JP2004111456A

JP2004111456A - Coil component

Info

Publication number: JP2004111456A
Application number: JP2002268539A
Authority: JP
Inventors: Toshiyuki Nakada; 中田　俊之; Tsuneji Imanishi; 今西　恒次; Hidetoshi Hiwatari; 樋渡　英敏; Hiroyuki Hamamoto; 浜本　洋行
Original assignee: Matsushita Electric Industrial Co Ltd
Current assignee: Panasonic Holdings Corp
Priority date: 2002-09-13
Filing date: 2002-09-13
Publication date: 2004-04-08
Anticipated expiration: 2022-09-13
Also published as: JP3707460B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil component which operates in a high-frequency range, is capable of dealing with a heavy current as it keeps an inductance and a very small DC resistance, and reduced in size. <P>SOLUTION: A plurality of rings 32 are formed of metal plates which are arranged in a two-dimensional manner, an angle which is made by center lines C each drawn between the centers (C) of the adjacent rings 32 connected together by connectors 31 is represented by (R1), an angle which is made by the center line (C) of the ring 32 connected to a holder 35 with an extension (E) which extends from the center (O) of the ring 32 to the end of the ring 32 where the terminal 35 is provided is represented by (R2), and (R1) and (R2) are so set as to satisfy the formula: (R1) + (R2) ≈ 180°. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、各種電子機器等に用いるコイル部品に関するものである。
【０００２】
【従来の技術】
以下、従来のコイル部品について図面を参照しながら説明する。
【０００３】
図１９は従来のコイル部品の分解斜視図である。
【０００４】
図１９において、従来のコイル部品は箔状導線からなる板状導線２１を渦巻き状に巻回して形成した空心コイル２２と、この空心コイル２２の両端に接続し、下方に突出させた端子２３と、空心コイル２２を載置する貫通孔を有した端子台２４と、この端子台２４の貫通孔に中央磁脚を挿入したＥ型磁芯２５と、このＥ型磁芯２５と組み合い閉磁路磁芯を形成するＩ型磁芯２６とを備えた構成である。
【０００５】
なお、この出願の発明に関する先行技術文献情報としては、例えば、特許文献１が知られている。
【０００６】
【特許文献１】
特開平９−２７５０２３号公報
【０００７】
【発明が解決しようとする課題】
近年、コンピュータ等に用いるコイル部品としては、作動領域が１ＭＨｚ程度の高周波領域で、１μＨ程度のインダクタンス値、数ｍΩの微小直流抵抗値を確保しつつ、１０数Ａ程度の大電流に対応したものが求められている。
【０００８】
上記従来の構成では、板状導線２１を渦巻き状に巻回して空心コイル２２を形成するとともに、Ｅ型磁芯２５とＩ型磁芯２６とを組み合わせることにより閉磁路磁芯を形成するので、大電流への対応が難しく、また小形化も図れないという問題点を有していた。
【０００９】
本発明は上記問題点を解決するもので、作動領域が高周波領域で、インダクタンス値および微小直流抵抗値を確保しつつ、大電流に対応でき、しかも小型化を図ったコイル部品を提供することを目的としている。
【００１０】
【課題を解決するための手段】
上記目的を達成するために本発明は以下の構成を有する。
【００１１】
本発明の請求項１記載の発明は、特に、平面状に配置した金属平板からなる複数のリング部において、リング連接部で連接された互いに隣接する前記リング部の中心を結ぶ中心線とによって形成される角度と、端子部と接続された前記リング部の中心線と前記リング部の中心から前記端子部を形成した端部に向かって延長した延長線との角度の和を１８０度にした構成である。
【００１２】
上記構成により、リング部は金属平板からなるので、高周波領域で作動し、インダクタンス値および微小直流抵抗値を確保しつつ、大電流に対応できる。
【００１３】
また、リング連接部で連接された互いに隣接するリング部の中心を結ぶ中心線とによって形成される角度と、端子部と接続されたリング部の中心線とリング部の中心から端子部を形成した端部に向かって延長した延長線との角度の和を１８０度にしているので、リング部を互いに上下に重ね合わせることが容易である。
【００１４】
特に、リング連接部を折曲してリング部を上下に重ね合わせたコイル部は、端子部を形成するリング部の円弧状部の端部をリング部の中心に対して相対向する位置に配置できるので、実装時における端子部の方向性等を考慮する必要がなく使い勝手がよい。
【００１５】
このとき、端子部を形成する端部を結んだ直線に対して略４５度の位置にリング連接部を配置できるので、実装面積に対する小型化を図ることができる。すなわち、このリング部を内接する方形状の実装箇所においては、実装箇所の角部にリング連接部を配置すれば実装面積が低減される。
【００１６】
さらに、外装部を角柱状にすれば、リング連接部を角部に配置することにより、外装部の外形寸法を小さくすることもでき小型化を図れる。
【００１７】
本発明の請求項２記載の発明は、請求項１記載の発明において、特に、端子部は、リング部の中心から前記端子部を形成した端部に向かって延長した延長線上に設けた構成である。
【００１８】
上記構成により、リング連接部を折曲してリング部を上下に重ね合わせたコイル部において、端子部はリング部の中心と端部との同一直線上に配置できるので、端子部はリング部の中心に対して互いに相対向する位置に配置され、実装時における端子部の方向性等を考慮する必要がなく使い勝手がよい。
【００１９】
本発明の請求項３記載の発明は、請求項１記載の発明において、特に、リング連接部には折曲用の溝部を設けた構成である。
【００２０】
上記構成により、折曲が容易に的確にできるので、リング部が撓んだりすることがない。また、連接部を１８０度曲げてもクラック発生を抑制できる。
【００２１】
本発明の請求項４記載の発明は、請求項３記載の発明において、特に、溝部は、リング連接部で連接された互いに隣接する前記リング部の中心を結ぶ中心線と垂直方向に設けた構成である。
【００２２】
上記構成により、的確にリング部を上下に重ね合わせることができる。
【００２３】
本発明の請求項５記載の発明は、請求項１記載の発明において、特に、リング部が互いに連接される前記リング部の円弧状部の端部には、切欠部に向かって突出部を延設した構成である。
【００２４】
上記構成により、リング部を上下に重ね合わせた際、上下方向から応力等が加わっても、切欠部を介して隣接する上下のリング部が変形し互いに接触したりすることがなく短絡を抑制できる。
【００２５】
本発明の請求項６記載の発明は、請求項１記載の発明において、特に、リング部の外径は略同等とした構成である。
【００２６】
上記構成により、インダクタンス値にバラツキが生じない。
【００２７】
本発明の請求項７記載の発明は、請求項１記載の発明において、特に、リング部の周縁部を面取りした構成である。
【００２８】
上記構成により、リング部を上下に重ね合わせた際、上下方向から応力等が加わっても、リング部の周縁部によって、隣接する上下のリング部が互いに傷つくことを抑制できる。
【００２９】
本発明の請求項８記載の発明は、請求項１記載の発明において、特に、平面状に配置した金属平板からなる複数のリング部において、前記リング部が互いに連接されない前記リング部の円弧状部の端部に形成した端子部は、段差を設けて形成しており、一方の端子部に設けた段差と他方の端子部に設けた段差とは、前記リング部を上下に重ね合わせた際、互いに近づき合う方向に向かって設けた構成である。
【００３０】
上記構成により、コイル部の高さ方向において、端子部は中央近傍に配置され、実装時における使い勝手がよい。外装部を加圧成形しても端子部への変形応力を抑制できる。
【００３１】
本発明の請求項９記載の発明は、請求項１記載の発明において、特に、リング部には、リング連接部を除いて、絶縁被膜層を設けた構成である。
【００３２】
上記構成により、上下に重ね合わせたリング部において、短絡を抑制できる。
【００３３】
特に、リング連接部を除いて、絶縁被膜層を設けているので、リング連接部を折曲した際に、絶縁被膜層が破れたりすることがなく、絶縁被膜層の破れに起因した特性劣化を抑制することができる。
【００３４】
本発明の請求項１０記載の発明は、請求項１記載の発明において、特に、リング部の円弧状部の一方の端部に形成したリング連接部の長さは、他方の端部に形成したリング連接部の長さよりも長くした構成である。
【００３５】
上記構成により、コイル部の外径が大きくなるのを抑制しつつ、平面状に配置した金属平板からなるリング部の重なり部分を低減でき、コイル部のインダクタンス値を確保しつつ、直流抵抗値を低減できる。
【００３６】
本発明の請求項１１記載の発明は、請求項１記載の発明において、特に、外装部の外形を角柱状とし、リング連接部を前記外装部の角部に配置するとともに、端子部を前記外装部の前記角部間の中央に配置した構成である。
【００３７】
上記構成により、外装部の外形寸法を小さくすることができ小型化を図ることができる。
【００３８】
特に、端子部を外装部の角部間の中央に配置しているので、外装部の角部からの距離が略等しくなり、外装部と端子部との間には、均等に応力が生じあうので外装部の割れや欠けが生じにくい。
【００３９】
本発明の請求項１２記載の発明は、請求項１記載の発明において、特に、平面状に配置した金属平板からなる複数のリング部は、エッチング又は打ち抜きにより形成した構成である。
【００４０】
上記構成により、リング部は容易に精度よく形成され、特性のバラツキを抑制できるとともに、生産性を向上できる。
【００４１】
本発明の請求項１３記載の発明は、請求項１記載の発明において、特に、外装部は、熱硬化性樹脂を含有した結合剤と磁性粉末とを前記熱硬化性樹脂が完全硬化しない非加熱状態で混合するとともに加圧成形した圧粉体を、前記コイル部を被覆するように再加圧成形するとともに前記熱硬化性樹脂が完全硬化するように加熱して成形しており、前記圧粉体には再加圧成形する際に前記圧粉体の形状がくずれる硬度の弱硬度部を設けるとともに、前記圧粉体を２個成形し、前記圧粉体の前記弱硬度部が前記コイル部を被覆するように前記圧粉体を再加圧成形した構成である。
【００４２】
上記構成により、通常、加圧成形には金型を用いて成形するが、圧粉体は固形物となるので、金型とコイル部との間で圧粉体の量が再加圧成形時に変動しにくく、外装部の被覆厚さがコイル部の周囲全体に渡って均一になりやすく、特性バラツキを抑制できるとともに、圧粉体自体によってコイル部を支持できるのでコイル部の位置決めが的確になり外装部の不良成形を防止できる。
【００４３】
特に、圧粉体には再加圧成形する際に圧粉体の形状がくずれる硬度の弱硬度部を設けて、この弱硬度部がコイル部を被覆するように圧粉体を再加圧成形しているので、圧粉体の弱硬度部はその形をくずしながら、くずれた圧粉体の弱硬度部がコイル部との間に隙間なく充填される。
【００４４】
さらに、磁気ギャップを減少させて磁気効率を向上することができる。
【００４５】
本発明の請求項１４記載の発明は、請求項１３記載の発明において、特に、圧粉体には再加圧成形する際に前記圧粉体の形状がくずれない硬度の強硬度部と前記再加圧成形する際に前記圧粉体の形状がくずれる硬度の弱硬度部とを設け、外装部は少なくとも一方の前記圧粉体の前記強硬度部がコイル部の一面を支持するようにした構成である。
【００４６】
上記構成により、圧粉体の硬度部はコイル部の一面を強固に支持するので、再加圧成形時にコイル部の位置ずれが生じにくく、コイル部の位置決めが的確にできる。
【００４７】
本発明の請求項１５記載の発明は、請求項１記載の発明において、特に、外装部は、磁性粉末を含有した圧粉磁心であって、コイル部の上方部分に対応する上面部と、前記コイル部の下方部分に対応する下面部と、前記コイル部の高さ部分に対応する中間部とを有し、前記コイル部を内包する内包厚寸法を前記コイル部の貫通孔の直径よりも小さくするとともに前記上面部の密度および前記下面部の密度を前記中間部の密度よりも大きくした構成である。
【００４８】
上記構成により、コイル部を内包する内包厚寸法（コイル部と外装部の表面との距離）をコイル部の貫通孔の直径よりも小さくなるまで、コイル部の上方部分に対応する外装部の上面部とコイル部の下方部分に対応する外装部の下面部とを薄く形成して全体として低背化を図っても、上面部の密度および下面部の密度を中間部の密度よりも大きくしているので、上面部および下面部において磁気飽和の発生を抑制することができる。
【００４９】
すなわち、コイル部の貫通孔の内部は、外装部の中間部に相当するが、この中間部の密度よりも外装部の上面部および下面部の密度の方が大きいので、貫通孔の内部を通過する磁束が、貫通孔の直径よりも小さい上面部および下面部を通過しても、上面部および下面部では中間部よりも密度が大きい分だけ透磁率を大きくすることができ、上面部および下面部において磁気飽和を発生させずに、低背化を図ることができるものである。
【００５０】
【発明の実施の形態】
以下、本発明の実施の形態を用いて、全請求項に記載の発明について図面を参照しながら説明する。
【００５１】
図１は本発明の一実施の形態におけるコイル部品の平面状に配置した金属平板からなる複数のリング部の平面図、図２は同コイル部品のコイル部の斜視図、図３は同コイル部品の斜視図、図４は同コイル部品の断面図である。
【００５２】
図１〜図４において、本発明の一実施の形態におけるコイル部３４は、互いにリング連接部３１で連接し平面状に配置した金属平板からなる複数のリング部３２を、リング連接部３１で折曲するとともに互いに上下に重ね合わせて形成した貫通孔３３を有するコイル部３４と、このコイル部３４に接続した端子部３５と、コイル部３４を被覆するとともに端子部３５を突出させた外装部３６とを備えている。
【００５３】
平面状に配置した金属平板からなる複数のリング部３２は、銅板を打ち抜いて形成したり、エッチングしたりして形成しており、それぞれのリング部３２は、その一部を切り欠いた切欠部３７を有した円弧状部３８からなる。
【００５４】
このリング部３２の円弧状部３８の端部にはリング部３２を互いに連接するリング連接部３１を形成するとともに、切欠部３７に向かって突出部３９を延設している。
【００５５】
また、このリング部３２は、図５および図６に示すように、外径を全て略同等とし、周縁部４０を面取りするとともに、リング連接部３１を除いて絶縁被膜層４１を設けている。
【００５６】
さらに、リング連接部３１は、リング連接部３１で連接された互いに隣接するリング部３２の中心（Ｏ）を結ぶ中心線（Ｃ）と垂直方向（Ｖ）に折曲用の溝部４２を設けている。このリング連接部３１の溝部４２は、図７（ａ）に示すように、断面がＶ字形状をし、この溝部４２を凹部５３の中に形成しており、図７（ｂ）に示すように折曲している。溝部４２の形状は図８に示すようなＵ字形状でもよいが、Ｖ字形状の方が望ましい。また、図８では凹部５３を形成していないが、形成する方が望ましい。
【００５７】
リング部３２が互いに連接されないリング部３２の円弧状部３８の端部には端子部３５を形成し、この端子部３５はリング部３２の中心（Ｏ）から端子部３５を形成した円弧状部３８の端部に向かって延長した延長線（Ｅ）上に形成している。
【００５８】
また、この端子部３５は、図４に示すように、段差３０を設けて形成しており、一方の端子部３５に設けた段差３０と他方の端子部３５に設けた段差３０とは、リング部３２を上下に重ね合わせた際、互いに近づき合う方向に向かって設けている。
【００５９】
このようなリング連接部３１と端子部３５とを有するリング部３２は、平面状に配置した金属平板からなる複数のリング部３２において、リング連接部３１で連接された互いに隣接するリング部３２の中心（Ｏ）を結ぶ中心線（Ｃ）とによって形成される角度（Ｒ１）と、端子部３５と接続されたリング部３２の中心線（Ｃ）とリング部３２の中心（Ｏ）から端子部３５を形成した端部に向かって延長した延長線（Ｅ）との角度（Ｒ２）の和を略１８０度になるようにしている。
【００６０】
外装部３６は、外形を角柱状とし、一方の端部に形成したリング連接部３１を外装部３６の角部４３に配置するとともに、他方の端部に形成したリング連接部３１を外装部３６の角部間４４に配置している。
【００６１】
上記構成のコイル部品の製造方法は、図９（ａ）〜（ｇ）に示すように、次の通りである。
【００６２】
第１に、貫通孔３３を有するコイル部３４を形成する（コイル部形成工程）（図９（ａ））。
【００６３】
このコイル部形成工程では、リング部形成工程と折曲工程とを有している。
【００６４】
まず、互いにリング連接部３１で連接し平面状に配置した金属平板からなる複数のリング部３２を、銅板から打ち抜いたり、銅板をエッチングしたりすることにより形成する（リング部形成工程）。
【００６５】
このリング部３２はその一部を切り欠いた切欠部３７を有する円弧状部３８とし、リング部３２の円弧状部３８の端部にリング連接部３１を、リング部３２が互いに連接されないリング部３２の円弧状部３８の端部に端子部３５を形成している。
【００６６】
リング連接部３１は、リング連接部３１で連接された互いに隣接するリング部３２の中心（Ｏ）を結ぶ中心線（Ｃ）と垂直方向（Ｖ）に折曲用の溝部４２を設け、一方の端部に形成したリング連接部３１の長さ（Ｔ１）を、他方の端部に形成したリング連接部３１の長さ（Ｔ２）よりも長くしている。
【００６７】
端子部３５は、リング部３２の中心（Ｏ）から端子部３５を形成した円弧状部３８の端部に向かって延長した延長線（Ｅ）上に形成している。また、段差３０を設けている。
【００６８】
このようなリング連接部３１と端子部３５とを有するリング部３２は、平面状に配置した金属平板からなる複数のリング部３２において、リング連接部３１で連接された互いに隣接するリング部３２の中心（Ｏ）を結ぶ中心線（Ｃ）とによって形成される角度（Ｒ１）と、端子部３５と接続されたリング部３２の中心線（Ｃ）とリング部３２の中心（Ｏ）から端子部３５を形成した端部に向かって延長した延長線（Ｅ）との角度（Ｒ２）の和を略１８０度になるようにしている。この際、（Ｒ１）は９６度、（Ｒ２）は４２度としている。
【００６９】
次に、このリング連接部３１で折曲するとともに互いのリング部３２を上下に重ね合わせる（折曲工程）（図９（ｂ）（ｃ））。
【００７０】
第２に、コイル部３４を外装部３６で被覆する（外装部形成工程）（図９（ｄ）〜（ｆ））。
【００７１】
この外装部形成工程では、圧粉成形工程と再加圧成形工程と熱硬化工程とを有している。
【００７２】
まず、熱硬化性樹脂を含有した結合剤と磁性粉末とを熱硬化性樹脂が完全硬化しないように非加熱状態で混合するとともに加圧成形して２個の圧粉体４５を成形する（圧粉体成形工程）。
【００７３】
この圧粉体４５は、その形状を背面部４６に中脚部４７と外脚部４８とを有したＥ字形状のポット型にし、背面部４６は再加圧成形時に圧粉体４５の形状がくずれない硬度の強硬度部にするとともに、中脚部４７および外脚部４８再加圧成形時に圧粉体４５の形状がくずれる硬度の弱硬度部になるように形成する。
【００７４】
この弱硬度部および強硬度部は、圧粉体４５の密度を小さくした部分（弱硬度部）と密度を大きくした部分（強硬度部）とにより形成しており、弱硬度部は数ｋｇ／ｃｍ^２の加圧により形状がくずれる硬度にしている。
【００７５】
ここで、圧粉体４５の形状がくずれる硬度とは、磁性粉末の粒子サイズでくずれることであり、圧粉体４５の形状がくずれない硬度の強硬度部において、ブロック的（団塊になって）にくずれた状態は、磁性粉末の粒子サイズでくずれてないので、くずれる硬度の範囲には含まないものとしている。
【００７６】
次に、一方の圧粉体４５の背面部４６をコイル部３４の一面（上面）に支持させ、他方の圧粉体４５の中脚部４７をコイル部３４の他面（下面）からコイル部３４の貫通孔３３に挿入する。
【００７７】
これらを内形状が角柱状の金型４９内に、リング連接部３１を金型４９の角部４３に配置するとともに、端子部３５を金型４９の角部間４４に配置するようにし、かつ、端子部３５を金型４９から突出するように組み込む。
【００７８】
２つの上下の金型４９の内、一方の金型４９により一方の圧粉体４５の弱硬度部の中脚部４７と外脚部４８とを押圧し、他方の金型４９により他方の圧粉体４５の強硬度部の背面部４６を押圧して、これらの圧粉体４５を再加圧成形する（再加圧成形工程）。
【００７９】
コイル部３４の一面側からは、圧粉体４５の中脚部４７および外脚部４８がくずれながら押圧され、コイル部３４の貫通孔３３の内壁面に対向した一方の圧粉体４５の背面部４６が、コイル部３４の貫通孔３３の中にブロック的に埋没するとともに、端子部３５に対向した圧粉体４５の背面部４６が、端子部３５に向かってブロック的に埋没する。
【００８０】
コイル部３４の他面側からは、他方の圧粉体４５の中脚部４７および外脚部４８がコイル部３４の貫通孔３３の中および端子部３５に向かってブロック的に埋没した一方の圧粉体４５の背面部４６と対向し、他方の圧粉体４５の中脚部４７および外脚部４８がくずれながら押圧される。
【００８１】
同時に、コイル部３４と圧粉体４５の背面部４６との隙間は、一方の圧粉体４５と他方の圧粉体４５のくずれた中脚部４７および外脚部４８によって充填される。
【００８２】
さらに、外装部３６は、コイル部３４を内包する内包厚寸法（Ｗ）をコイル部３４の貫通孔３３の直径よりも小さくし、コイル部３４の上方部分に対応する外装部３６の上面部５０と、コイル部３４の下方部分に対応する外装部３６の下面部５１と、コイル部３４の高さ部分に対応する外装部３６の中間部５２とにおいて、上面部５０の密度および下面部５１の密度を中間部５２の密度よりも大きくしている（上面部５０の密度および下面部５１の密度を５．０〜６．０ｇ／ｃｍ^３とし、中間部５２の密度をその８５％〜９８％の密度となるようにしている）。
【００８３】
特に、中間部５２は、コイル部３４の貫通孔３３内に対応する内側中間部５２ａと、コイル部３４の外周面の外側部分に対応する外側中間部５２ｂとにおいて、外側中間部５２ｂの密度を内側中間部５２ａの密度よりも大きくしている。
【００８４】
そして、熱硬化性樹脂が完全硬化するように加熱成形して外装部３６を成形する（熱硬化工程）。
【００８５】
最後に、外装部３６に沿って端子部３５を折曲する（図９（ｇ））。
【００８６】
上記構成のコイル部品は以下の作用を有する。
【００８７】
このコイル部３４のリング部３２は、金属平板からなるので、高周波領域で作動し、インダクタンス値および微小直流抵抗値を確保しつつ、大電流に対応できる。
【００８８】
平面状に配置した金属平板からなるこのリング部３２は、リング連接部３１で連接された互いに隣接するリング部３２の中心（Ｏ）を結ぶ中心線（Ｃ）とによって形成される角度（Ｒ１）と、端子部３５と接続されたリング部３２の中心線（Ｃ）とリング部３２の中心（Ｏ）から端子部３５を形成した端部に向かって延長した延長線（Ｅ）との角度（Ｒ２）の和を１８０度にしているので、リング部３２を互いに上下に重ね合わせることが容易である。
【００８９】
このリング部３２は、外径が略同等で、エッチング又は打ち抜きにより形成しているので、リング部３２が容易に精度よく形成され、特性のバラツキを抑制できる。特に、周縁部４０を面取りしているので、図１０（ａ）に示すように、絶縁被膜層４１がリング部３２の周囲に均等に形成でき、図１０（ｂ）に示すように、リング部３２を上下に重ね合わせた際、上下方向から応力等が加わっても、リング部３２の周縁部４０によって、隣接する上下のリング部３２が互いに傷つくこと（Ａ部分における被膜剥離）も抑制できる。面取りをしない場合は、図１１（ａ）に示すように、絶縁被膜層４１がリング部３２の周囲に均等に形成できず、図１１（ｂ）に示すように、リング部３２を上下に重ねた際、上下のリング部３２が互いに傷つきやすくなる（Ａ部分における被膜剥離）。
【００９０】
また、リング部３２には、リング連接部３１を除いて、絶縁被膜層４１を設けているので、上下に重ね合わせたリング部３２において、短絡を抑制できる。特に、リング連接部３１を除いて、絶縁被膜層４１を設けているので、リング連接部３１を折曲した際に、絶縁被膜層４１が破れたりすることがなく、絶縁被膜層４１の破れに起因した特性劣化を抑制することができる。図１２（ａ）〜（ｃ）に示すように、リング連接部３１を折曲した際、特に、図１２（ｃ）に示すように、折曲された部分において、絶縁被膜層４１が形成されていないので、この折曲に応じて（折曲すればリング連接部３１の内側と外側において膨張伸縮具合が異なる）、絶縁被膜層４１が伸縮させられたり膨張させられたりすることがなく、絶縁被膜層４１の破れを抑制できる。
【００９１】
さらに、リング部３２には、リング部３２が互いに連接されるリング部３２の円弧状部３８の端部に、切欠部３７に向かって突出部３９を延設しているので、リング部３２を上下に重ね合わせた際、上下方向から応力等が加わっても、切欠部３７を介して隣接する上下のリング部３２が変形し互いに接触したりすることがなく短絡を抑制できる。図１３及び図１４に示すように、突出部３９を延設しない場合は、図１４（ａ）に示すように、上下のリング部３２は変形し互いに接触するが、突出部３９を延設した場合は、図１３（ａ）に示すように、上下のリング部３２の変形が抑制され互いに接触しない。
【００９２】
このリング部３２のリング連接部３１は、端子部３５を形成する端部を結んだ直線に対して略４５度の位置にリング連接部３１を配置できるので、実装面積に対する小型化を図ることができる。すなわち、このリング部３２を内接する方形状の実装箇所においては、実装箇所の角部４３にリング連接部３１を配置すれば実装面積が低減される。
【００９３】
また、リング連接部３１には折曲用の溝部４２を設けているので折曲が容易に的確にでき、リング部３２が撓んだり、リング連接部３１にクラックが生じたりすることがない。特に、溝部４２は、リング連接部３１で連接された互いに隣接するリング部３２の中心（Ｏ）を結ぶ中心線（Ｃ）と垂直方向（Ｖ）に設けているので、的確にリング部３２を上下に重ね合わせることができる。
【００９４】
このコイル部３４の端子部３５は、平面状に配置した金属平板からなる複数のリング部３２において、段差３０を設けて形成しており、一方の端子部３５に設けた段差３０と他方の端子部３５に設けた段差３０とは、リング部３２を上下に重ね合わせた際、互いに近づき合う方向に向かって設けているので、コイル部３４の高さ方向において、端子部３５は中央近傍に配置され、実装時における使い勝手がよい。段差３０がない場合は、図１５に示すように、外装部３６の形成時にコイル部３４のゆがみが生じて、端子部３５が中央近傍に配置されにくい。
【００９５】
特に、リング連接部３１を折曲してリング部３２を上下に重ね合わせたコイル部３４において、端子部３５が形成されるリング部３２の円弧状部３８の端部をリング部３２の中心（Ｏ）に対して相対向する位置に配置できるので、実装時における端子部３５の方向性等を考慮する必要がなく使い勝手がよい。
【００９６】
この際、端子部３５は、リング部３２の中心（Ｏ）から円弧状部３８の端子部３５を形成する端部に向かって延長した延長線（Ｅ）上に設けることにより、端子部３５はリング部３２と円弧状部３８の端部との同一直線上に配置でき、端子部３５はリング部３２の中心（Ｏ）に対して互いに相対向する位置に的確に配置され、実装時における端子部３５の方向性等を考慮する必要がなく使い勝手がより向上する。
【００９７】
外装部３６は、その外形を角柱形状とし、一方の端部に形成したリング連接部３１を外装部３６の角部４３に配置するとともに、他方の端部に形成したリング連接部３１を外装部３６の角部間４４に配置しているので、外形寸法を小さくすることができ小型化を図ることができる。
【００９８】
また、外装部３６は、金型４９を用いて加圧成形するが、外装部３６を形成する圧粉体４５は固形物となるので、金型４９とコイル部３４との間で圧粉体４５の量が再加圧成形時に変動しにくく、外装部３６の被覆厚さがコイル部３４の周囲全体に渡って均一になりやすく、特性バラツキを抑制できるとともに、圧粉体４５自体によってコイル部３４を支持できるのでコイル部３４の位置決めが的確になり外装部３６の不良成形を防止できる。
【００９９】
この際、圧粉体４５の硬度部はコイル部３４の一面を強固に支持するので、再加圧成形時にコイル部３４の位置ずれが生じにくく、コイル部３４の位置決めが的確にできる。
【０１００】
特に、圧粉体４５には再加圧成形する際に圧粉体４５の形状がくずれる硬度の弱硬度部を設けて、この弱硬度部がコイル部３４を被覆するように圧粉体４５を再加圧成形しているので、圧粉体４５の弱硬度部はその形をくずしながら、くずれた圧粉体４５の弱硬度部がコイル部３４との間に隙間なく充填される。これにより、磁気ギャップを減少させて磁気効率も向上することができる。
【０１０１】
さらに、コイル部３４を内包する内包厚寸法（コイル部３４と外装部３６の表面との距離）をコイル部３４の貫通孔３３の直径よりも小さくなるまで、コイル部３４の上方部分に対応する外装部３６の上面部５０とコイル部３４の下方部分に対応する外装部３６の下面部５１とを薄く形成して全体として低背化を図っても、上面部５０の密度および下面部５１の密度を中間部５２の密度よりも大きくしているので、上面部５０および下面部５１において磁気飽和の発生を抑制することができる。
【０１０２】
すなわち、コイル部３４の貫通孔３３の内部は、外装部３６の中間部５２に相当するが、この中間部５２の密度よりも外装部３６の上面部５０および下面部５１の密度の方が大きいので、貫通孔３３の内部を通過する磁束が、貫通孔３３の直径よりも小さい上面部５０および下面部５１を通過しても、上面部５０および下面部５１では中間部５２よりも密度が大きい分だけ透磁率を大きくすることができ、上面部５０および下面部５１において磁気飽和を発生させずに、低背化を図ることができるものである。
【０１０３】
また、本発明の製造方法によれば、上記コイル部品を製造することができる。
【０１０４】
このように本発明の一実施の形態によれば、リング部３２は金属平板からなるので、高周波領域で作動し、インダクタンス値および微小直流抵抗値を確保しつつ、大電流に対応できる。
【０１０５】
本発明の一実施の形態では、リング部３２が３個のものを用いたが、図１６に示すように、リング部３２が４個のものを用いてもよい。
【０１０６】
図１７に示すように、この４つのリング部３２にはリング連接部３１を除いて絶縁被膜層４１を形成し、図１８に示すように、リング連接部３１を折曲してコイル部３４を形成する。
【０１０７】
この際、円弧状部３８の一方の端部に形成したリング連接部３１の長さ（Ｔ１）を、他方の端部に形成したリング連接部３１の長さ（Ｔ２）よりも長くすることにより、コイル部３４の外径が大きくなるのを抑制しつつ、平面状に配置した金属平板からなるリング部３２の重なり部分を低減でき、コイル部３４のインダクタンス値を確保しつつ、直流抵抗値を低減できる。
【０１０８】
【発明の効果】
以上のように本発明によれば、リング部は金属平板からなるので、高周波領域で作動し、インダクタンス値および微小直流抵抗値を確保しつつ、大電流に対応したコイル部品を提供することができる。
【０１０９】
また、リング連接部で連接された互いに隣接するリング部の中心を結ぶ中心線とによって形成される角度と、端子部と接続されたリング部の中心線とリング部の中心から端子部を形成した端部に向かって延長した延長線との角度の和を１８０度にしているので、リング部を互いに上下に重ね合わせることが容易である。
【０１１０】
特に、リング連接部を折曲してリング部を上下に重ね合わせたコイル部は、端子部を形成するリング部の円弧状部の端部をリング部の中心に対して相対向する位置に配置できるので、実装時における端子部の方向性等を考慮する必要がなく使い勝手がよい。
【０１１１】
このとき、端子部を形成する端部を結んだ直線に対して略４５度の位置にリング連接部を配置できるので、実装面積に対する小型化を図ることができる。すなわち、このリング部を内接する方形状の実装箇所においては、実装箇所の角部にリング連接部を配置すれば実装面積が低減される。
【０１１２】
さらに、外装部を角柱状にすれば、リング連接部を角部に配置することにより、外装部の外形寸法を小さくすることもでき小型化を図れる。
【図面の簡単な説明】
【図１】本発明の一実施の形態におけるコイル部品の平面状に配置した金属平板からなる複数のリング部の平面図
【図２】同コイル部品のコイル部の斜視図
【図３】同コイル部品の斜視図
【図４】同コイル部品の断面図
【図５】同コイル部品に用いる絶縁被膜層を施したリング部の平面図
【図６】同コイル部品に用いる絶縁被膜層を施したリング部の断面図
【図７】（ａ）リング部の折曲前のリング連接部近傍の断面図
（ｂ）リング部の折曲後のリング連接部近傍の断面図
【図８】他のリング部の折曲前のリング連接部近傍の断面図
【図９】同コイル部品の製造工程図
【図１０】（ａ）絶縁被膜層を施した面取り加工済の同コイル部品のリング部の断面図
（ｂ）同リング部を重ね合わせた際のリング部の外周縁近傍の断面図
【図１１】（ａ）絶縁被膜層を施した面取り未加工のリング部の断面図
（ｂ）同リング部を重ね合わせた際のリング部の外周縁近傍の断面図
【図１２】同コイル部品の製造工程におけるリング部の折曲工程を示す工程図
【図１３】（ａ）突出部を延設したリング部の外装部形成後の変形具合を示す断面図
（ｂ）同リング部の平面図
【図１４】（ａ）突出部を非延設したリング部の外装部形成後の変形具合を示す断面図
（ｂ）同リング部の平面図
【図１５】段差がない場合における同コイル部品の断面図
【図１６】他の実施の形態におけるコイル部品の平面状に配置した金属平板からなる４つのリング部の平面図
【図１７】絶縁被膜層を施した同リング部の平面図
【図１８】同リング部の折曲工程を示す工程図
【図１９】従来のコイル部品の分解斜視図
【符号の説明】
３０　段差
３１　リング連接部
３２　リング部
３３　貫通孔
３４　コイル部
３５　端子部
３６　外装部
３７　切欠部
３８　円弧状部
３９　突出部
４０　周縁部
４１　絶縁被膜層
４２　溝部
４３　角部
４４　角部間
４５　圧粉体
４６　背面部
４７　中脚部
４８　外脚部
４９　金型
５０　上面部
５１　下面部
５２　中間部
５２ａ　内側中間部
５２ｂ　外側中間部
５３　凹部[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a coil component used for various electronic devices and the like.
[0002]
[Prior art]
Hereinafter, a conventional coil component will be described with reference to the drawings.
[0003]
FIG. 19 is an exploded perspective view of a conventional coil component.
[0004]
In FIG. 19, the conventional coil component includes an air-core coil 22 formed by spirally winding a plate-shaped wire 21 made of a foil-shaped wire, and terminals 23 connected to both ends of the air-core coil 22 and protruding downward. , A terminal block 24 having a through hole for mounting the air-core coil 22, an E-shaped magnetic core 25 having a center magnetic leg inserted into the through-hole of the terminal block 24, and a closed magnetic circuit magnetic field combined with the E-shaped magnetic core 25. And an I-shaped magnetic core 26 forming a core.
[0005]
As prior art document information related to the invention of this application, for example, Patent Document 1 is known.
[0006]
[Patent Document 1]
JP-A-9-275023
[0007]
[Problems to be solved by the invention]
In recent years, as coil components used in computers and the like, those capable of handling a large current of about 10 several A while securing an inductance value of about 1 μH and a small DC resistance value of several mΩ in a high frequency area of about 1 MHz in an operation area. Is required.
[0008]
In the above-described conventional configuration, the plate-shaped conductor 21 is spirally wound to form the air-core coil 22, and the E-type magnetic core 25 and the I-type magnetic core 26 are combined to form a closed magnetic circuit core. There was a problem that it was difficult to cope with a large current, and that miniaturization could not be achieved.
[0009]
The present invention has been made to solve the above-mentioned problems, and provides a coil component capable of coping with a large current while ensuring an inductance value and a small DC resistance value in an operation region in a high-frequency region, and further reducing the size. The purpose is.
[0010]
[Means for Solving the Problems]
In order to achieve the above object, the present invention has the following configuration.
[0011]
The invention according to claim 1 of the present invention is particularly formed by a plurality of ring portions made of a flat metal plate and a center line connecting centers of adjacent ring portions connected by a ring connecting portion. And the sum of the angle between the center line of the ring portion connected to the terminal portion and the extension line extending from the center of the ring portion toward the end where the terminal portion is formed is 180 degrees. It is.
[0012]
According to the above configuration, since the ring portion is formed of a metal flat plate, it operates in a high frequency region, and can cope with a large current while securing an inductance value and a minute DC resistance value.
[0013]
Further, the terminal portion is formed from the angle formed by the center line connecting the centers of the adjacent ring portions connected to each other at the ring connecting portion, and the center line of the ring portion connected to the terminal portion and the center of the ring portion. Since the sum of the angles with the extension line extending toward the end is 180 degrees, the ring portions can be easily overlapped with each other up and down.
[0014]
In particular, the coil portion in which the ring connecting portion is bent and the ring portion is overlapped with the upper and lower portions is disposed at a position where the end of the arc-shaped portion of the ring portion forming the terminal portion is opposed to the center of the ring portion. Since it is possible, it is not necessary to consider the directionality of the terminal portion at the time of mounting, and the usability is good.
[0015]
At this time, the ring connecting portion can be arranged at a position substantially 45 degrees with respect to a straight line connecting the ends forming the terminal portions, so that the mounting area can be reduced. That is, in a rectangular mounting portion in which the ring portion is inscribed, the mounting area can be reduced by disposing the ring connecting portion at a corner of the mounting portion.
[0016]
Furthermore, if the exterior portion is formed in a prismatic shape, the outer dimensions of the exterior portion can be reduced by arranging the ring connecting portion at the corner portion, thereby achieving downsizing.
[0017]
The invention according to claim 2 of the present invention, in the invention according to claim 1, has a configuration in which the terminal portion is provided on an extension extending from the center of the ring portion toward the end portion where the terminal portion is formed. is there.
[0018]
According to the above configuration, in the coil portion in which the ring connecting portion is bent and the ring portion is vertically overlapped, the terminal portion can be arranged on the same straight line between the center and the end portion of the ring portion. They are arranged at positions facing each other with respect to the center, so that it is not necessary to consider the directionality of the terminal portion at the time of mounting, and the device is easy to use.
[0019]
According to a third aspect of the present invention, in the first aspect of the present invention, the ring connecting portion is provided with a groove for bending.
[0020]
According to the above configuration, bending can be easily and accurately performed, so that the ring portion does not bend. Further, even if the connecting portion is bent by 180 degrees, the occurrence of cracks can be suppressed.
[0021]
According to a fourth aspect of the present invention, in the third aspect of the invention, in particular, the groove is provided in a direction perpendicular to a center line connecting centers of the adjacent ring portions connected by a ring connecting portion. It is.
[0022]
According to the above configuration, the ring portions can be accurately overlapped with each other vertically.
[0023]
According to a fifth aspect of the present invention, in the invention according to the first aspect, in particular, a protruding portion extends toward a notch at an end of an arc-shaped portion of the ring portion to which the ring portion is connected. It is a configuration provided.
[0024]
With the above configuration, when the ring portions are vertically stacked, even if stress or the like is applied from the vertical direction, the adjacent upper and lower ring portions are not deformed through the cutout portions and do not contact with each other, thereby suppressing a short circuit. .
[0025]
The invention according to claim 6 of the present invention has a configuration in which, in the invention according to claim 1, in particular, the outer diameter of the ring portion is substantially equal.
[0026]
With the above configuration, there is no variation in the inductance value.
[0027]
The invention according to a seventh aspect of the present invention is the invention according to the first aspect, in which the peripheral portion of the ring portion is particularly chamfered.
[0028]
With the above configuration, when the ring portions are vertically overlapped, even if stress or the like is applied in the vertical direction, the adjacent upper and lower ring portions can be prevented from being damaged by the peripheral edge portion of the ring portion.
[0029]
The invention according to an eighth aspect of the present invention is the invention according to the first aspect, in particular, in a plurality of ring portions formed of a flat metal plate, the ring portions are not connected to each other. The terminal portion formed at the end of is formed by providing a step, the step provided in one terminal and the step provided in the other terminal portion, when the ring portion is vertically overlapped, This is a configuration provided in a direction approaching each other.
[0030]
According to the above configuration, the terminal portion is arranged near the center in the height direction of the coil portion, so that the usability at the time of mounting is good. Deformation stress on the terminal part can be suppressed even when the exterior part is pressure-formed.
[0031]
According to a ninth aspect of the present invention, in the first aspect of the present invention, the ring portion is provided with an insulating coating layer except for a ring connecting portion.
[0032]
With the above-described configuration, a short circuit can be suppressed in the ring portion that is vertically overlapped.
[0033]
In particular, since the insulating coating layer is provided except for the ring connecting portion, when the ring connecting portion is bent, the insulating coating layer is not broken, and the characteristic deterioration caused by the breaking of the insulating coating layer is prevented. Can be suppressed.
[0034]
According to a tenth aspect of the present invention, in the invention according to the first aspect, in particular, the length of the ring connecting portion formed at one end of the arc-shaped portion of the ring portion is formed at the other end. The configuration is longer than the length of the ring connecting portion.
[0035]
With the above configuration, it is possible to reduce the overlapping portion of the ring portion formed of a flat metal plate while suppressing the outer diameter of the coil portion from increasing, and to reduce the DC resistance value while securing the inductance value of the coil portion. Can be reduced.
[0036]
According to an eleventh aspect of the present invention, in the invention according to the first aspect, in particular, the outer shape of the outer portion has a prismatic shape, a ring connecting portion is disposed at a corner of the outer portion, and the terminal portion is the outer shape. It is a configuration arranged at the center between the corners of the portion.
[0037]
According to the above configuration, the outer dimensions of the exterior part can be reduced, and the size can be reduced.
[0038]
In particular, since the terminal portion is disposed at the center between the corner portions of the exterior portion, the distance from the corner portion of the exterior portion becomes substantially equal, and stress is evenly generated between the exterior portion and the terminal portion. Therefore, cracking and chipping of the exterior part are not easily generated.
[0039]
According to a twelfth aspect of the present invention, in the first aspect of the present invention, the plurality of ring portions formed of flat metal plates are formed by etching or punching.
[0040]
According to the above configuration, the ring portion can be easily formed with high accuracy, the variation in characteristics can be suppressed, and the productivity can be improved.
[0041]
According to a thirteenth aspect of the present invention, in the first aspect of the present invention, in particular, the exterior part includes a non-heated binder in which the thermosetting resin is not completely cured by bonding the binder containing the thermosetting resin and the magnetic powder. The green compact mixed and press-molded in a state is re-pressed and molded so as to cover the coil portion, and is heated and molded so that the thermosetting resin is completely cured. The body is provided with a weakly hardened portion having a hardness at which the shape of the green compact is deformed when the green compact is re-pressed, and two compacts are formed, and the weakly hardened portion of the green compact is formed by the coil portion. Is formed by re-pressing the green compact so as to cover the surface.
[0042]
According to the above configuration, usually, a mold is used for pressure molding, but since the compact is a solid, the amount of the compact between the mold and the coil portion is reduced during re-press molding. It is hard to fluctuate, and the coating thickness of the exterior part is easy to be uniform over the entire circumference of the coil part, and it is possible to suppress variation in characteristics and to support the coil part by the green compact itself, so positioning of the coil part is accurate Poor molding of the exterior part can be prevented.
[0043]
In particular, the green compact is provided with a weakly hardened portion having such a hardness that the shape of the green compact is deformed during the re-pressing, and the green compact is re-pressed so that the weakly hardened portion covers the coil portion. As a result, the weakly hardened portion of the green compact loses its shape, and the weakly hardened portion of the green compact is filled with no gap between itself and the coil portion.
[0044]
Further, the magnetic efficiency can be improved by reducing the magnetic gap.
[0045]
The invention according to claim 14 of the present invention is characterized in that, in the invention according to claim 13, in particular, when the green compact is subjected to re-press molding, the strong hard portion having a hardness such that the shape of the green compact is not lost. A structure in which a shape of the green compact is weakened when the green compact is pressed, and the exterior portion has at least one of the high hardness portions of the green compact supporting one surface of the coil portion. It is.
[0046]
According to the above configuration, since the hardness portion of the green compact firmly supports one surface of the coil portion, the coil portion is less likely to be displaced at the time of re-press molding, and the coil portion can be accurately positioned.
[0047]
In the invention according to claim 15 of the present invention, in the invention according to claim 1, in particular, the exterior part is a dust core containing magnetic powder, and an upper surface part corresponding to an upper part of a coil part; It has a lower surface portion corresponding to a lower portion of the coil portion, and an intermediate portion corresponding to a height portion of the coil portion, and has a thickness dimension including the coil portion smaller than a diameter of a through hole of the coil portion. And the density of the upper surface portion and the density of the lower surface portion are higher than the density of the intermediate portion.
[0048]
With the above configuration, the upper surface of the outer portion corresponding to the upper portion of the coil portion until the thickness of the inner portion enclosing the coil portion (the distance between the coil portion and the surface of the outer portion) becomes smaller than the diameter of the through hole of the coil portion. Even if the lower part is formed by thinning the lower part of the exterior part corresponding to the lower part of the coil part and the lower part, the density of the upper part and the density of the lower part are made larger than the density of the middle part. Therefore, occurrence of magnetic saturation can be suppressed in the upper surface portion and the lower surface portion.
[0049]
That is, the inside of the through hole of the coil portion corresponds to the middle portion of the exterior portion, but since the density of the upper surface portion and the lower surface portion of the exterior portion is higher than the density of this middle portion, the inside of the through hole passes through the inside of the through hole. Even if the magnetic flux that passes through the upper and lower portions that are smaller than the diameter of the through hole, the magnetic permeability can be increased by an amount corresponding to the density higher at the upper and lower portions than at the intermediate portion. The height can be reduced without causing magnetic saturation in the portion.
[0050]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0051]
FIG. 1 is a plan view of a plurality of ring portions made of a metal flat plate arranged in a plane of a coil component according to an embodiment of the present invention, FIG. 2 is a perspective view of the coil portion of the coil component, and FIG. FIG. 4 is a sectional view of the coil component.
[0052]
1 to 4, a coil portion 34 according to an embodiment of the present invention is formed by folding a plurality of ring portions 32 formed of a flat metal plate connected to each other by a ring connection portion 31 and arranged in a planar shape at the ring connection portion 31. A coil portion 34 having a through-hole 33 formed by being bent and superimposed on each other, a terminal portion 35 connected to the coil portion 34, and an exterior portion 36 covering the coil portion 34 and projecting the terminal portion 35 And
[0053]
The plurality of ring portions 32 made of a flat metal plate are formed by stamping or etching a copper plate, and each ring portion 32 is formed by cutting out a part thereof. It comprises an arc-shaped portion 38 having 37.
[0054]
A ring connecting portion 31 for connecting the ring portions 32 to each other is formed at an end of the arc-shaped portion 38 of the ring portion 32, and a projecting portion 39 extends toward the notch 37.
[0055]
As shown in FIGS. 5 and 6, the ring portion 32 has substantially the same outer diameter, has a chamfered peripheral portion 40, and is provided with an insulating coating layer 41 except for the ring connecting portion 31.
[0056]
Further, the ring connecting portion 31 is provided with a groove 42 for bending in a direction (V) perpendicular to a center line (C) connecting the centers (O) of the adjacent ring portions 32 connected by the ring connecting portion 31. I have. The groove 42 of the ring connecting portion 31 has a V-shaped cross section as shown in FIG. 7A, and the groove 42 is formed in the concave portion 53, as shown in FIG. 7B. It is bent. The shape of the groove 42 may be a U-shape as shown in FIG. 8, but a V-shape is more preferable. Although the concave portion 53 is not formed in FIG. 8, it is preferable to form it.
[0057]
A terminal portion 35 is formed at an end of an arc-shaped portion 38 of the ring portion 32 where the ring portion 32 is not connected to each other, and the terminal portion 35 is an arc-shaped portion formed by forming the terminal portion 35 from the center (O) of the ring portion 32. It is formed on an extension line (E) extending toward the end of 38.
[0058]
As shown in FIG. 4, the terminal portion 35 is formed by providing a step 30. The step 30 provided on one terminal portion 35 and the step 30 provided on the other terminal portion 35 are formed by a ring. When the parts 32 are vertically overlapped, they are provided in directions approaching each other.
[0059]
The ring portion 32 having such a ring connecting portion 31 and the terminal portion 35 is formed of a plurality of ring portions 32 formed of a flat metal plate and formed of a plurality of ring portions 32 which are adjacent to each other and connected by the ring connecting portion 31. An angle (R1) formed by a center line (C) connecting the centers (O) and a terminal portion from the center line (C) of the ring portion 32 connected to the terminal portion 35 and the center (O) of the ring portion 32 The sum of the angle (R2) with the extension (E) extending toward the end where 35 is formed is set to be approximately 180 degrees.
[0060]
The exterior part 36 has a prismatic outer shape, a ring connecting part 31 formed at one end is arranged at a corner 43 of the exterior part 36, and the ring connecting part 31 formed at the other end is connected to the exterior part 36. Are arranged between the corners 44 of the.
[0061]
As shown in FIGS. 9A to 9G, the method for manufacturing the coil component having the above configuration is as follows.
[0062]
First, a coil part 34 having a through hole 33 is formed (coil part forming step) (FIG. 9A).
[0063]
The coil part forming step includes a ring part forming step and a bending step.
[0064]
First, a plurality of ring portions 32 formed of a flat metal plate connected to each other at a ring connection portion 31 and formed in a planar shape are formed by punching out a copper plate or etching a copper plate (ring portion forming step).
[0065]
The ring portion 32 is formed into an arc-shaped portion 38 having a cut-out portion 37 in which a part is cut out. A ring connecting portion 31 is provided at an end of the arc-shaped portion 38 of the ring portion 32, and a ring portion where the ring portion 32 is not connected to each other. Terminal portions 35 are formed at the ends of the 32 arcuate portions 38.
[0066]
The ring connecting portion 31 is provided with a groove 42 for bending in a direction (V) perpendicular to a center line (C) connecting the centers (O) of the adjacent ring portions 32 connected by the ring connecting portion 31. The length (T1) of the ring connecting portion 31 formed at the end is longer than the length (T2) of the ring connecting portion 31 formed at the other end.
[0067]
The terminal portion 35 is formed on an extension (E) extending from the center (O) of the ring portion 32 toward the end of the arc-shaped portion 38 on which the terminal portion 35 is formed. In addition, a step 30 is provided.
[0068]
The ring portion 32 having such a ring connecting portion 31 and the terminal portion 35 is formed of a plurality of ring portions 32 formed of a flat metal plate and formed of a plurality of ring portions 32 which are adjacent to each other and connected by the ring connecting portion 31. An angle (R1) formed by a center line (C) connecting the centers (O) and a terminal portion from the center line (C) of the ring portion 32 connected to the terminal portion 35 and the center (O) of the ring portion 32 The sum of the angle (R2) with the extension (E) extending toward the end where 35 is formed is set to be approximately 180 degrees. At this time, (R1) is 96 degrees, and (R2) is 42 degrees.
[0069]
Next, it bends at this ring connection part 31, and mutually overlaps the ring part 32 up and down (bending process) (FIGS. 9B and 9C).
[0070]
Second, the coil part 34 is covered with the exterior part 36 (exterior part formation step) (FIGS. 9D to 9F).
[0071]
The exterior part forming step includes a powder molding step, a re-pressing step, and a thermosetting step.
[0072]
First, a binder containing a thermosetting resin and a magnetic powder are mixed in a non-heated state so that the thermosetting resin is not completely cured, and are molded under pressure to form two compacts 45 (compacting). Powder molding process).
[0073]
The green compact 45 has an E-shaped pot shape having a middle leg portion 47 and an outer leg portion 48 on a rear portion 46, and the rear portion 46 has the shape of the green compact 45 at the time of re-press molding. It is formed so as to be a hard portion having a hardness that does not collapse, and a weak portion having a hardness such that the shape of the green compact 45 is deformed at the time of re-press molding of the middle leg portion 47 and the outer leg portion 48.
[0074]
The weakly hardened portion and the hardly hardened portion are formed by a portion where the density of the green compact 45 is reduced (weakly hardened portion) and a portion where the density is increased (strongly hardened portion). cm ² The hardness is such that the shape is broken by the pressure of.
[0075]
Here, the hardness at which the shape of the green compact 45 is broken means that the shape of the green powder is broken by the particle size. Since the broken state is not broken by the particle size of the magnetic powder, it is not included in the range of the broken hardness.
[0076]
Next, the back portion 46 of one compact 45 is supported on one surface (upper surface) of the coil portion 34, and the middle leg 47 of the other compact 45 is moved from the other surface (lower surface) of the coil portion 34 to the coil portion. 34 into the through hole 33.
[0077]
These are arranged in a mold 49 having a prismatic inner shape, the ring connecting portion 31 is arranged at the corner 43 of the mold 49, and the terminal portion 35 is arranged between the corners 44 of the mold 49, and The terminal 35 is assembled so as to protrude from the mold 49.
[0078]
Of the two upper and lower molds 49, one of the molds 49 presses the middle leg 47 and the outer leg 48 of the low hardness part of one green compact 45, and the other mold 49 presses the other. The back surface 46 of the hard part of the powder 45 is pressed to re-press these compacts 45 (re-press molding step).
[0079]
From the one surface side of the coil portion 34, the middle leg portion 47 and the outer leg portion 48 of the compact 45 are pressed while being distorted, and the back surface of one compact 45 facing the inner wall surface of the through hole 33 of the coil portion 34 The part 46 is buried in the through hole 33 of the coil part 34 in a block manner, and the back part 46 of the green compact 45 facing the terminal part 35 is buried in a block toward the terminal part 35.
[0080]
From the other surface side of the coil portion 34, one of the middle leg portion 47 and the outer leg portion 48 of the other compact 45 is buried in a block shape toward the through hole 33 of the coil portion 34 and toward the terminal portion 35. The middle leg portion 47 and the outer leg portion 48 of the other compact 45 oppose the back surface portion 46 of the compact 45 and are pressed while being collapsed.
[0081]
At the same time, the gap between the coil portion 34 and the back surface portion 46 of the green compact 45 is filled with the deformed middle leg portion 47 and outer leg portion 48 of one green compact 45 and the other green compact 45.
[0082]
Further, the exterior portion 36 has a thickness (W) including the coil portion 34 smaller than the diameter of the through hole 33 of the coil portion 34, and the upper surface portion 50 of the exterior portion 36 corresponding to the upper portion of the coil portion 34. And the lower part 51 of the outer part 36 corresponding to the lower part of the coil part 34 and the intermediate part 52 of the outer part 36 corresponding to the height part of the coil part 34, the density of the upper part 50 and the lower part 51. The density is set to be higher than the density of the intermediate portion 52 (the density of the upper surface portion 50 and the density of the lower surface portion 51 are 5.0 to 6.0 g / cm). ³ The density of the intermediate portion 52 is set to be 85% to 98% of the density).
[0083]
In particular, the intermediate portion 52 has a lower density of the outer intermediate portion 52b in the inner intermediate portion 52a corresponding to the inside of the through hole 33 of the coil portion 34 and the outer intermediate portion 52b corresponding to the outer portion of the outer peripheral surface of the coil portion 34. The density is larger than the density of the inner intermediate portion 52a.
[0084]
Then, the exterior part 36 is molded by heat molding so that the thermosetting resin is completely cured (thermosetting step).
[0085]
Finally, the terminal 35 is bent along the exterior 36 (FIG. 9G).
[0086]
The coil component having the above configuration has the following operation.
[0087]
Since the ring portion 32 of the coil portion 34 is made of a metal flat plate, it operates in a high-frequency region, and can handle a large current while securing an inductance value and a small DC resistance value.
[0088]
This ring portion 32 made of a flat metal plate is formed at an angle (R1) formed by a center line (C) connecting centers (O) of adjacent ring portions 32 connected to each other by a ring connecting portion 31. And the angle between the center line (C) of the ring portion 32 connected to the terminal portion 35 and the extension line (E) extending from the center (O) of the ring portion 32 toward the end where the terminal portion 35 is formed. Since the sum of R2) is 180 degrees, the ring portions 32 can be easily overlapped with each other vertically.
[0089]
Since the ring portion 32 has substantially the same outer diameter and is formed by etching or punching, the ring portion 32 is easily and accurately formed, and variation in characteristics can be suppressed. In particular, since the peripheral portion 40 is chamfered, the insulating coating layer 41 can be uniformly formed around the ring portion 32 as shown in FIG. 10A, and the ring portion 32 can be formed as shown in FIG. When the upper and lower parts 32 are vertically overlapped with each other, even if a stress or the like is applied from the upper and lower sides, the adjacent upper and lower ring parts 32 can be prevented from being mutually damaged by the peripheral part 40 of the ring part 32 (peeling of the coating at the portion A). When chamfering is not performed, the insulating coating layer 41 cannot be formed uniformly around the ring portion 32 as shown in FIG. 11A, and the ring portions 32 are vertically stacked as shown in FIG. 11B. In this case, the upper and lower ring portions 32 are easily damaged by each other (the film peeling at the portion A).
[0090]
In addition, since the insulating coating layer 41 is provided on the ring portion 32 except for the ring connecting portion 31, a short circuit can be suppressed in the ring portion 32 which is vertically overlapped. In particular, since the insulating coating layer 41 is provided except for the ring connecting portion 31, the insulating coating layer 41 is not broken when the ring connecting portion 31 is bent, and the insulating coating layer 41 is broken. It is possible to suppress the characteristic deterioration caused. As shown in FIGS. 12A to 12C, when the ring connecting portion 31 is bent, particularly, as shown in FIG. 12C, the insulating coating layer 41 is formed in the bent portion. In accordance with this bending (the degree of expansion and contraction is different between the inside and outside of the ring connecting portion 31 if bent), the insulating coating layer 41 is not expanded or contracted, and Breakage of the coating layer 41 can be suppressed.
[0091]
Further, the ring portion 32 has a protruding portion 39 extending toward the notch 37 at the end of the arc-shaped portion 38 of the ring portion 32 to which the ring portion 32 is connected. When they are vertically overlapped, even if a stress or the like is applied in the vertical direction, the adjacent upper and lower ring portions 32 are not deformed via the cutout portions 37 and do not come into contact with each other, so that a short circuit can be suppressed. As shown in FIGS. 13 and 14, when the protrusion 39 is not extended, as shown in FIG. 14A, the upper and lower ring portions 32 are deformed and come into contact with each other, but the protrusion 39 is extended. In this case, as shown in FIG. 13A, the deformation of the upper and lower ring portions 32 is suppressed and they do not contact each other.
[0092]
In the ring connecting portion 31 of the ring portion 32, the ring connecting portion 31 can be arranged at a position of approximately 45 degrees with respect to a straight line connecting the ends forming the terminal portions 35, so that the size of the mounting area can be reduced. it can. In other words, in a rectangular mounting portion that inscribes the ring portion 32, the mounting area can be reduced by disposing the ring connecting portion 31 at the corner 43 of the mounting portion.
[0093]
Further, since the ring connecting portion 31 is provided with the bending groove portion 42, the bending can be easily and accurately performed, and the ring portion 32 does not bend and the ring connecting portion 31 does not crack. In particular, since the groove portion 42 is provided in a direction (V) perpendicular to a center line (C) connecting the centers (O) of the adjacent ring portions 32 connected by the ring connecting portion 31, the ring portion 32 is accurately formed. Can be overlapped vertically.
[0094]
The terminal portion 35 of the coil portion 34 is formed by providing a step 30 in a plurality of ring portions 32 formed of a flat metal plate, and the step 30 provided in one terminal portion 35 and the other terminal are provided. The step 30 provided in the portion 35 is provided in a direction approaching each other when the ring portions 32 are vertically overlapped, so that the terminal portion 35 is disposed near the center in the height direction of the coil portion 34. This is convenient for mounting. When there is no step 30, as shown in FIG. 15, the coil portion 34 is distorted when the exterior portion 36 is formed, and the terminal portion 35 is difficult to be disposed near the center.
[0095]
In particular, in the coil portion 34 in which the ring connecting portion 31 is bent and the ring portion 32 is vertically overlapped, the end of the arc-shaped portion 38 of the ring portion 32 where the terminal portion 35 is formed is positioned at the center of the ring portion 32 ( Since it can be arranged at a position opposite to O), it is not necessary to consider the directionality of the terminal portion 35 at the time of mounting, and the device is easy to use.
[0096]
At this time, the terminal portion 35 is provided on an extension line (E) extending from the center (O) of the ring portion 32 toward the end of the arc-shaped portion 38 forming the terminal portion 35, so that the terminal portion 35 is formed. The ring portion 32 and the end of the arc-shaped portion 38 can be arranged on the same straight line, and the terminal portion 35 is accurately arranged at a position opposite to the center (O) of the ring portion 32, and the terminal at the time of mounting is provided. It is not necessary to consider the directionality of the portion 35, and the usability is further improved.
[0097]
The exterior part 36 has a prismatic outer shape, a ring connection part 31 formed at one end is disposed at a corner 43 of the exterior part 36, and the ring connection part 31 formed at the other end is connected to the exterior part. Since they are arranged between the corners 44 of the 36, the external dimensions can be reduced and the size can be reduced.
[0098]
The exterior part 36 is press-molded using a mold 49. However, since the compact 45 forming the exterior part 36 is a solid, the compact is formed between the mold 49 and the coil part 34. 45 is hard to fluctuate during re-press molding, the coating thickness of the exterior portion 36 is likely to be uniform over the entire periphery of the coil portion 34, and characteristic variations can be suppressed. Since the coil part 34 can be supported, the positioning of the coil part 34 becomes accurate, and defective molding of the exterior part 36 can be prevented.
[0099]
At this time, since the hardness portion of the green compact 45 firmly supports one surface of the coil portion 34, the coil portion 34 is less likely to be displaced at the time of re-pressing, and the coil portion 34 can be accurately positioned.
[0100]
In particular, the green compact 45 is provided with a weak hardness portion having a hardness such that the shape of the green compact 45 is deformed during re-pressing, and the green compact 45 is coated so that the weak hardness portion covers the coil portion 34. Since the re-pressing is performed, the weakly hardened portion of the green compact 45 is filled with no gap between itself and the coil portion 34 while the weakly hardened portion of the green compact 45 loses its shape. Thereby, the magnetic gap can be reduced and the magnetic efficiency can be improved.
[0101]
Further, the inner thickness dimension (the distance between the coil part 34 and the surface of the exterior part 36) that includes the coil part 34 corresponds to the upper part of the coil part 34 until it becomes smaller than the diameter of the through hole 33 of the coil part 34. Even if the upper surface portion 50 of the exterior portion 36 and the lower surface portion 51 of the exterior portion 36 corresponding to the lower portion of the coil portion 34 are formed thin to reduce the overall height, the density of the upper surface portion 50 and the lower surface portion 51 Since the density is higher than the density of the intermediate portion 52, it is possible to suppress the occurrence of magnetic saturation in the upper surface portion 50 and the lower surface portion 51.
[0102]
That is, the inside of the through hole 33 of the coil portion 34 corresponds to the intermediate portion 52 of the exterior portion 36, and the density of the upper surface portion 50 and the lower surface portion 51 of the exterior portion 36 is higher than the density of the intermediate portion 52. Therefore, even if the magnetic flux passing through the inside of the through hole 33 passes through the upper surface portion 50 and the lower surface portion 51 smaller than the diameter of the through hole 33, the density is higher at the upper surface portion 50 and the lower surface portion 51 than at the intermediate portion 52. The magnetic permeability can be increased by that much, and the height can be reduced without causing magnetic saturation in the upper surface portion 50 and the lower surface portion 51.
[0103]
Further, according to the manufacturing method of the present invention, the above-described coil component can be manufactured.
[0104]
As described above, according to the embodiment of the present invention, since the ring portion 32 is formed of a metal flat plate, it operates in a high-frequency region, and can cope with a large current while securing an inductance value and a minute DC resistance value.
[0105]
In the embodiment of the present invention, three ring portions 32 are used. However, as shown in FIG. 16, four ring portions 32 may be used.
[0106]
As shown in FIG. 17, an insulating coating layer 41 is formed on the four ring portions 32 except for the ring connecting portion 31, and as shown in FIG. 18, the ring connecting portion 31 is bent to form the coil portion 34. Form.
[0107]
At this time, the length (T1) of the ring connecting portion 31 formed at one end of the arc-shaped portion 38 is made longer than the length (T2) of the ring connecting portion 31 formed at the other end. The overlapping portion of the ring portion 32 formed of a flat metal plate can be reduced while suppressing the outer diameter of the coil portion 34 from becoming large, and the DC resistance value can be reduced while securing the inductance value of the coil portion 34. Can be reduced.
[0108]
【The invention's effect】
As described above, according to the present invention, since the ring portion is formed of a metal flat plate, it is possible to provide a coil component that operates in a high-frequency region and that can handle a large current while ensuring an inductance value and a small DC resistance value. .
[0109]
Further, the terminal portion is formed from the angle formed by the center line connecting the centers of the adjacent ring portions connected to each other at the ring connecting portion, and the center line of the ring portion connected to the terminal portion and the center of the ring portion. Since the sum of the angles with the extension line extending toward the end is 180 degrees, the ring portions can be easily overlapped with each other up and down.
[0110]
In particular, the coil portion in which the ring connecting portion is bent and the ring portion is overlapped with the upper and lower portions is disposed at a position where the end of the arc-shaped portion of the ring portion forming the terminal portion is opposed to the center of the ring portion. Since it is possible, it is not necessary to consider the directionality of the terminal portion at the time of mounting, and the usability is good.
[0111]
At this time, the ring connecting portion can be arranged at a position substantially 45 degrees with respect to a straight line connecting the ends forming the terminal portions, so that the mounting area can be reduced. That is, in a rectangular mounting portion in which the ring portion is inscribed, the mounting area can be reduced by disposing the ring connecting portion at a corner of the mounting portion.
[0112]
Furthermore, if the exterior portion is formed in a prismatic shape, the outer dimensions of the exterior portion can be reduced by arranging the ring connecting portion at the corner portion, thereby achieving downsizing.
[Brief description of the drawings]
FIG. 1 is a plan view of a plurality of ring portions made of a flat metal plate arranged in a plane of a coil component according to an embodiment of the present invention.
FIG. 2 is a perspective view of a coil portion of the coil component.
FIG. 3 is a perspective view of the coil component.
FIG. 4 is a sectional view of the coil component.
FIG. 5 is a plan view of a ring portion provided with an insulating coating layer used for the coil component.
FIG. 6 is a sectional view of a ring portion provided with an insulating coating layer used for the coil component.
FIG. 7A is a cross-sectional view of the vicinity of a ring connecting portion before bending of a ring portion.
(B) Sectional view of the vicinity of the ring connecting part after bending of the ring part
FIG. 8 is a cross-sectional view of the vicinity of a ring connection portion before bending of another ring portion.
FIG. 9 is a manufacturing process diagram of the coil component.
FIG. 10 (a) is a cross-sectional view of a ring portion of the same coil component which has been subjected to chamfering and provided with an insulating coating layer.
(B) A cross-sectional view near the outer peripheral edge of the ring portion when the ring portions are overlapped.
FIG. 11 (a) is a cross-sectional view of an unchamfered ring portion provided with an insulating coating layer.
(B) A cross-sectional view near the outer peripheral edge of the ring portion when the ring portions are overlapped.
FIG. 12 is a process chart showing a bending process of a ring portion in a manufacturing process of the coil component.
FIG. 13A is a cross-sectional view showing how a ring portion having a protruding portion is deformed after forming an exterior portion.
(B) Plan view of the ring portion
FIG. 14A is a cross-sectional view showing a deformation state of a ring portion having a protruding portion that is not extended after forming an exterior portion.
(B) Plan view of the ring portion
FIG. 15 is a sectional view of the coil component when there is no step.
FIG. 16 is a plan view of four ring portions made of a metal plate arranged in a plane of a coil component in another embodiment.
FIG. 17 is a plan view of the ring portion provided with an insulating coating layer.
FIG. 18 is a process diagram showing a bending process of the ring portion.
FIG. 19 is an exploded perspective view of a conventional coil component.
[Explanation of symbols]
30 steps
31 Ring connection
32 Ring section
33 Through hole
34 coil
35 Terminal
36 Exterior
37 Notch
38 arc-shaped part
39 Projection
40 Perimeter
41 Insulation coating layer
42 groove
43 corner
44 between corners
45 green compact
46 back
47 Middle leg
48 Outer leg
49 Mold
50 Top part
51 Lower part
52 Middle part
52a middle part
52b Outside middle part
53 recess

Claims

A coil portion having a through-hole formed by bending a plurality of ring portions made of a flat metal plate connected to each other at a ring connection portion and arranged in a planar shape at the ring connection portion and vertically overlapping each other; and A terminal part connected to the coil part, and an exterior part that covers the coil part and protrudes the terminal part. The ring part includes an arc-shaped part having a cutout part that is partially cut away. The ring portion is connected to each other at the end of the arc-shaped portion of the ring portion, while the ring connecting portion is formed at the end of the arc-shaped portion of the ring portion is not connected to each other at the end of the arc-shaped portion of the ring. A plurality of the ring portions formed of a flat metal plate, and formed by a center line connecting centers of the adjacent ring portions connected by the ring connection portion. And the angle between the center line of the ring portion connected to the terminal portion and the extension line extending from the center of the ring portion toward the end portion forming the terminal portion is approximately 180 degrees. Coil parts.

The coil component according to claim 1, wherein the terminal portion is provided on an extension extending from a center of the ring portion toward an end portion where the terminal portion is formed.

The coil component according to claim 1, wherein a bending groove is provided in the ring connecting portion.

The coil component according to claim 3, wherein the groove is provided in a direction perpendicular to a center line connecting centers of the adjacent ring portions connected to each other at the ring connection portion.

The coil component according to claim 1, wherein a projecting portion extends toward a notch at an end of the arc-shaped portion of the ring portion to which the ring portion is connected.

The coil component according to claim 1, wherein the outer diameters of the ring portions are substantially equal.

The coil component according to claim 1, wherein a peripheral portion of the ring portion is chamfered.

In a plurality of ring portions made of a metal plate arranged in a plane, a terminal portion formed at an end of an arc-shaped portion of the ring portion where the ring portions are not connected to each other is formed by providing a step, The coil component according to claim 1, wherein the step provided in the terminal portion and the step provided in the other terminal portion are provided in directions approaching each other when the ring portions are vertically overlapped.

The coil component according to claim 1, wherein the ring portion is provided with an insulating coating layer except for a ring connection portion.

The coil component according to claim 1, wherein a length of the ring connecting portion formed at one end of the arc-shaped portion of the ring portion is longer than a length of the ring connecting portion formed at the other end.

The coil component according to claim 1, wherein the outer shape of the outer portion is a prismatic shape, a ring connecting portion is disposed at a corner of the outer portion, and a terminal portion is disposed between the corners of the outer portion.

The coil component according to claim 1, wherein the plurality of ring portions made of a flat metal plate are formed by etching or punching.

The exterior part is formed by mixing a binder containing a thermosetting resin and a magnetic powder in a non-heated state in which the thermosetting resin is not completely cured, and press-molding a green compact to cover the coil part. The thermosetting resin is molded by heating so that the thermosetting resin is completely cured. When the green compact is re-pressed, the shape of the green compact is weakened. The coil according to claim 1, wherein a hardened portion is provided, the two compacts are formed, and the green compact is re-pressed so that the weakly hardened portion of the green compact covers the coil portion. parts.

The green compact has a strong hardness portion having a hardness that does not deform the shape of the green compact when repressing and a weak hardness portion having a hardness that deforms the shape of the green compact when performing the repressing. 14. The coil component according to claim 13, wherein the exterior portion is configured such that the hard portion of at least one of the green compacts supports one surface of the coil portion.

The exterior part is a dust core containing magnetic powder, and corresponds to an upper surface part corresponding to an upper part of the coil part, a lower surface part corresponding to a lower part of the coil part, and a height part of the coil part. An intermediate portion having a thickness that encloses the coil portion is made smaller than a diameter of a through hole of the coil portion, and the density of the upper surface portion and the density of the lower surface portion are made higher than the density of the intermediate portion. 2. The coil component according to claim 1, wherein the coil component is enlarged.