1st～the 5th mode of the present invention is described.
The 1st mode of the present invention
With reference to the accompanying drawings the 1st mode of the present invention is described below.In addition, among the figure, same-sign is represented identical or counterpart.
Fig. 1 represents the vertical section of the coil device of present embodiment.Coil device 501 mainly has: FERRITE CORE 503, coil 505, insulation crust body 507 and pair of terminal 509,511.In addition, coil device 501 for example be applicable in the automobile need not push-button two-way no key open-door system (keyless entry system), anti-locking system (immobilizer), the pneumatic pressure monitoring system of tire etc. usurped.
Coil 505 is by being that the coiling of reeling on the outer peripheral face of this FERRITE CORE 503 in the center constitutes with FERRITE CORE 503.Insulation crust body 507 is set to cover whole these FERRITE CORE 503 and coil 505.
The sintered body that FERRITE CORE 503 can be by ferrite powder, the machining of ferrite bar or with both in conjunction with obtaining.As shown in Figures 2 and 3, FERRITE CORE 503 reality are bar-like member, and the both ends of its length direction (directions X) have flange part 513,515, and, have volume core 517 between these flange parts 513,515.
Pair of flanges portion 513,515 and volume core 517 have Y direction size than the big rectangular section of Z direction size.And pair of flanges portion 513,515 and volume core 517 traverse the core length direction and form same width dimensions (Y direction size).
About gauge (Z direction size), pair of flanges portion 513,515 forms thicker than volume core 517.Thus, face 513a, the 515a towards core length direction center side in the pair of flanges portion 513,515 exists from the upper and lower surface approximate vertical of volume core 517 respectively with erecting.
On face 513b, the 515b of the opposite side with face 513a, 515a of pair of flanges portion 513,515, form a pair of groove 519,521 of V-shape.A pair of groove 519,521 prolongs along the Y direction, and in the both ends of the surface upper shed of the Y of FERRITE CORE 503 direction.
In above-mentioned a pair of groove 519,521, engaging corresponding pair of terminal 509,511.Get back to Fig. 1, pair of terminal 509,511 is from the ZX vertical section, for being bent into the roughly metallic plate-shaped member of U font.In more detail, can use non magnetic and rubber-like, for example stainless steel-like metallic plate such as phosphor bronze sheet or SUS 304-CSP.
Pair of terminal 509,511 has three planar sections that plate-shaped member is formed in the bending of two places.In three planar sections, part 1 523,525 and the 3rd part 531,533 are extended along the XY face, and part 2 527,529 is extended along the YZ face.Part 1 523,525 runs through insulation crust body 507.One end of part 1 523,525 inserts in the corresponding a pair of groove 519,521, and fixing by adhesive 535.And, pass through the coiling end 537 that solder joints coil 505 on the part 1 523,525.The other end of part 1 523,525 is connecting the 1st bend 539.
Part 2 527,529 is extended between the 1st bend 539 and the 2nd bend 541.And, on part 2 527,529, run through the sectional area that makes this part 2 527,529 being set than part 1 523,525 and the little through hole 543 of the 3rd part 531,533.The 3rd part 531,533 from the 2nd bend 541 towards core length direction central authorities and and the lower surface almost parallel ground prolongation of insulation crust body 507.
Insulation crust body 507 be cover FERRITE CORE 503 and coil 505, profile is roughly the parts of rectangular shape.By this insulation crust body 507, in protection FERRITE CORE 503 and coil 505, can improve pair of terminal 509,511 adhesion strengths with respect to FERRITE CORE 503, can realize the form that Mechanical Reliability is good.
Then, according to Fig. 4 coil 505 is elaborated.Coil 505 is set on the outer peripheral face of volume core 517 of FERRITE CORE 503 and between an opposite 513a, 515a.And coil 505 has the 1st coil portion 551 and the 2nd coil portion 553 in the present embodiment.The 1st coil portion 551 and the 2nd coil portion 553 are respectively 555 to reel to be layered on the FERRITE CORE 503 in the prescribed limit of core length direction and form by winding the line.
In addition, the polyurethane electric wire is used in coiling 555 in the present embodiment.The polyurethane electric wire is not have the electric wire that the such adhesive of adhesive (cement) cover type electric wire covers.The border end face CF of the 2nd coil portion 553 sides in the 1st coil portion 551 1Be not with the direction of the axis direction of FERRITE CORE 503 and outer peripheral face quadrature on extend, interior all sides of border end face than outer circumferential side more near the 2nd coil portion 553 crustal inclination.In addition, the border end face CF of the 1st coil portion 551 sides in the 2nd coil portion 553 2Also along border end face CF 1Extend, that is, tilt.
In addition, the 1st coil portion 551 and end face TF the 2nd coil portion 553 opposite sides 1Be not yet with the direction of the axis direction of FERRITE CORE 503 or outer peripheral face quadrature on extend, the outer circumferential side in the end face than interior all sides further from flange part 515 crustal inclination.Equally, the 2nd coil portion 553 and end face TF the 1st coil portion 551 opposite sides 2Also with end face TF 1The same, the outer circumferential side in its end face than interior all sides more away from flange part 515 crustal inclination.Like this, in the 1st coil portion 551 and the 2nd coil portion 553, the end face TF of pair of flanges portion 513,515 sides 1And TF 2Tilt, thus, form from the vertical section the roughly remaining space 557,559 of del between the two ends of coil 505 and the pair of flanges portion 513,515.
Then, the manufacture method of the coil device 501 of structure describes to having as above.At first, in the pair of flanges portion 513,515 in the FERRITE CORE 503, be connected and fixed corresponding pair of terminal 509,511 by adhesive 535.Then, be welded on 555 one coiling of coiling terminal 537 on the terminal 509 after, the coiling 555 of reeling on the volume core 517 of FERRITE CORE 503 forms coil 505.
Coiling is by making nozzle with respect to rotated flywheel (flyer) winding method that carries out by the magnetic core of stationary fixing.In addition, the formation of coil 505 is cutting apart the coiling form,, forms after having formed the 1st coil portion 551 that the form of the 2nd coil portion 553 carries out that is.
Form after the coil 505, a coiling terminal 537 of coiling 555 is welded on the terminal 511, after cleaning, drying process etc., in molding process, covers insulation crust body 507 around FERRITE CORE 503 and coil 505.
And,, the order that forms coil 505 on FERRITE CORE 503 is elaborated according to Fig. 5.At first, should form the 1st coil portion 551 of coil 505,, 555 be wound on the FERRITE CORE 503 from winding the line in the face 513a of the flange part 513 in left side and the bight between the volume core 517 from Fig. 5.
At first, shown in arrow among the figure, the winding position of coiling 555 is advanced along the outer peripheral face flange part 515 to the right of volume core 517, as the 1st layer, reel about 100 circles after the coiling 555, turn back, and flange part to the left 513 is reeled with as the 2nd layer.Below identical, winding position flange part 515 is to the right advanced forms the 3rd layer, turn back, and flange part to the left 513 advances and forms the 4th layer, and stack gradually and form the 5th layer, the 6th layer, the 7th layer, the 8th layer, the 9th layer.In addition, enumerated the 1st coil portion 551 in the present embodiment and the 2nd coil portion 553 forms 9 layers structure respectively, still, the present invention is not limited to this, can the appropriate change number of plies.
Like this, winding position round the moving in prescribed limit by making coiling 555 is formed on the 1st coil portion 551 of the radial layer lap wound line 555 of FERRITE CORE 503.In addition, at this moment, past more upper strata, promptly the layer of outer radial periphery side reduces by every layer the number of turn.Thus, make the border end face CF of the 1st coil portion 551 1Form to above-mentioned direction.
Then, after forming the 1st coil portion 551, form the 2nd coil portion 553.The border end face CF of the 2nd coil portion 553 2Form the border end face CF that is positioned in the 1st coil portion 551 1On.Formed after the 1st coil portion 551, at first, the winding position of coiling 555 has been advanced from the superiors of the 1st coil portion 551 to the outer peripheral face of volume core 517.In addition,, coiling 555 winding position is advanced along the outer peripheral face flange part 515 to the right of volume core 517, and after reeling about 100 circles, turn back, and flange part to the left 513 is reeled with as the 2nd layer as the 1st layer in the 2nd coil portion 553.Below identical, winding position flange part 515 is to the right advanced forms the 3rd layer, turn back, and flange part to the left 513 advances and forms the 4th layer, and stack gradually and form the 5th layer, the 6th layer, the 7th layer, the 8th layer, the 9th layer.Like this, the 2nd coil portion 553 is to move by coiling 555 winding position is come and gone in prescribed limit equally, and form at the radial layer lap wound line 555 of FERRITE CORE 503.
Here, be not set cutting apart under the coiling form of flange on the volume core 517, form when being arranged on the coil portion of front, under the state that the space side of the coil portion that then forms is opened, the coiling that winds the line.The coiling of the coil portion that therefore, forms previously may be lost shape during the coiling of the coil portion that after this coiling forms.In addition, for example, have in use under the situation of the electric wire that adhesive covers, the stage of coiling is finished in the coiling of the coil portion of Xing Chenging in front, in case heat, by because the curing of adhesive composition is solidified the end face (not only comprising the flange part side but also comprise other coil portion side) of coil portion, can expect the effect that prevents to wind the line and lose shape.But, have in use under the situation of the electric wire that adhesive covers, after the formation of coil integral body is finished, before forming the insulation crust body, must remove the adhesive composition of coiling by solvent etc. by molding process.That is, can produce the numerous and diverse problem of manufacturing process.
To this, in the present embodiment, because the border end face CF of the 1st coil portion 551 that forms previously 1Tilt, therefore, even the electric wire that uses adhesives such as not having the polyurethane electric wire to cover, what also can prevent to wind the line loses shape.That is the border end face CF of the 1st coil portion 551, 1, adopt more to the stepped construction of its terminal of upper strata (layer of outer circumferential side) the closer to the central authorities of winding section, therefore,, also can make the coiling good stability even the space of the 2nd coil portion 553 sides does not have the support of flange etc., can not lose shape.In addition, among Fig. 4 and Fig. 5, clear in order preferentially to make figure, the 1st coil portion 551 and the 2nd coil portion 553 separated illustrate, still, in fact, shown in the dashdotted partial graph of Fig. 5, the boundary portion of two coil portions and the same forming almost not at interval in a coil portion.
As mentioned above,,, supports such as flange are not set on the FERRITE CORE 503, just can prevent that the coiling of the coil portion that forms previously from losing shape during formation coil portion after this when cutting apart the coiling form and form coil by the coil device 501 of present embodiment.Therefore, can be to cut apart the coiling form and omit flange, can realize the miniaturization of FERRITE CORE.In addition, FERRITE CORE 503 to be to have under the situation about constituting with the identical total length of FERRITE CORE of reeling cutting apart of flange with existing, only just can reel and more winds the line because omitted flange.
In addition,, can between pair of flanges portion 513,515, constitute the same volume core 517, therefore, can simplify the form of FERRITE CORE 503, and can realize the reduction of magnetic core manufacturing cost by omitting flange.
In addition, cut apart the coil 505 of coiling form, in higher frequency, can have the peak value of inductance.Therefore, can have the inductance zone little, in the frequency of utilization band of expectations of customers, realize the stabilisation of inductance easily at frequency band widely with respect to the rate of change of frequency.
And, as mentioned above, even make the border end face CF of the 1st coil portion 551 that forms previously 1Tilt the border end face CF of the 2nd coil portion 553 2Tilt too, therefore, the zone between the pair of flanges portion 513,515 effectively can be utilized as the coiling wrapping range.
And, the end face TF of the 1st coil portion 551 1And between the face 513a of flange part 513, and the end face TF of the 2nd coil portion 553 2And between the face 515a of flange part 515, can guarantee remaining space 557,559 respectively.Therefore, even the heat during owing to molding process that insulation crust body 507 is set expands the coiling of coil 505, remaining space 557,559 also can have the effect of the portion of keeping out of the way as it, can avoid residual stress to act in the pair of flanges portion 513,515 of FERRITE CORE 503.
And, in order to have this remaining space 557,559, the end face TF of coil portion 551,553 1, TF 2Can not adopt the structure that supports by face 513a, 515a.But, because the end face TF of coil portion 551,553 1, TF 2Tilt to above-mentioned direction respectively, therefore, can prevent end face TF 1, TF 2In the coiling of coiling lose shape.
As mentioned above, content of the present invention is specified, still, for a person skilled in the art, obviously can carry out various modes and change according to basic technological thought of the present invention and enlightenment with reference to preferred implementation.
For example, in the above-mentioned execution mode, the end face TF of flange part 513,515 sides of the correspondence of coil portion 551,553 1, TF 2Tilt, but the present invention is not limited to this.Thereby, as shown in Figure 6, in the coil portion 751,753 that constitutes coil 505, also can form the end face of corresponding flange part 513,515 sides along face 513a, the 515a of flange part 513,515.According to this mode, can not cause waste with the zone between the pair of flanges portion 513,515 as the coiling wrapping range.
In addition, in the above-mentioned execution mode, the polyurethane electric wires are used in coiling 555, and still, the present invention is not limited to this, also can suitably use the electric wire of good heat resistance such as polyimides electric wire.
In addition, the end face of the coil portion in the coil 505 (both comprised the flange part side, and also comprised other coil portion side) is not limited to the accurately mode of a coiling of skew crustal inclination of each layer.That is, as long as guarantee certain tilt relationship between the outer circumferential side of coil portion and the interior all sides, thereby the end face of coil portion for example, also can be stepped tilts, and perhaps makes the offset crustal inclination of coiling according to irregular form.
And the coil 505 in the coil device 501 of the present invention is not limited in by two coil portions and constitutes, and also can be to have three or more than the structure of three coil portions.In this case, also be in the coil portion that forms in front, make the formed border of the coil portion side end slope that forms next, and set gradually coil portion, thus, can obtain the effect identical with above-mentioned execution mode.
And, coil device 501 of the present invention, except no key open-door system, locking system, pressure monitoring system, be not limited in car antenna even be used for automobile, also can be as antenna, transponder, inductor (inductor) as general electronic unit.
The 2nd mode of the present invention
Below, with reference to accompanying drawing the 2nd mode of the present invention is described.
Fig. 7 is the stereogram of the coil device of expression another embodiment of the present invention, and Fig. 8 is the front section view of expression coil device shown in Figure 7, and Fig. 9 is that the part of presentation graphs 7 and coil device shown in Figure 8 enlarges stereogram.This coil device can be used for the inductor of antenna, car antenna, transponder, choke, electronic equipment etc.
With reference to Fig. 7 and Fig. 8, coil device comprises: magnetic core 110, coiling 104, terminal 151,152, and further comprise insulating resin 107.
Magnetic core 110 has terminal installation portion 121,122 at its relative two ends, has winding section 101 at pars intermedia.In the magnetic core 110, representative is FERRITE CORE, and its material can characteristic as requested be selected.The sintered body that FERRITE CORE can be by ferrite powder, the machining of ferrite bar or with both in conjunction with obtaining.
Winding section 101 has the elongated shape that extends more longways at length direction X.In illustrated embodiment, winding section 101 is the quadrangle section.In addition, also can adopt arbitrary section shapes such as other polygon sections, circular section and oval-shaped profile.
Terminal installation portion 121,122 two ends of 101 length direction X and winding section 101 consubstantiality settings in the winding section respectively, and have recess 131,132 in the outer face of length direction X.Diagram terminal installation portion 121,122 is flange shape, and not have the section of the position of recess 131,132 be the quadrangle section.The outer ledge part and the choosing of medial angle quality award from the ministry of terminal installation portion 121,122 have fillet, perhaps micro-lead angle.
Recess 131,132 is respectively, and its depth direction is consistent with length direction X, extend to Width Y, and width is narrow more to the bottom more.Recess 131,132, in the drawings, intersect in the bottom on two inclined planes, is the depth direction roughly complete V-arrangement consistent with length direction X.In addition, also can be the shape of bottom for the shape of tabular surface or arc surface.In addition, recess 131,132, the whole width of crossing over terminal installation portion 121,122 in the drawings forms, and still, also can be shorter and in the structure of closed at both ends than whole width.
Coiling 104 is wound on the winding section 101 of magnetic core 110.The coil device that bases such as coiling 104 the number of turn, line footpath will obtain and difference.Terminal 151,152 is made of a slice bending metallic plate.The sheet metal that constitutes terminal 151,152 can use non magnetic and rubber-like, for example stainless steel-like metallic plate such as phosphor bronze sheet or SUS 304-CSP.
Terminal 151,152 comprises the 1st kink 1F1 and the 2nd kink 1F2.The 1st kink 1F1 is used for from the installation portion 911,921 of the guiding of X along its length away from the direction of magnetic core 110, be created in outer face devices spaced apart and the direction faced mutually on the installation portion 911,921 that bends.
The 2nd kink 1F2 be used for from installation portion 911,921 along its length X be created in the bottom 913,923 that the direction near magnetic core 110 bends.The front end of bottom 913,923, promptly free end from length direction X, is positioned at the outside of the outer face of magnetic core 110.By this setting, can improve frequency-inductance characteristic and frequency-Q characteristic.
Installation portion 911,921, one end are fixed on the terminal installation portion 121,122 of magnetic core 110.Specifically, at certain position, be positioned at the inside of recess 131,132 by the thickness of slab decision.Therefore, terminal 151,152 determines with respect to the position of magnetic core 110 is unique, and can not produce the change of frequency-inductance characteristic of the shift in position that is accompanied by terminal 151,152 and the change of frequency-Q characteristic.
Installation portion 911,921 further is fixed on recess 131,132 inside by the adhesive 61,62 that is filled in the recess 131,132.At this moment, if breach etc. is set,, therefore, can improve terminal 151,152 installation strength with respect to magnetic core 110 because adhesive 61,62 is being filled in the inside of breach at an end that inserts recess 131,132 inside.The coiling terminal 41,42 on installation portion 911,921, reel 2～3 the circle, preferably wait to engage by Pb-free solder.
And pars intermedia 912,922 has hole 914,924 in face.Hole 914,924 at least in one direction, two relative inward flanges are curved.
Pars intermedia the 912, the 922nd, the part relative with the end face of magnetic core 110, the plate face is in and by flowing through the magnetic flux quadrature that electric current produced of coiling or the relation of intersection.Therefore, become the obstruction part of the smooth circulation that hinders magnetic flux, may make frequency-inductance characteristic and frequency-Q characteristic variation.Therefore, among the present invention, hole 914,924 is set in the face of pars intermedia 912,922.
Because the existence in above-mentioned hole 914,924, become the sectional area little structure of the sectional area of pars intermedia 912,922 than installation portion 911,921 and bottom 913,923, therefore, the obstruction of flowing of magnetic flux is diminished, can blanketing frequency-inductance characteristic and frequency-Q characteristic variation.
Because hole 914,924 is set on pars intermedia 912,922, the mechanical strength of pars intermedia 912,922 reduces.The reduction of mechanical strength must be inhibited as far as possible.Otherwise, can not guarantee desired resistance to impact and vibration resistance in the purposes of environment for use strictnesses such as vehicle-mounted coil device.
As its method, among the present invention, the shape in hole 914,924 is that at least in one direction, two relative inward flanges are curved.According to the shape in above-mentioned hole, for example different with four jiaos of holes with acutangulate interior angle, can guarantee sufficient mechanical, fully satisfy desired resistance to impact and vibration resistance in the purposes of environment for use strictnesses such as vehicle-mounted coil device.At first sight, only just four jiaos of holes being become the simple technical finesse of circular hole, still, in the structure that limits, is the utmost point effective method that can bring into play maximum efficiency.
Fig. 9 is the expansion stereogram of terminal.Hole 914,924 is circular, is arranged in the face of pars intermedia 912,922.Desired is, the aperture in hole 914,924 is the about 1/3 of terminal 151,152 integral width Y10, about Width, produces the space of same widths Y11, Y12 respectively.
In addition, hole 914,924 preferably is arranged on from the direction of height Z, from the 2nd kink 1F2 to bore edges apart from Z11 than the position big apart from Z12 from the 1st kink 1F1 to bore edges, that is, preferably hole 914,924 is set to be partial to the direction of installation portion 911,921.
Fig. 7 and coil device shown in Figure 8 also comprise insulation crust body 7.Insulation crust body 7 covers the part of the installation portion 911,921 of magnetic core 110, coiling 104 and terminal 151,152.By this structure, can and wind the line 104 by insulation crust body 107 protection magnetic cores 110, and terminal 151,152 is improved with respect to the bond strength of magnetic core 110, can realize the coil device that Mechanical Reliability is good.
Figure 10 is the figure of the user mode of presentation graphs 7, coil device shown in Figure 8.As shown in the figure, under the user mode, bottom 913,923 is welded 184 on the conductor fig 182 that substrate 181 is had.Coil device is set to, and produces the gap between the surface of the lower surface of insulation crust body 107 and substrate 181.
Terminal 151,152 has the 1st kink 1F1, the 2nd kink 1F2, and therefore, the elasticity that can be produced by the 1st and the 2nd kink 1F1,1F2 absorbs and impacts and vibration.Therefore, can realize the coil device that resistance to impact and vibration resistance are good.
In addition, under the situation of Fig. 7 and coil device shown in Figure 8, the aperture in hole 914,924 is decided to be about 1/3 of terminal 151,152 integral width Y10, and about Width, produce the space of same widths Y11, Y12 respectively, therefore, make about the Width in hole 914,924, leg forms with the space and increases, and the intensity of welding 184 increases.
In addition, hole 914,924 preferably is arranged on from short transverse Z, if from the 2nd kink 1F2 to bore edges apart from Z11 than the position big apart from Z12 from the 1st kink 1F1 to bore edges, promptly, hole 914,924 is set to be partial to the direction of installation portion 911,921, then by this structure, 914,924 the downside in the hole, can increase leg formation and use the space, and increase the intensity of welding 184.
The hole 914,924 that is provided with on the pars intermedia 912,922 satisfying under the situation of above-mentioned condition, can obtain variety of way.With reference to Figure 11～Figure 16 its example is described.
At first, in the example of Figure 11, hole 914,924 has minor axis and major diameter, the minor axis direction with from installation portion 911,921 towards the bottom 913,923 short transverse Z consistent.
Then, in the example of Figure 12, illustration have the non-circular example of minor axis and major diameter equally, still, on the direction that makes major diameter and 913,923 the consistent this point of short transverse Z, different with the execution mode of Figure 11 from installation portion 911,921 towards the bottom.
The example of Figure 11 and Figure 12 is the shape that the arcuation part at two ends is connected by straight line portion, and is promptly so-called run-track shaped, still, as shown in figure 13, also can be elliptical shape.
Figure 14 is the figure of other examples of expression terminal, terminal 151,152, from pars intermedia 912,922 to the bottom 913,923, have from pars intermedia 912,922 to the bottom 913,923 the extended widening portion 915,925 of its width of direction.
Figure 15 is the figure of other examples of expression terminal, and the situation with Figure 14 is identical having on the widening portion this point, but the crooked place difference.
Describe with regard to this point with reference to Figure 16.Figure 16 is the plane outspread drawing of terminal.Among Figure 16, installation portion 911,921 and pars intermedia 912,922 width are roughly the same, and the width of bottom 913,923 is bigger than above-mentioned width.Has widening portion 915,925 between pars intermedia 912,922 and the bottom 913,923.
For the terminal of the type that obtains Figure 14, among Figure 16, near the border P4 of bottom 913,923 and widening portion 915,925, set the 2nd kink 1F2.For the terminal of the type that obtains Figure 15, between widening portion 915,925, that is, in Figure 16, between the P2-P3 of border, set the 2nd kink 1F2 and get final product.
According to the terminal of Figure 14 and Figure 15, can increase leg by widening portion 915,925 and form and to use the space, and fully satisfy desired resistance to impact and vibration resistance in the purposes of environment for use strictnesses such as vehicle-mounted coil device.
Figure 17 is the cutaway view of the coil device of another embodiment of the present invention.Among the figure, to being marked with same-sign, and omit repeat specification with Fig. 7 and the represented suitable part of component part of Fig. 8.In this execution mode, magnetic core 110 has spacer portion 123 at pars intermedia, and 104 coiling winds the line in its both sides.That is, winding section 101 is divided into many parts.Coiling 104 is being divided on many parts the winding section 101 continuous reeling on same direction.Under the situation of this execution mode, also has the action effect that is equal to Fig. 7 and execution mode shown in Figure 8.
Described or each structure of being enlightened of the 2nd mode of the present invention can obtain by the 1st mode of the present invention arbitrary structures described or that enlightened is combined.For example, about the coil that constitutes by the coiling 104 on the winding section 101 that is wound on magnetic core 110, can adopt the present invention's the 1st mode arbitrary structures, configuration, shape described or that enlightened to wait and obtain.Concrete example is as described below.
This coil has the 1st coil portion and the 2nd coil portion.The 1st coil portion and the 2nd coil portion are respectively to reel by winding the line in the prescribed limit of core length direction (coil wireline reel direction) to form in the coiling portion that is layered in magnetic core.And the border end face of the 2nd coil portion side of the 1st coil portion more tilts near the mode of the 2nd coil portion than outer circumferential side with all sides in it.
The 3rd mode of the present invention
With reference to the accompanying drawings the 3rd mode of the present invention is described below.In addition, among the figure, same-sign is represented identical or counterpart.
Figure 18 is the longitudinal section of the coil device of expression another embodiment of the present invention.Coil device 201 mainly has: FERRITE CORE 203, coil 205, insulation crust body 207 and pair of terminal 209,211.In addition, coil device 201 for example be applicable in the automobile need not push-button two-way no key open-door system, anti-locking system, the pneumatic pressure monitoring system of tire etc. usurped.
Coil 205 is by being that the coiling of reeling on the outer peripheral face of this FERRITE CORE 203 in the center constitutes with FERRITE CORE 203.Insulation crust body 207 is set to cover whole these FERRITE CORE 203 and coil 205.
As Figure 19 and shown in Figure 20, FERRITE CORE 203 reality are bar-like member, and the both ends of its length direction (directions X) have flange part 213,215, and, have volume core 217 between these flange parts 213,215.
The groove 219,221 of a pair of V-shape of the last formation of outside end face 213b, the 215b with the opposite side of face 213a, 215a of rolling up the core side of pair of flanges portion 213,215.A pair of groove 219,221 prolongs along the Y direction, and in the both ends of the surface upper shed of the Y of FERRITE CORE 203 direction.
In above-mentioned a pair of groove 219,221, engaging corresponding pair of terminal 209,211.Get back to Figure 18, pair of terminal 209,211 is from the ZX vertical section, for being bent into the roughly metallic plate-shaped member of U font.In more detail, can use non magnetic and rubber-like, for example stainless steel-like metallic plate such as phosphor bronze sheet or SUS 304-CSP.
Pair of terminal 209,211 has three planar sections that plate-shaped member is formed in the bending of two places.In three planar sections, part 1 223,225 and the 3rd part 231,233 are extended along the XY face, and part 2 227,229 is extended along the YZ face.Part 1 223,225 runs through insulation crust body 207.One end of part 1 223,225 inserts in the corresponding a pair of groove 219,221, and fixing by adhesive 235.And, pass through the coiling end 237 that solder joints coil 205 on the part 1 223,225.The other end of part 1 223,225 is connecting the 1st bend 239.
Part 2 227,229 is extended between the 1st bend 239 and the 2nd bend 241.And, on part 2 227,229, run through the sectional area that makes this part 2 227,229 being set than part 1 223,225 and the little through hole 243 of the 3rd part 231,233.The 3rd part 231,233 from the 2nd bend 241 towards core length direction central authorities and and the lower surface almost parallel ground prolongation of insulation crust body 207.
Insulation crust body 207 be cover FERRITE CORE 203 and coil 205, profile is roughly the parts of rectangular shape.That is, identical with existing surface mounted type coil device, the section shape with coil wireline reel direction (directions X) quadrature of insulation crust body 207 is a quadrangle.By this insulation crust body 207, in protection FERRITE CORE 203 and coil 205, can improve pair of terminal 209,211 adhesion strengths with respect to FERRITE CORE 203, can realize the form that Mechanical Reliability is good.
Then, according to Figure 19, Figure 20 and Figure 21 FERRITE CORE 203 is elaborated.It is bigger with respect to Z direction size that pair of flanges portion 213,215 and volume core 217 all form Y direction size.And pair of flanges portion 213,215 forms, and its Z direction size and Y direction size are all than rolling up the big of core 217.Thus, in the pair of flanges portion 213,215, volume core side 213a, 215a exist from the upper and lower surface and the two sides approximate vertical of volume core 217 respectively with erecting.
Pair of flanges portion 213,215 constitutes roughly cube shaped respectively, and has: volume core side 213a, 215a; Respectively with its outside end face 213b, 215b that faces mutually; The outer peripheral face that connects the corresponding sides of this face 213a, 215a and face 213b, 215b, that is, and upper surface 213c, 215c, lower surface 213d, 215d, a pair of side 213e, 213f and 215e, 215f.
Volume core 217 is between the pair of flanges portion 213,215, has upper surface 261, lower surface 263 and a pair of side 265,267.Especially, as shown in figure 21, core 217 and section axis direction (directions X) quadrature are promptly rolled up in the cross section of volume core 217, have following shape,, are provided with bulge 269 on the opposite of facing mutually in quadrangle shown in the dotted line that is.
Thus, in the present embodiment, a pair of side 265,267 is made of bulge 269 and a pair of par 271 that forms in its two sides.In other words, a pair of tabular surface 271 is formed between bulge 269 and the upper surface 261 and lower surface 263 as an opposite of facing mutually.
In addition, a pair of bulge 269, the cross section from Figure 21 is made of curve, in the present embodiment, especially constitutes with circular-arc curve.And, be provided with four coilings in the volume core 217 and keep out of the way portion 273.Portion 273 is kept out of the way in each coiling, from the cross section of Figure 21, forms the arcuation line L more virtual than aftermentioned and caves in more to the inside.Arcuation line L is to join with bulge 269, and connecting the dummy line of the tetragonal bight E that is positioned at bulge 269 both sides.
In addition, on the connecting portion 275 of volume core side 213a, the 215a of volume upper surface 261 of core 217 and pair of flanges portion 213,215, shown in the expansion section (a) of Figure 20, carry out R processing, perhaps, shown in the expansion section (b) of Figure 20, carry out tapering processing.And, also carry out R processing on volume core side 213a, the 215a of pair of flanges portion 213,215 and the connecting portion 277 of upper surface 213c, 215c.
In addition, if enumerate the concrete size in the present embodiment, then, the directions X of volume core 217 is of a size of 7mm, the directions X of flange part 213,215 is of a size of 1.3mm, and the erecting of Z direction from 217 beginnings of volume core of volume core side 213a, the 215a of flange part 213,215 is of a size of 0.5mm.With respect to this structure, under the situation that connecting portion 275 is processed by R, the radius that the R in this connecting portion 275 and 277 adds the Ministry of worker is 0.215mm.In addition, carry out in the present embodiment the R first being processed, the radius of spontaneous natural R is about 0.05～0.07mm in the processing.Thus, the R of connecting portion 275,277 adds about 2～3 times value that the radius of the Ministry of worker is nature R.On the other hand, under the situation that connecting portion 275 is processed by tapering, it is 30～60 ° that the tapering of connecting portion 275 is added the wireline reel C that the inclination angle [theta] of the Ministry of worker is set at respect to volume core 217.
In addition, the manufacturing of the volume core 217 of FERRITE CORE 203 is by known mode, that is, and and by what the extrusion forming of ferrite powder compression was carried out.Extrusion forming uses a pair of mould bases (frame type), patrix and counterdie to carry out.A pair of mould bases separates the predetermined distance setting, fills ferrite powder between a pair of like this mould bases, and this powder is by the patrix and the counterdie compression forming that are inserted in from upper and lower between a pair of mould bases.The upper surface 261 and the lower surface 263 of volume core 217 are formed by a pair of mould bases, and a pair of side 265,267 of rolling up core 217 is formed by patrix and counterdie.
Coil device with said structure can obtain following effect.Form bulge 269 on the relative a pair of side of volume core 217.Therefore, during the coiling of coiling coil 205, this coiling from the cross section shape of Figure 21, is wound into the shape of comparing more approaching circle with the situation that does not possess bulge on volume core 217.Thereby, even the heat when insulation crust body 207 is molded makes coil 205 expand, also can relax the stress that produces on the part of insulation crust body 207 of coiling of the bight E that covers volume core 217 and concentrate, can prevent from this part, to crack.
Especially, under the situation about implementing as vehicle-mounted transponder, it is many that the number of turns of coil 205 becomes, and therefore, the coiling expansion rate becomes big, and the crackle generation rate uprises.Thereby under the situation about implementing as vehicle-mounted transponder, the present invention is especially effective.
In addition, bulge 269 is made of curve in cross section shape, therefore, by bulge 269 is set, can also avoids producing new stress and concentrate.
And, as mentioned above, the same cross section of using with existing surface mounted type coil device is tetragonal insulation crust body, and use simultaneously under the situation of cross section shape as the volume core of circle, be difficult to guarantee the thickness of insulation crust body, perhaps, have the problem of the size increase of coil device integral body.But, among the present invention, by bulge 269 is set, the a pair of mask of facing mutually that the cross section shape of volume core forms in quadrangle has bulge, therefore, and as mentioned above, can prevent to crack on the insulation crust body 207, and can satisfy the requirement of coil device miniaturization.Especially, be set to laterally conforming to when installing, can realize the slimming (highly reducing) of coil device by a pair of side that is provided with bulge 269.
In addition, form coiling on the volume core 217 and keep out of the way portion 273, therefore, as mentioned above, under the situation that the thermal conductance induced coil 205 when insulation crust body 207 is molded expands, the part of coiling can enter coiling and keep out of the way in the portion 273, that is, can expand more to the inside than arcuation line L.Thereby like this, the ratio of expansive force that the coiling of expansion imposes on the insulation crust body 207 in the outside reduces, especially, even the corner periphery of the insulation crust body 207 that can have problems at crackle also can effectively prevent the generation of crackle.
In addition, volume core 217, as mentioned above, when making by the compression forming of powder, usually, the volume core has under the situation of circular-arc profile from the cross section, two adjacent moulds contact with acute angle relation, can be accompanied by and can not apply adequate compressive forces, perhaps significantly damage the problem of mould.That is, suppose that the bulge of volume core 217 is crossed under the situation about expanding on 265,267 ground, whole side from quadrangle bight E, acutangulate relation between mould bases and patrix and the counterdie.
But in the actual present embodiment, bulge 269 is 265,267 demi-inflations in the side, that is, the both sides of bulge 269 form par 271, therefore, contact with the approximate right angle relation between mould bases and patrix and the counterdie.Therefore, can prevent from acting on bigger compression counter-force on the end of mould.Thereby, can apply adequate compressive forces, and prevent that mould from damaging at short notice.
In addition, at the volume upper surface 261 of core 217 and the volume core side 213a of flange part 213,215, the connecting portion 275 of 215a, and on the connecting portion 277 of volume core side 213a, the 215a of flange part 213,215 and upper surface 213c, 215c, carry out going up the bigger R processing of spontaneous form than processing.Thus, can prevent from the border of volume core 217 and flange part 213,215, to crack, perhaps on flange part 213,215, produce crack or shortcoming.The generation of this crackle, crack or shortcoming, coil 205 was insulated shell body 207 and surrounds when the coil 205 of resulting from expanded, and expansive force to act on the coil 205 as counter-force also be main cause.Therefore, as described herein, especially can be insulated under the situation of shell body 207 coverings, effectively prevent crackle, crack or shortcoming at coil 205.In addition, even under the situation that the connecting portion 275 of volume core side 213a, the 215a of volume upper surface 261 of core 217 and flange part 213,215 is processed by tapering, also can obtain and effect that above-mentioned R processing is same.
Abovely content of the present invention is specified, still, still, for a person skilled in the art, obviously can carry out various modes and change according to basic technological thought of the present invention and enlightenment with reference to preferred implementation.
For example, in the above-mentioned execution mode, the bulge 269 of volume core 217 is made of continuous curve from its cross section, and still, the present invention is not limited to this, also can use discontinuous curve or part to use straight line to constitute.
And coil device 201 of the present invention except above-mentioned no key open-door system, locking system, pressure monitoring system, is not limited in car antenna even is used for automobile, also can be as antenna, transponder, the inductor as general electronic unit.
Described or each structure of being enlightened of the 3rd mode of the present invention can obtain by the 1st mode of the present invention arbitrary structures described or that enlightened is combined.For example, about the coil 205 that constitutes by the coiling on the volume core 217 that is wound on FERRITE CORE 203, can adopt the present invention's the 1st mode arbitrary structures, configuration, shape described or that enlightened to wait and obtain.Concrete example is as described below.
This coil has the 1st coil portion and the 2nd coil portion.The 1st coil portion and the 2nd coil portion are respectively to reel by winding the line in the prescribed limit of core length direction (coil wireline reel direction) to form on the volume core that is layered in FERRITE CORE.And the border end face of the 2nd coil portion side of the 1st coil portion more tilts near the mode of the 2nd coil portion than outer circumferential side with all sides in it.
The 4th mode of the present invention
With reference to the accompanying drawings the 4th mode of the present invention is described below.
Figure 22 is the cutaway view of the coil device of expression another embodiment of the present invention, and Figure 23 is in the expression coil device shown in Figure 22, the stereogram of the state before the terminal bending.The coil device of illustrated embodiment also can be used for the inductor of antenna, car antenna, transponder, electronic equipment etc.Illustrated coil device comprises: magnetic core 301, coil 304, two terminals 351,352 and insulation nappes 307.
Magnetic core 301 has coil coiling portion 311 and two flange parts 321,322.The magnetic core 301 of illustrated embodiment is made of ferrite, sintered body that can be by ferrite powder, the machining of ferrite bar or with both in conjunction with obtaining.
Coil coiling portion 311 extends at length direction X.In illustrated embodiment, coil coiling portion 311 is the quadrangle section.In addition, also can adopt arbitrary section shapes such as other polygon sections, circular section and oval-shaped profile.Coil coiling portion 311 has the elongated shape that extends more longways at length direction X.
Flange part 321,322 be separately positioned on coil coiling portion 311 length direction X two ends and and the 311 consubstantiality settings of coil coiling portion, the outer face of length direction X has groove 331,332.In the flange part 321,322, the section that does not have the position of groove 331,332 is the quadrangle section.The outer ledge part and the choosing of medial angle quality award from the ministry of flange part 321,322 have fillet, perhaps micro-lead angle.
Groove 331,332 is respectively, and its depth direction is consistent with length direction X, has the groove width of thickness direction Z, extend to Width Y, and groove width Z3 is narrow more to the bottom more.According to this structure,, can obtain the good reliability of resistance to impact and vibration resistance high magnetic core and coil device by selecting degree of depth size, groove 331,332 with respect to the length direction X of flange part 321,322.
Groove 331,332, in the drawings, intersect in the bottom on two inclined planes, is the depth direction roughly complete V-arrangement consistent with length direction X.In addition, also can be the shape of bottom for the shape of tabular surface or arc surface.In addition, the whole width of crossing over flange part 321,322 in the drawings forms, and still, also can be shorter and in the structure of closed at both ends than whole width.
Coil 304 and terminal 351,352 are combined on the magnetic core 301.Coil 304 is wound in the coil coiling portion 311 of magnetic core 301.The coil device that bases such as the number of turn of coil 304, line footpath will obtain and difference.
Terminal 351,352 is made of metallic plate respectively, has two place's bending parts of bending to the inside, and is also fixing in the groove 331,332 of one end insertion magnetic core 301, is connected with the end 41,42 of coil 304.The sheet metal that constitutes terminal 351,352 can use non magnetic and rubber-like, for example stainless steel-like metallic plate such as phosphor bronze sheet or SUS 304-CSP.
Terminal 351,352, one end insert respectively in the groove 331,332 of magnetic core 301.Groove 331,332, as mentioned above, its groove width is narrow more to the bottom more, and therefore, terminal 351,352 is positioned at groove 331,332 inside respectively on the certain position by the thickness of slab decision.Therefore, terminal 351,352 determines with respect to the position of magnetic core 301 is unique, and can not produce the change of frequency-inductance characteristic of the shift in position that is accompanied by terminal 351,352 and the change of frequency-Q characteristic.
Intersect in the bottom on each groove 331,332, two inclined planes of flange part 321,322, and its depth direction is consistent with length direction X, has the groove width of thickness direction Z, and extends to Width Y.Thereby each terminal 351,352 with respect to the flange part 321,322 of magnetic core 301, from thickness direction Z, is fixed in the groove 331,332 and the plate face is parallel to each other.
Terminal 351,352 is by being filled in the inside that adhesive 61,62 in the groove 331,332 is fixed on groove 331,332.In the illustrated embodiment, an end of terminal 351,352 insertion grooves 331,332 inside has breach.If such structure because adhesive 61,62 is being filled in the inside of breach, therefore, can improve terminal 351,352 installation strength with respect to magnetic core 301.
Insulation nappe 307 covers the part of magnetic core 301, coil 304 and terminal 351,352.By this structure, can protect magnetic core 301 and coils 304 by insulation nappe 307, and terminal 351,352 is improved with respect to the bond strength of magnetic core 301, can realize the coil device that Mechanical Reliability is good.
Magnetic core 301 and coil 304 are positioned at the substantial middle portion of insulation nappe 307.That is, among Figure 22, the thickness t 1 of the upper surface of covering magnetic core 301 and the insulation nappe 307 of lower surface, t2 are about equally.Though it is not shown,, from the section perpendicular to upper surface and lower surface, in the two sides that connect upper surface and lower surface, the thickness of insulation nappe 307 and cladding thickness t1, t2 on upper surface and the lower surface are about equally.According to this structure, magnetic core 301 and coil 304 are sealed in the inside of insulation nappe 307, and prevent that the whole of magnetic core 301 and coil 304 or part from exposing, and can realize the coil device of the high reliability that resistance to impact and vibration resistance are good.
And,, thickness t 1, the t2 of insulation nappe 307 can be set at necessary minimum value because magnetic core 301 and coil 304 are positioned at the substantial middle portion of insulation nappe 307.Therefore,, set the magnetic core 301 of inside and the overall dimension of coil 304 relatively large, can obtain good electrical characteristics with respect to the overall dimension of the coil device that is determined.
Figure 24 is that expression is applicable to the figure of molding process that magnetic core 301 and coil 304 is positioned at the substantial middle portion of insulation nappe 307.In the example of Figure 24, in the chamber of counterdie A and patrix B, projection A1, the B1 of roughly the same height is set,, magnetic core 301 and coil 304 can be accurately positioned in the assigned position of counterdie A and patrix B inside by projection A1, B1.Projection A1, B1, preferably its front end leaves the surface of magnetic core 301 a little.Thus, magnetic core 301 and coil 304 can be positioned at the substantial middle portion of insulation nappe, can not be exposed to the outside, cover fully by insulation nappe 307 from insulation nappe 307.
In addition, according to above-mentioned molding process, by projection A1, B1 position limit to magnetic core 301 and coil 304, space G1, G2 between counterdie A and patrix B and magnetic core 301 and the coil 304 can be kept certain, therefore, thickness t 1, the t2 (with reference to Figure 22) of insulation nappe 307 can be set at necessary minimum value.Therefore,, can set the magnetic core 301 of inside and the overall dimension of coil 304 relatively large, can obtain good electrical characteristics with respect to the overall dimension of the coil device that is determined.
Insulation nappe 307 is made of the thermoplastic insulating resin.When insulation nappe 307 is made of the thermoplastic insulating resin, compare, reduce with respect to the thermal expansion of the insulation nappe of magnetic core 301, the influence of contraction with situation about constituting by the Thermocurable insulating resin.Therefore, the thermal stress of magnetic core 301 reduces, and the variable quantity of the inductance value that temperature change causes diminishes.
Figure 25 is the figure of expression temperature-L rate of change performance data.Among the figure, transverse axis be temperature (℃), the longitudinal axis is the L rate of change (%) as the variation inductance rate.Curve C r represents not have the characteristic under the situation of insulation nappe 307, curve C 1 expression is with the characteristic of thermoplastic resin (liquid crystal polymer) as the coil device of the present invention of insulation nappe 307, and curve C 2 expressions are with the characteristic of heat-curing resin (the adjacent benzene resin of diallyl) as the coil device of insulation nappe 307.Characteristic curve Cr, C1, C2 except insulation nappe 307 this point, all can obtain by the coil device with Figure 22, structure shown in Figure 23.
With reference to Figure 25, under with the situation of heat-curing resin as insulation nappe 307, shown in characteristic curve C2, temperature-L rate of change characteristic deviates from the characteristic curve Cr as benchmark greatly.With respect to this, coil device of the present invention showed with as the very similar temperature of the characteristic curve Cr of benchmark-L rate of change characteristic.By inference, this be because, when insulation nappe 307 is made of the thermoplastic insulating resin, (characteristic curve C2) compares with situation about being made of heat-curing resin, thermal expansion, contraction are littler for the influence of magnetic core 301, the stress of magnetic core 301 reduces, and can bring into play the intrinsic magnetic characteristic (characteristic curve Cr) of magnetic core 301.
Described or each structure of being enlightened of the 4th mode of the present invention can obtain by the 1st mode of the present invention arbitrary structures described or that enlightened is combined.For example, the coil 304 about forming in the coil coiling portion 311 of magnetic core 301 can adopt the present invention's the 1st mode arbitrary structures, configuration, shape described or that enlightened to wait and obtain.Concrete example is as described below.
This coil has the 1st coil portion and the 2nd coil portion.The 1st coil portion and the 2nd coil portion are respectively to reel by winding the line in the prescribed limit of core length direction (coil wireline reel direction) to form in the coil coiling portion that is layered in magnetic core.And the border end face of the 2nd coil portion side of the 1st coil portion more tilts near the mode of the 2nd coil portion than outer circumferential side with all sides in it.
The 5th mode of the present invention
With reference to the accompanying drawings the 5th mode of the present invention is described below.
Figure 26 is the stereoscopic figure of the coil device of expression another embodiment of the present invention, Figure 27 be expression for the internal structure of coil device shown in the presentation graphs 26 with insulating resin shell body abridged stereogram, Figure 28 is the front section view of expression Figure 26 and coil device shown in Figure 27.This coil device can be used for the inductor of antenna, car antenna, transponder, choke, electronic equipment etc.
With reference to Figure 26～28, coil device comprises: magnetic core 410, coiling 404, terminal 451,452 and insulating resin shell body 407.
Magnetic core 410 has terminal installation portion 421,422 at its relative two ends, has winding section 401 at pars intermedia.In the magnetic core 410, representative is FERRITE CORE, and its material can characteristic as requested be selected.The sintered body that FERRITE CORE can be by ferrite powder, the machining of ferrite bar or with both in conjunction with obtaining.
Winding section 401 has the elongated shape that extends more longways at length direction X.In illustrated embodiment, winding section 401 is the quadrangle section.In addition, also can adopt arbitrary section shapes such as other polygon sections, circular section and oval-shaped profile.
Terminal installation portion 421,422 two ends of 401 length direction X and winding section 401 consubstantiality settings in the winding section respectively, and have recess 431,432 in the outer face of length direction X.Diagram terminal installation portion 421,422 is flange shape, and not have the section of the position of recess 431,432 be the quadrangle section.The outer ledge part and the choosing of medial angle quality award from the ministry of terminal installation portion 421,422 have fillet, perhaps micro-lead angle.
Recess 431,432 is respectively, and its depth direction is consistent with length direction X, extend to Width Y, and width is narrow more to the bottom more.Recess 431,432, in the drawings, intersect in the bottom on two inclined planes, is the depth direction roughly complete V-arrangement consistent with length direction X.In addition, also can be the shape of bottom for the shape of tabular surface or arc surface.In addition, recess 431,432, the whole width of crossing over terminal installation portion 421,422 in the drawings forms, and still, also can be shorter and in the structure of closed at both ends than whole width.
Coiling 404 is wound on the winding section 401 of magnetic core 410.The coil device that bases such as coiling 404 the number of turn, line footpath will obtain and difference.
Terminal 451,452 is made of a slice bending metallic plate.The sheet metal that constitutes terminal 451,452 can use non magnetic and rubber-like, for example stainless steel-like such as phosphor bronze sheet or SUS304-CSP metallic plate.
Terminal 451,452 comprises the 1st zigzag part 4F1 and the 2nd zigzag part 4F2.The 1st zigzag part 4F1 is used for from the installation portion 811,821 of the guiding of X along its length away from the direction of magnetic core 410, be created in outer face devices spaced apart and the direction faced mutually on the installation portion 811,821 that bends.The 1st zigzag part 4F1 and the 2nd zigzag part 4F2 are positioned at the outside of insulating resin shell body 407.
The 2nd zigzag part 4F2 be used for from installation portion 811,821 along its length X be created in the bottom 813,823 that the direction near magnetic core 410 bends.The front end of bottom 813,823, promptly free end from length direction X, is positioned at the outside of the outer face of magnetic core 410.By this setting, can improve frequency-inductance characteristic and frequency-Q characteristic.
Installation portion 811,821, one end are fixed on the terminal installation portion 421,422 of magnetic core 410.Specifically, on certain position, be positioned at the inside of recess 431,432 by the thickness of slab decision.Therefore, terminal 451,452 determines with respect to the position of magnetic core 410 is unique, and can not produce the change of frequency-inductance characteristic of the shift in position that is accompanied by terminal 451,452 and the change of frequency-Q characteristic.
Installation portion 811,821 further is fixed on recess 431,432 inside by the adhesive 61,62 that is filled in the recess 431,432.At this moment, if breach etc. is set,, therefore, can improve terminal 451,452 installation strength with respect to magnetic core 410 because adhesive 61,62 is being filled in the inside of breach at an end that inserts recess 431,432 inside.The coiling terminal 41,42 on installation portion 811,821, reel 2～3 the circle, preferably wait to engage by Pb-free solder.
Insulating resin shell body 407 integral body have covered magnetic core 410 and have wound the line 404.And at least a portion on insulating resin shell body 407 surfaces is roughened.Insulating resin shell body 407 can be made of epoxy resin etc.
Figure 29 is the cutaway view of the user mode of expression Figure 26～coil device shown in Figure 28.As shown in the figure, coil device under user mode, is used for the conductor fig 482 that bottom 813,823 welding 484 are had at substrate 481.Coil device is set to, and produces the gap between the surface of the lower surface of insulation crust body 407 and substrate 481.
Here, insulating resin shell body 407 integral body have covered magnetic core 410 and have wound the line 404, therefore, have the magnetic core 410 of physics fragility and 404 integral body that wind the line by 407 protections of insulating resin shell body, can realize good coil devices such as resistance to impact and vibration resistance.
In addition, the terminal 451,452 that connects coiling 404 ends is made of a slice metallic plate, and the one end is fixed on the terminal installation portion 811,821 of magnetic core 410.And at one end and have the 1st zigzag part 4F1 and the 2nd zigzag part 4F2 between the other end, the 1st zigzag part 4F1 and the 2nd zigzag part 4F2 are positioned at the outside of insulating resin shell body 407.
By this structure, as shown in figure 29, this coil device is installed under the situation on the substrate 481, can guarantee the elasticity of the 1st zigzag part 4F1 and the 2nd zigzag part 4F2, can absorb and impact and vibration.Therefore, can realize good coil devices such as resistance to impact and vibration resistance.
As mentioned above, insulating resin shell body 407 integral body have covered magnetic core 410 and have wound the line 404, therefore, can improve resistance to impact and vibration resistance etc., and still, insulating resin shell body 407 can hinder the heat radiation of coiling 404 heats that produce.The resistance value of coiling 404 has temperature dependency, and therefore, if do not promote heat radiation, characteristic will change.About magnetic core 410, also can see the characteristic variations that causes by temperature.
Therefore, as the means that address this problem, in the present embodiment, with at least a portion roughening on insulating resin shell body 407 surfaces.The typical example of roughening is so-called " texture processing ".
As mentioned above, during the surface roughening of insulating resin shell body 407, according to the character of the surface area of roughening, roughening and state etc., the surface area of insulating resin shell body 407 increases.Therefore, in fact enlarged area of dissipation, promoted heat radiation, therefore, the thermal stability of characteristic improves.
It is desirable to the whole surface roughening with insulating resin shell body 407, still, the part roughening also can.Method as roughening, the surface (inner surface) that can adopt the mould of the formation that will be used for insulating resin shell body 407 is by texture edm roughening to 3～9 μ m, and it is transferred to the method on insulating resin shell body 407 surfaces, perhaps, method of the surface roughening of the insulating resin shell body 407 that will form by sandblast, chemical treatment etc. etc.
And in the present embodiment, terminal 451,452 has the 1st zigzag part 4F1 and the 2nd zigzag part 4F2, therefore, by the elasticity of the 1st zigzag part 4F1 and the 2nd zigzag part 4F2, can absorb and impact and vibration.Therefore, can realize the coil device that resistance to impact and vibration resistance are good.
And in the present embodiment, pars intermedia 812,822 has hole 814,824 in face.Hole 814,824 at least in one direction, two relative inward flanges are curved.Describe with regard to this point below.
Pars intermedia the 812, the 822nd, the part relative with the end face of magnetic core 410, the plate face is in and by flowing through coiling 404 the magnetic flux quadrature that electric current produced or the relation of intersection.Therefore, become the obstruction part of the smooth circulation that hinders magnetic flux, may make frequency-inductance characteristic and frequency-Q characteristic variation.Therefore, in the present embodiment, hole 814,824 is set in the face of pars intermedia 812,822.
Because the existence in above-mentioned hole 814,824, become the sectional area little structure of the sectional area of pars intermedia 812,822 than installation portion 811,821 and bottom 813,823, therefore, the obstruction of magnetic flux flow is diminished, can blanketing frequency-inductance characteristic and frequency-Q characteristic variation.
As mentioned above, because hole 814,824 is set on pars intermedia 812,822, the mechanical strength of pars intermedia 812,822 reduces.The reduction of mechanical strength must be inhibited as far as possible.Otherwise, can not guarantee desired resistance to impact and vibration resistance in the purposes of environment for use strictnesses such as vehicle-mounted coil device.
As its method, among the present invention, the shape in hole 814,824 is that at least in one direction, two relative inward flanges are curved.Hole 814,824 is not limited to circular hole, also can be slotted hole, elliptical aperture etc.
According to the shape in above-mentioned hole, for example different with four jiaos of holes with acutangulate interior angle, can guarantee sufficient mechanical, fully satisfy desired resistance to impact and vibration resistance in the purposes of environment for use strictnesses such as vehicle-mounted coil device.At first sight, only just four jiaos of holes being become the simple technical finesse of circular hole, still, in the structure that limits, is the utmost point effective method that can bring into play maximum efficiency.
In addition, hole 814,824 preferably is arranged on from short transverse Z, from the 1st zigzag part 4F1 and the 2nd zigzag part 4F2 to bore edges apart from Z11 than the position big apart from Z12 from the 1st zigzag part 4F1 and the 2nd zigzag part 4F2 to bore edges, that is, hole 814,824 is set to be partial to the direction of installation portion 811,821.
Figure 30 is the cutaway view of the coil device of expression another embodiment of the present invention.Among the figure, and the represented suitable part of component part of Figure 26～Figure 28 is marked with same-sign and omits repeat specification.In this execution mode, magnetic core 410 has spacer portion 423 at pars intermedia, and 404 coiling winds the line in its both sides.That is, winding section 401 is divided into many parts.Coiling 404 is being divided on many parts the winding section 401 continuous reeling on same direction.The roughly whole surface roughening of insulating resin shell body 407.Under the situation of this execution mode, also have and action effect that Figure 26～execution mode shown in Figure 29 is equal to.
Described or each structure of being enlightened of the 5th mode of the present invention can obtain by the 1st mode of the present invention arbitrary structures described or that enlightened is combined.For example, about the coil that constitutes by the coiling 404 on the winding section 401 that is wound on magnetic core 410, can adopt the present invention's the 1st mode arbitrary structures, configuration, shape described or that enlightened to wait and obtain.Concrete example is as described below.
This coil has the 1st coil portion and the 2nd coil portion.The 1st coil portion and the 2nd coil portion are respectively to reel by winding the line in the prescribed limit of core length direction (coil wireline reel direction) to form in the coiling portion that is layered in magnetic core.And the border end face of the 2nd coil portion side of the 1st coil portion more tilts near the mode of the 2nd coil portion than outer circumferential side with all sides in it.
In addition, between each that put down in writing or enlighten in the 1st mode of the present invention, the 2nd mode, the 3rd mode, the 4th mode and the 5th mode constitutes, also there is combination arbitrarily.
With reference to preferred implementation content of the present invention is specified above, still, for a person skilled in the art, obviously can carry out various modes and change according to basic technological thought of the present invention and enlightenment.

Claims (21)

1. coil device, it comprises magnetic core and is arranged on coil around this magnetic core, it is characterized in that,
Above-mentioned coil has the 1st coil portion and the 2nd coil portion at least,
The border end face in above-mentioned the 2nd coil portion side of above-mentioned the 1st coil portion more tilts near the mode of the 2nd coil portion than outer circumferential side with all sides in it,
Above-mentioned coil device also comprises the insulation crust body that covers above-mentioned magnetic core and coil,
Above-mentioned magnetic core has the winding section of the coiling of the above-mentioned coil that is used to reel, and the pair of flanges portion as the terminal installation portion that forms at the two ends of this winding section,
The section with coil wireline reel direction quadrature of above-mentioned winding section has following shape: have outstanding part at a tetragonal relative opposite side, this outstanding part constitutes bulge.
2. coil device as claimed in claim 1 is characterized in that: the border end face in above-mentioned the 1st coil portion side of above-mentioned the 2nd coil portion, more tilt near the mode of the 1st coil portion than interior all sides with its outer circumferential side.
3. coil device as claimed in claim 1 is characterized in that:
Also comprise terminal,
Above-mentioned winding section is arranged on the pars intermedia of above-mentioned magnetic core,
Above-mentioned coil is made of the coiling that is wound on the above-mentioned winding section,
Above-mentioned terminal is the part that connects the end of above-mentioned coiling, is made of a slice metallic plate, comprises installation portion, terminal pars intermedia and bottom,
Above-mentioned installation portion, one end are fixed on the above-mentioned terminal installation portion of above-mentioned magnetic core,
Above-mentioned terminal pars intermedia, the one end is connected with the other end of above-mentioned installation portion by the 1st kink,
Above-mentioned bottom, the one end is connected with the other end of above-mentioned terminal pars intermedia by the 2nd kink, and relative with above-mentioned installation portion, and its other end is a free end,
And, in the face of above-mentioned terminal pars intermedia, have the hole, above-mentioned hole be arcuation at two relative inward flanges of direction at least.
4. coil device as claimed in claim 3 is characterized in that: above-mentioned hole is set to be partial to the direction of above-mentioned installation portion.
5. coil device as claimed in claim 3 is characterized in that: above-mentioned terminal from above-mentioned terminal pars intermedia to the above-mentioned bottom, have from above-mentioned terminal pars intermedia towards the extended widening portion of the direction width of above-mentioned bottom.
6. as each described coil device in the claim 3～5, it is characterized in that: above-mentioned hole is for circular.
7. as each described coil device in the claim 3～5, it is characterized in that: above-mentioned hole has minor axis and major diameter, and the direction of minor axis is consistent with direction from above-mentioned installation portion towards above-mentioned bottom.
8. as each described coil device in the claim 3～5, it is characterized in that: above-mentioned hole has minor axis and major diameter, and the direction of major diameter is consistent with direction from above-mentioned installation portion towards above-mentioned bottom.
9. coil device as claimed in claim 7 is characterized in that: above-mentioned hole has the shape of the arcuation part at its two ends by the straight line portion connection.
10. coil device as claimed in claim 7 is characterized in that: above-mentioned hole is an elliptical shape.
11. coil device as claimed in claim 1 is characterized in that: the bulge of above-mentioned winding section is made of curve at the section with coil wireline reel direction quadrature.
12., it is characterized in that as claim 1 or 11 described coil devices: form at least one coiling in above-mentioned winding section and keep out of the way portion,
The above-mentioned coiling portion of keeping out of the way is formed, and from the cross section of above-mentioned winding section, be connected with above-mentioned bulge, and the arcuation line that connects than the above-mentioned quadrangle bight with these bulge both sides caves in more to the inside.
13., it is characterized in that as claim 1 or 11 described coil devices:
Above-mentioned winding section has the par in the both sides of above-mentioned bulge,
Above-mentioned par is formed in the above-mentioned quadrangle another between face under the limit of facing mutually and the above-mentioned bulge.
14., it is characterized in that: passed through R processing or tapering processing between the face of this winding section side of the outer peripheral face of above-mentioned winding section and above-mentioned flange part as claim 1 or 11 described coil devices.
15., it is characterized in that: passed through R processing between the face of the above-mentioned winding section side of above-mentioned flange part and the outer peripheral face radially of above-mentioned flange part as claim 1 or 11 described coil devices.
16. coil device as claimed in claim 1 is characterized in that:
Extend at the length direction of above-mentioned magnetic core above-mentioned winding section,
Above-mentioned insulation crust body is made of the thermoplastic insulating resin,
Above-mentioned magnetic core and above-mentioned coil are positioned in the central portion of above-mentioned insulation crust body.
17. coil device as claimed in claim 16 is characterized in that: above-mentioned insulation crust body is made of liquid crystal polymer.
18. coil device as claimed in claim 1 is characterized in that:
Also comprise terminal,
Above-mentioned magnetic core is the clava that extends in a direction, and above-mentioned winding section is arranged on the pars intermedia of above-mentioned magnetic core,
Above-mentioned coil is made of the coiling that is wound on the above-mentioned winding section,
Above-mentioned insulation crust body covers the part of above-mentioned magnetic core, coiling and terminal installation portion,
Above-mentioned terminal is the part that connects the end of above-mentioned coiling, is made of a slice metallic plate, and an end is fixed on the above-mentioned terminal installation portion of above-mentioned magnetic core, has kink between an above-mentioned end and the other end, and above-mentioned bending part is in the outside of above-mentioned insulation crust body,
And at least a portion on the surface of above-mentioned insulation crust body is roughened.
19. as each described coil device in the claim 1～5,11,16～18, it is characterized in that: above-mentioned coil device is antenna, choke or inductor.
20. the manufacture method of a coil device, this coil device forms the coil that has the 1st coil portion and the 2nd coil portion at least around magnetic core, also comprise the insulation crust body that covers above-mentioned magnetic core and coil, above-mentioned magnetic core has the winding section of the coiling of the above-mentioned coil that is used to reel, and the pair of flanges portion that forms at the two ends of this winding section, it is characterized in that:
The section with coil wireline reel direction quadrature of above-mentioned winding section is formed following shape: have outstanding part at a tetragonal relative opposite side, this outstanding part constitutes bulge;
When forming above-mentioned the 1st coil portion, above-mentioned the 1st coil portion at the border of above-mentioned the 2nd coil sides end face, be formed with all sides in it more to tilt near the mode of the 2nd coil portion than outer circumferential side,
After forming above-mentioned the 1st coil portion, form above-mentioned the 2nd coil portion.
21. the manufacture method of coil device as claimed in claim 20 is characterized in that: the border end face in above-mentioned the 1st coil portion side of above-mentioned the 2nd coil portion is formed on the border end face that is positioned in the 1st coil portion.
CN2004800323568A 2003-11-05 2004-11-05 Coil device Active CN1875441B (en)

Applications Claiming Priority (11)

Application Number Priority Date Filing Date Title
JP2003375434A JP3846798B2 (en) 2003-11-05 2003-11-05 Coil device manufacturing method
JP375434/2003 2003-11-05
JP244278/2004 2004-08-24
JP244280/2004 2004-08-24
JP2004244279A JP2006066469A (en) 2004-08-24 2004-08-24 Coil device
JP244279/2004 2004-08-24
JP2004244278A JP4757466B2 (en) 2004-08-24 2004-08-24 Coil device and method of manufacturing coil device
JP2004244280A JP2006066470A (en) 2004-08-24 2004-08-24 Coil device
JP2004245723A JP4131515B2 (en) 2004-08-25 2004-08-25 Coil device
JP245723/2004 2004-08-25
PCT/JP2004/016425 WO2005045858A1 (en) 2003-11-05 2004-11-05 Coil device

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WO2009037978A1 (en) * 2007-09-19 2009-03-26 Murata Manufacturing Co., Ltd. Coil antenna, and its manufacturing method
CN105825997B (en) * 2015-01-22 2019-03-22 株式会社村田制作所 Coil component
JP5841686B1 (en) * 2015-05-12 2016-01-13 株式会社Maruwa Chip antenna
CN108462258A (en) * 2018-01-31 2018-08-28 上海安费诺永亿通讯电子有限公司 A kind of Wireless charging coil and wireless charging system
JP7146178B2 (en) * 2019-05-24 2022-10-04 株式会社オートネットワーク技術研究所 Reactor
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