JP2004214371A - Surface-mounting coil component and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a surface-mounting coil component which enables miniaturization and can restrain the dispersion of a coil property for every product. <P>SOLUTION: The surface-mounting coil component provided with a drum type core 12 around which a winding is wound, and an outer package core 14 surrounds the drum type core 12 along its axis. Sheets 15s, 16s are interposed between the drum type core 12 and the outer package core 14. The outer package core 14 is divided into a plurality of partial cores 15, 16. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a surface-mounted coil component that is surface-mounted on a circuit board of an electronic device, and a method for manufacturing the same.
[0002]
[Prior art]
In recent years, electronic devices such as mobile phones, hard disk devices, and notebook personal computers have been required to have small surface-mount coil components. When the size of a component is reduced, the accuracy of the component is reduced, and it is difficult to maintain a certain characteristic. Since this characteristic depends on the gap between the drum core and the outer core, a method of managing such a gap with a spacer has been proposed (for example, see Patent Document 1).
[0003]
[Patent Document 1]
JP-A-2002-313635
[0004]
[Problems to be solved by the invention]
If such a spacer is formed in a sheet shape, it is considered that the spacer comes into surface contact. However, when an integrated exterior core is used, there is a tendency that the sheet interposed between the exterior core and the drum core does not easily come into surface contact with no gap. If the diameter of the inner surface of the exterior core is reduced, the sheet comes into contact with the drum core and makes surface contact. However, if it is slightly reduced, the drum core cannot be inserted into the interior of the exterior core.
[0005]
Therefore, the diameter of the inner surface of the outer core is designed with a margin so that the sheet comes into contact with the drum core, but in such a case, the surface mount type coil component is enlarged by the margin and the sheet is Since it does not yet contact the drum core, the coil characteristics for each product cannot be maintained constant.
[0006]
The present invention has been made in view of such a problem, and a surface mount type coil component capable of achieving miniaturization and suppressing variation in coil characteristics for each product, and a device therefor.
It is intended to provide a manufacturing method.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, a surface-mount type coil component according to the present invention includes a surface-mount type coil component having a drum-type core on which a winding is wound, and an exterior core surrounding the drum-type core around its axis. A coil component, wherein a sheet is interposed between the drum core and the outer core, and the outer core has a plurality of portions such that the sheet abuts on both surfaces of the drum core and the outer core. It is characterized by being divided into cores.
[0008]
In this case, since the armor core is divided, the sheet of the partial core can abut on the drum core independently, and therefore, the sheet regulates the gap between the drum core and the armor core. Can be. That is, since it is not necessary to provide the above-mentioned margin, the area of the surface mount type coil component itself is reduced, and since the sheet inevitably comes into contact with the drum core, the gap becomes constant for each component, It is possible to suppress variations in coil characteristics for each.
[0009]
It should be noted that even when the adhesive is thinly interposed between the sheet and the drum core or between the sheet and the partial core, the "contact" is also assumed.
[0010]
Further, when the sheet is fixed to at least one of the opposing surfaces with an adhesive, the sheet is bonded to one of the partial core and the drum core in advance, so that the sheet does not shift when bonded to the other, and Adhesion becomes easy.
[0011]
Various methods are conceivable for bonding the drum core and the partial core. It is assumed that the plurality of partial cores facing the drum core include first and second partial cores.
[0012]
In the first bonding method, the sheet is bonded only to the first partial core on the facing surface of the first partial core, and the first partial core and the drum-shaped portion are bonded in a region other than the sheet attachment region of the first partial core. In this method, an adhesive is interposed between the cores.
[0013]
In this case, since the adhesive is interposed only between the first partial core and the sheet, the variation in the gap between the drum core and the partial core due to the sheet can be suppressed. In the area other than the sheet attachment area of the first partial core, the adhesive is interposed. However, since this does not restrict the above-mentioned gap as in the case of the sheet, the gap rule by the sheet is maintained. .
[0014]
When the sheet is adhered to both the first partial core and the drum-shaped core, the gap control is inferior to the above-described method. This does not hinder the effect of suppressing the variation in the above.
[0015]
According to a second bonding method, the sheet includes first and second sheet portions separated from each other along the axial direction of the drum core on the opposing surface of the first partial core, and the first and second sheet portions are bonded to each other. It is characterized in that an agent is interposed.
[0016]
In this case, the above-mentioned gap can be regulated by the first and second sheet portions. However, since the drum-shaped core and the partial core are adhered by an adhesive provided at a position different from these, the gap regulation by the sheet is performed. Is performed well. Further, when the first and second sheet portions are adhered only to the drum core, when they are adhered only to the first partial core, and when they are adhered to both the drum core and the first partial core. Although three types of bonding methods are conceivable, in the former two, the gap is regulated only by one adhesive, so that the variation in the gap is suppressed, and in the latter, the gap is regulated by the adhesive on both sides. This does not hinder the effect of the above-mentioned downsizing and the suppression of the variation in coil characteristics of each component due to the division of the exterior core.
[0017]
Further, since the first and second sheet portions are separated from each other along the axial direction of the drum core, there is also an effect that the adhesive does not flow outside along this direction. That is, the first and second sheet portions also function as weirs as adhesive outflow prevention means.
[0018]
In a third bonding method, the sheet is bonded to both the first partial core and the drum-shaped core on the opposing surface of the first partial core. As described above, the gap regulation is inferior to that in which the adhesive is interposed only on one side, but it does not hinder the effect of the above-mentioned miniaturization and the suppression of the variation in coil characteristics of each part due to the division of the outer core. In addition, there is no need to provide an adhesive for directly bonding the drum core and the partial core at another position. Note that it is not unfortunate to apply an adhesive to the different position as needed.
[0019]
A method for manufacturing a surface-mount type coil component according to the present invention includes a drum core wound with a winding, and an armor core surrounding the drum core around its axis. In the method for manufacturing a surface-mount type coil component having a second partial core, (a) a step of preparing a first partial core having a concave surface and a second partial core having a concave surface; and (b) a step of preparing the first partial core. A step of interposing a sheet between the concave surface and the drum core; and (c) attaching a concave surface of the second partial core to an outer peripheral surface of the drum core.
[0020]
According to the method for manufacturing a surface-mounted coil component of the present invention, since the exterior core is composed of the first partial core and the second partial core with the sheet interposed between the drum core and the concave surface, The sheet reliably contacts the outer peripheral surface of the drum core. Therefore, it is possible to suppress the variation of the gap between the drum core and the outer core defined by the sheet, and to make the characteristics of each product constant.
[0021]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, preferred embodiments of a surface mount type coil component and a method of manufacturing the same according to the present invention will be described in detail with reference to the accompanying drawings. In addition, the same reference numerals are used for the same elements, and redundant description will be omitted.
[0022]
(1st Embodiment)
FIG. 1A is a perspective view of a surface-mount type coil component 10 of the present embodiment, FIG. 1B is a perspective view of one partial core 16 constituting an exterior core 14, and FIG. It is Ic-Ic arrow sectional drawing of the coil component 10.
[0023]
2A is a plan view of the surface-mounted coil component 10, FIG. 2B is a front view of the surface-mounted coil component 10, and FIG. 2C is a side view of the surface-mounted coil component 10.
[0024]
The surface mount type coil component 10 is mounted on a printed wiring board or the like by reflow soldering or the like, and then applied to a power supply circuit of an electronic device such as a mobile phone, a hard disk device, or a notebook personal computer, for example, 250 kHz to 1 MHz. The switching frequency is preferably used.
[0025]
The surface-mount type coil component 10 mainly includes a drum-type core 12 in which a winding 11 is wound around a body 12a, and an exterior core 14 provided so as to surround the drum-type core 12 around its axis. ing. In this example, the winding 11 has a rectangular shape (having a rectangular cross section). A round wire type winding can be used as the winding 11.
[0026]
The exterior core 14 is formed of two partial cores (a first partial core 15 and a second partial core 16) having the same shape, and each of the partial cores 15 and 16 has a core gap 18 between the core and the drum core 12. Are arranged through. A pair of electrodes 25, 26 is attached to each of the partial cores 15, 16, and both ends 11a, 11b of the winding 11 are connected to the electrodes 25, 26, respectively.
[0027]
In order to facilitate understanding of the invention, in FIG. 2A, the electrode 25 side shows a state in which the wire and the electrode are connected, and the electrode 26 side shows a state before the connection work is performed. Is shown.
[0028]
The drum-type core 12 is formed of, for example, a Ni—Cu—Zn-based magnetic material, and has a cylindrical body 12a around which the winding 11 is wound, and disks provided at both axial ends of the body 12a. And a pair of flanges 12b and 12c. The axial center of the cylindrical body 12a and the axial centers of the disc-shaped flanges 12b and 12c coincide with each other.
[0029]
The winding 11 is formed by applying a urethane coating for insulation to a copper wire, and the urethane coating is removed at both ends in order to achieve conduction with the electrodes 25 and 26. In the present embodiment, the winding 11 is wound around the body 12a by a so-called crosswise method (see FIGS. 3A, 3B, and 3C described later).
[0030]
The outer core 14 can be formed of, for example, a Ni—Cu—Zn-based magnetic material, similarly to the drum core 12. Each of the partial cores 15 and 16 has a substantially V-shaped cross section, and the inner wall surface thereof has a concave curved surface corresponding to the outer peripheral surface of the drum core 12 in order to keep the core gap 18 constant along the circumferential direction. Is composed.
[0031]
A core gap 18, which is a gap between the drum core 12 and the outer core 14, affects the coil characteristics. The core gap 18 is defined by the thickness of the sheets 15 s and 16 s interposed between the inner surfaces of the partial cores 15 and 16 constituting the outer core 14 and the outer peripheral surface of the drum core 12, respectively.
[0032]
The shapes of the partial core 15 and the partial core 16 are the same, the sheet 15s and the sheet 16s provided therein are the same, and the adhesives 15a and 15b applied to the partial core 15 and the sheet are the same as the adhesives 16a and 16b. Identical. The relationship between the partial core 15, the sheet 15s, and the adhesives 15a, 15b with respect to the drum core 12 is the same as the relationship between the partial core 16, the sheet 16s, and the adhesives 16a, 16b with respect to the drum core 12. These relations are symmetric with respect to the center axis of the drum core 12.
[0033]
Therefore, only one partial core 16 will be described.
[0034]
The partial core 16 is provided with a semi-cylindrical surface composed of a set of points equidistant from the center axis of the drum core 12, that is, a concave surface facing the drum core 12. A sheet 16s is provided on the concave surface, and adhesives 16a and 16b are applied to the remaining area where the sheet 16s is provided. The application area of the adhesives 16a and 16b is separated along the circumferential direction of the drum core 12, and the sheet 16s is located between them.
[0035]
The opening angle θ between the positions of both ends of the sheet 16s along the circumferential direction of the partial core 16 is set as follows. That is, assuming that the opposing surfaces of the partial core 16 and the drum core 12 are the respective opposing surfaces, one of these opposing surfaces, in this example, the opposing surface of the partial core 16 is a sheet with respect to one partial core 16. 16s corresponds.
[0036]
An angle θ2 (θ1) formed by a line segment connecting the center of the drum core 12 and both ends of the sheet 16 is set to 90 ± 30 degrees in this example. When the drum-type core 12 is placed on the partial core 16 to which the sheet 16s is adhered, the stability of the drum-type core at the time of manufacturing when the angle θ2 (θ1) is 90 ± 30 degrees. In the surface mount type coil component 10, the position of the drum type core can be stabilized during manufacturing. It is not unfortunate that θ2 (θ1) is set to 90 degrees or more as necessary.
[0037]
As shown in FIG. 1C, the sheet 16s extends from one flange 12b of the drum core 12 toward the other flange 12c in the axial direction of the drum core 12.
[0038]
Here, when the sheet 16s is not bonded to any of the partial core 16 and the drum core 12, when the sheet 16s is bonded only to the partial core 16, and when the sheet 16s is bonded only to the drum core 12, May be glued. When the sheet 16s is fixed to at least one of the opposing surfaces of the drum core 12 and the partial core 16 with an adhesive, the sheet 16s is bonded to one of the partial core 16 and the drum core 12 in advance. In addition, the sheet does not shift at the time of bonding to the other, and the bonding is facilitated.
[0039]
Various methods for bonding the drum core 12 and the partial core 16 are conceivable. In the above-described bonding method, the sheet 16s is bonded only to the first partial core 16 on the surface facing the first partial core 16, and the first partial core 16 is bonded to the first partial core 16 in a region other than the sheet attachment region. Adhesives 16a and 16b for adhering the drum core 16 and the drum core 12 are interposed.
[0040]
In this case, since the adhesives 16a and 16b are interposed only between the first partial core 16 and the sheet 16s, it is possible to suppress the variation in the gap between the drum core 12 and the partial core 16 due to the sheet 16s. it can. In the area other than the sheet attaching area of the first partial core 16, the adhesives 16a and 16b are interposed. However, since the adhesive 16a and 16b do not restrict the above-described gap as the sheet 16s, the gap by the sheet 16s The law is maintained.
[0041]
As described above, the relationship between the partial core 15, the sheet 15s, and the adhesives 15a, 15b is the same as the description of the partial core 16, the sheet 16s, and the adhesives 16a, 16; , Sheet 15s and adhesives 15a and 15b.
[0042]
As described above, the above-described surface-mount type coil component is a surface-mount type coil component including the drum-type core 12 on which the winding 11 is wound and the outer core 14 surrounding the drum-type core 12 around its axis. It is a coil component, and sheets 15 s and 16 s are interposed between the drum core 12 and the outer core 14, and the outer core 14 is such that the sheets 15 s and 16 s are both the drum core 12 and the outer core 14. Are divided into a plurality of partial cores 15 and 16 so as to abut on the opposing surface of the core.
[0043]
Since the exterior core 14 is divided, the sheets 15 s and 16 s of the partial cores 15 and 16 can independently abut on the drum core 12, so that the sheets 15 s and 16 s can be brought into contact with the drum core 12 and the exterior core 14 can be regulated. That is, in the case of the split type exterior core 14, since there is no need for a margin for inserting the drum type core 12, the area of the surface mount type coil component itself is reduced, and the sheets 15s and 16s are inevitably provided. Since the core gap 18 is in contact with the drum core 12, the core gap 18 is constant for each component, and it is possible to suppress variations in coil characteristics for each component.
[0044]
In addition, when the adhesive is thinly interposed between the sheets 15 s and 16 s and the drum core 12, and between the sheets 15 s and 16 s and the partial cores 15 and 16, it is also referred to as “contact”.
[0045]
As can be seen from FIGS. 2B and 2C, the heights of the partial cores 15 and 16 are slightly lower than the drum core 12. Further, each of the partial cores 15 and 16 is disposed around the drum-type core 12 such that two distal ends thereof face each other in a plan view, and gaps 21 and 22 (see FIG. 2 (a) is formed.
[0046]
Each of the partial cores 15 and 16 has a shape in which not each end portion facing the other partial core is cut or chamfered, instead of simply dividing the exterior core having a rectangular shape in a plan view along a diagonal line. It is formed by sintering. Then, the surface (first surface) SA of the partial core 15 ₁ And partial core 16 surface (second surface) SB ₁ And the gap portion 21 is defined, and the surface (first surface) SA of the partial core 15 is formed. ₂ And partial core 16 surface (second surface) SB ₂ And a gap portion 22 is defined.
[0047]
More specifically, surface SA defining gap 21 in partial core 15 ₁ And a surface SB defining the gap portion 21 in the partial core 16 adjacent to the partial core 15 ₁ Is formed so that the interval between them increases as the distance from the center of the drum core 12 increases. Even on the gap portion 22 side, the surface SA ₂ And plane SB ₂ Is formed so as to spread outward.
[0048]
That is, each of the gap portions 21 and 22 is a space that expands outward. In this embodiment, the surface SA ₁ And plane SB ₁ Has a substantially vertical positional relationship with the surface SA. ₂ And plane SB ₂ Also have a substantially vertical positional relationship. Here, “substantially perpendicular” means that the angle between the two surfaces does not necessarily need to be 90 °, and that there may be some deviation. The range of the deviation may be, for example, 80 ° to 100 °.
[0049]
The electrodes 25 and 26 are composed of main bodies 25a and 26a attached near the gaps 21 and 22 of the partial cores 15 and 16, and a strip-shaped protruding piece (continuously provided on the main bodies and located in the gaps 21 and 22). Guide pieces) 25b and 26b. The main body portions 25a and 26a have a rectangular central portion that comes into surface contact with the outer wall of the partial core, and a portion smaller in height than the central portion extends in the left-right direction in FIG. 2C.
[0050]
The extended portion on the right side of FIG. ₁ The protruding pieces 25b and 26b protrude outward from this bent portion. Further, as shown on the right side of FIG. 2B, the bottoms of the electrodes 25 and 26 are bent inward, and the bottoms are accommodated in steps formed on the bottom surface of the partial core. Then, the electrodes 25 and 26 are adhered to the partial core by various adhesives such as a one-component epoxy resin. By applying reflow soldering or the like to the bottom of such an electrode, the surface-mount type coil component 10 is mounted on the printed wiring board.
[0051]
The electrodes 25 and 26 are made of phosphor bronze, and are plated except for a region facing the partial core. The plating may be performed, for example, by plating an underlayer with 0.5 μm thick Ni and then plating 4 μm thick Sn 100%.
[0052]
Also, the protruding pieces 25b and 26b of the electrodes 25 and 26 are connected to the surface SA of the partial core 15 as shown by a two-dot chain line in FIG. ₁ In the substantially normal direction (X direction). This state can also be seen from FIG. Then, at the time of connection, the ends 11a and 11b of the winding are passed through the gap portions 21 and 22, respectively, and the protruding pieces 25b and 26b are bent toward the main body parts 25a and 26a of the electrode by caulking or the like. And the portions from which the coatings of the terminals 11a and 11b of the windings have been removed are sandwiched.
[0053]
Incidentally, the pinching by the protruding pieces is a temporary fixing, and an arc welding, a laser beam welding, a soldering, or the like is applied from above on the gap portion 21 side in FIG. By employing the method of temporarily fixing with the protruding pieces 25b and 26b in this manner, subsequent work such as soldering can be easily and reliably performed. Furthermore, when mounting the surface mount type coil component 10 on a printed wiring board or the like, even if the welded portion or the solder applied to the connecting portion is melted by heat such as soldering, the winding is suppressed by the projecting piece. As a result, disconnection from the electrodes 25 and 26 can be prevented.
[0054]
Next, effects obtained from the surface mount type coil component will be described. As described above, the terminals 11 a and 11 b of the winding are connected to the electrodes 25 and 26 at the gap portions 21 and 22 between the partial cores 15 and 16, respectively. That is, since the winding 11 does not bypass the upper side of the outer core 14, the problem that the height of the coil component is increased by the amount of the winding 11 mounted on the outer core 14 does not occur, and the thickness of the winding 11 is almost equivalent to the thickness ( Further, the height by welding or soldering can be reduced. Further, in the connection work between the winding 11 and the electrodes 25 and 26, it is not necessary to bend the winding 11 at the shoulder of the exterior core 14, so that the work can be easily performed.
[0055]
The surface SA of the partial core 15 ₁ And surface SB of partial core 16 ₁ Are substantially perpendicular to each other, and are formed so that the interval between them gradually increases toward the outside, so that the gap portion 21 is a sufficient space for performing the connection work. The same can be said for the gap portion 22.
[0056]
In the present embodiment, the connection is made in the gap portions 21 and 22. However, the connection may be made by drawing out the ends 11a and 11b of the windings from the gap portions 21 and 22. That is, the terminal of the winding may be connected to the electrode after passing through the gap portions 21 and 22. To explain this form in detail, the windings drawn out of the gap portion are connected to, for example, a surface SA. ₁ And is connected to the electrode in the region of the outer peripheral portion of the exterior core 14.
[0057]
Also in this case, since it is not necessary to bend the winding 11 at the shoulder of the exterior core 14, the connecting operation can be easily performed. However, if the outer peripheral portion of the outer core 14 is connected, the dimensions of the coil component 10 are increased by the protrusions of the electrodes required for the connection and the protrusions of the welds. In the above, it is preferable to connect the winding and the electrode.
[0058]
Further, in the present embodiment, as shown in FIGS. 2B and 2C, the ends 11a and 11b of the windings are not bent in the height direction (Z direction) of the drum type core 12 and the gap portions are not bent. 21 and 22. That is, when the surface mount type coil component 10 is viewed from the side, the terminals 11a and 11b of the windings are linear. With such a configuration, the wiring pattern of the winding in the coil component 10 is extremely simple compared to the case where the line segment from the trunk 12a of the winding toward the exterior core 14 is bent, Line work can also be easily performed.
[0059]
Moreover, since the winding 11 is wound around the drum core 12 by a crosswise method as described later, the width direction thereof coincides with the height direction of the drum core 12 (FIG. 3C). reference). Since the gap portions 21 and 22 also extend in the height direction of the drum core 12, the gap portion can be passed without twisting the winding wire 11, and the connection work is also easy from this viewpoint. It can be said.
[0060]
As shown in FIG. 1, the protruding pieces 25 b of the electrodes 25 attached to the partial core 15 are adjacent to each other when extended in a direction (X direction) orthogonal to the height direction of the drum core 12. It does not come into contact with the core 16. Accordingly, the protrusion of the protruding piece 25b in the X direction is not hindered by the partial core 16, so that a sufficient interval between the main body 25a of the electrode and the tip of the protruding piece 25b can be ensured, and the winding can be connected to the electrode. It becomes easy to pass between the main body part 25a and the protruding piece 25b, and the connecting work becomes easy.
[0061]
Here, the protruding pieces 25b and 26b of the electrodes 25 and 26 will be described in detail with reference to FIG. As shown in the figure, the base portion 26c of the protruding piece 26b of the electrode, that is, the vicinity of the boundary with the main body portion 26a is located around the flange portion 12c in the height direction (Z direction) of the drum core. (In the figure, the hidden portion of the flange portion 12c is indicated by a broken line).
[0062]
In this manner, by positioning the base portion 26c of the projecting piece around the flange portion 12c instead of around the trunk portion 12a, the existence of the projecting piece 26b is prevented when the terminal 11b of the winding 11 is passed through the gap portion 22. And the connection work can be done smoothly. In addition, as shown in FIG. 2 (b), the root of the protruding piece 25b is also located around the flange 12c instead of the trunk 12a.
[0063]
Further, the length X in the longitudinal direction of the protruding pieces 25b and 26b is equal to or larger than the distance between the flange 12b and the flange 12c. For this reason, even if both ends 11a and 11b of the winding are pulled out from any height position of the body 12a, the protrusions 25b and 26b can suppress the ends. In the present embodiment, the winding is wound by the crosswise method, and the winding is stacked in two layers in the body 12a, and one end 11a of the winding is pulled out from the upper side as shown in FIG. As shown in FIG. 2 (c), the other end 11b of the winding is drawn out from below. Even in the case where the height positions of the windings drawn out are different on both ends, the ends Xa and Xb can be suppressed by setting the length X of the protruding piece as described above.
[0064]
Therefore, it is not necessary to prepare electrodes for each of the terminals 11a and 11b, and it is possible to use only one type of electrode, so that production efficiency can be increased and cost can be reduced. As another method for sharing one end of the winding with one type of electrode as described above, projecting pieces are provided on both the upper and lower sides of the electrode, and the total length of each projecting piece is determined between the flanges 12b and 12c. Or more.
[0065]
Here, a method of manufacturing the partial cores 15 and 16 will be described.
[0066]
First, a lower mold having a semi-cylindrical convex surface is prepared, a composite material containing a magnetic material is provided on the lower mold, and the composite material is sandwiched between the lower mold and the upper mold, and wet press molding is performed. Is sintered to form a partial core 15, and finally, one of the partial cores is fixed to the drum core 12.
[0067]
As the above-mentioned composite material, an additive and water are added to a Ni-Cu-Zn-based ferrite powder and mixed with a ball meal for, for example, 20 hours to obtain a ceramic slurry. Examples of conventionally known additives include a dispersant: polyoxyalkylene glycol (1.0% by weight based on the weight of the raw material), an antifoaming agent: a polyether-based antifoaming agent (0.1% by weight of the raw material). 5% by weight) and a binder: an acrylic binder (0.5% by weight based on the weight of the raw material). In this case, for example, water is added at 50.0% by weight based on the weight of the raw material.
[0068]
Another composite material includes another resin PPS (polyphenylene sulfide) resin. As an example, a ceramic slurry is obtained by kneading 85 parts by weight of a Ni—Cu—Zn ferrite powder with 100 parts by weight of PPS. Is also good.
[0069]
The pressure during press molding is, for example, 100 kgf / cm ² Set to pressure. The molded body is taken out from the molding die, and the molded body is dried at, for example, 40 ° C. for 50 hours, then the molded body is placed in an alumina box, and calcined at 800 ° C., and then heated to a temperature higher than the calcining temperature. For example, the main firing is performed at 930 ° C. or 960 ° C. for 2 hours. As a result, the ceramic component of the pre-sintered body completes the contraction and becomes the magnetic core. The magnetic core may be made of a sintered body of only ferrite powder.
[0070]
The drum core 12 can be manufactured by the same method as that of the partial cores 15 and 16, except for the mold.
[0071]
After the partial core 15 manufactured as described above is placed on the magnet such that the concave surface faces upward, the drum core 12 is placed on the concave surface. Adheres to the partial core 15. In this state, the above-mentioned adhesive is cured to fix the drum core 12 to the partial core 15. In the fixing, an adhesive is used. This adhesive can be applied to the partial core 15 or the sheets 15s and 16s in advance.
[0072]
Thereafter, the partial core 16 manufactured by the same method as the partial core 15 is prepared, and the partial core 16 is fixed to the drum core 12 by using the same method as the fixing method of the partial core 15. After the previous fixation of the partial core 15, the intermediate body is turned upside down, and then the intermediate body is arranged in a magnetic field such that the drum core 12 and the partial core 15 are sequentially positioned on the partial core 16. And fix it.
[0073]
That is, in the step of attaching the partial cores 15 and 16 to the drum core 12, the partial cores 15 (16) and the drum cores 12 (16) are placed in a state where the drum core 12 and the partial cores 15 (16) are arranged in a magnetic field. And are arranged in close proximity. That is, when the drum core 12 and the partial core 15 (16) are arranged in a magnetic field, since these cores are made of a magnetic material, an attractive force acts between them. Therefore, the partial core 15 (16) and the drum core 12 are attracted, and the concave sheets 15 s and 16 s of the partial core 15 (16) surely come into contact with the outer peripheral surface of the drum core 12.
[0074]
As described above, in the method of manufacturing the surface-mounted coil component, the drum-type core 12 on which the winding 11 is wound, and the outer core 14 surrounding the drum-type core 12 around its axis are provided. The method is directed to a method of manufacturing a surface-mounted coil component in which the exterior core 14 has the first and second partial cores 15 and 16, and the following steps are sequentially performed.
[0075]
(1) a step of preparing a first partial core 15 having a concave surface and a second partial core 16 having a concave surface; (2) a step of interposing a sheet between the concave surface of the first partial core 15 and the drum core 12 (3) attaching the concave surface of the second partial core 16 to the outer peripheral surface of the drum core 12;
[0076]
According to the method for manufacturing a surface-mounted coil component of the present invention, since the exterior core 14 is composed of the first partial core 15 and the second partial core 16 with a sheet interposed between the drum core and the concave surface, In this case, the sheet reliably contacts the outer peripheral surface of the drum core. Therefore, it is possible to suppress the variation of the gap between the drum core and the outer core defined by the sheet, and to make the characteristics of each product constant.
[0077]
Next, a method for manufacturing the surface-mounted coil component 10 of the present embodiment will be described with reference to FIGS.
[0078]
First, as shown in FIG. 3A, the winding 11 is started to be wound around the body 12a of the drum core 12 by a crosswise method. In the crosswise method, one winding is wound around the lower and upper sides of the drum core in opposite directions. In the figure, the upper flange 12b is omitted. FIGS. 3B and 3C show a state in which the winding of the winding 11 has been completed.
[0079]
As shown in FIG. 3B, after the winding is completed, the insulating coating on the ends of both ends 11a and 11b of the winding 11 is removed. Further, as shown in FIG. 3C, in the crosswise method, the windings 11 have a two-tiered shape, and the width direction of the windings is along the height direction of the drum core 12. Thus, by suppressing the number of laminations to two, the height of the coil component 10 can be reduced.
[0080]
Next, as shown in FIG. 4, the partial cores 15 and 16 are bonded to the drum core 12 by the above-described method. At this time, the ends 11a and 11b of the windings pass through the respective gap portions 21 and 22.
[0081]
Next, as shown in FIG. 5, after the terminals 11a and 11b of the windings are brought closer to the body portions 25a and 26a of the electrodes by wire forming, the windings are temporarily fixed by caulking the protruding pieces 25b and 26b. At this time, since the gap portions 21 and 22 have a sufficient space for connection as described above, the work can be performed smoothly. It is also possible to crimp the protruding pieces 25b, 26b from the state shown in FIG. 4 and press the protruding pieces so that the ends 11a, 11b of the windings are naturally guided to the main body sections 25a, 26a. If the protruding pieces 25b and 26b are used as the guide pieces, the wire forming step can be omitted.
[0082]
Next, as shown in FIG. 6, the leading end portion of the winding sandwiched between the projecting pieces 25b and 26b is cut by a cutter or the like.
[0083]
As shown in FIG. 7, thereafter, arc welding, laser beam welding, soldering, or the like is performed so as to cover the protruding pieces 25b, 26b, and the connection work between the winding 11 and the electrodes 25, 26 is completed. As described above, the surface mount type coil component 10 of the present embodiment is completed.
[0084]
FIG. 8A is a perspective view of a surface-mounted coil component 10 according to a first modified example of the first embodiment, FIG. 8B is a perspective view of one partial core 16 constituting the exterior core 14, FIG. (C) is VIIIc-VIIIc arrow sectional drawing of the surface mount type coil component 10. FIG.
[0085]
The surface-mounted coil component 10 of this example is different from the above-described surface-mounted coil component 10 only in the method of attaching the drum core 12 and the partial cores 15 and 16, and the other configuration is the same.
[0086]
In this example, on the surface facing the first partial core 15, the sheet 15s includes a first sheet portion 15s1 and a second sheet portion 15s2 separated along the axial direction of the drum core 12. An adhesive 15a1 is interposed between the first and second sheet portions 15s1 and 15s2.
[0087]
In this case, the core gap 18 can be regulated by the first and second sheet portions 15s1 and 15s2, but the drum core 12 and the partial core are bonded by the adhesive 15a1 provided at a position different from these. In addition, the gap is properly controlled by the sheet. When the first and second sheet portions 15s1 and 15s2 are bonded only to the drum core 12, when the first and second sheet portions 15s1 and 15s2 are bonded only to the first partial core 15s1, the first and second sheet portions 15s1 and 15s2 are bonded to the drum core 12 and the first partial core 15s2. In the former case, the core gap 18 is restricted to only one adhesive, so that the variation in the gap is suppressed. In the latter case, the adhesive is applied to both sides. Although the core gap 18 is restricted, the effect of the above-described downsizing and the suppression of the variation in the coil characteristics of each component due to the division of the exterior core 14 are not hindered.
[0088]
Further, since the first and second sheet portions 15s1 and 15s2 are separated from each other along the axial direction of the drum core 12, there is also an effect that the adhesive does not flow out along this direction. That is, the first and second sheet portions 15s1 and 15s2 also function as weirs as adhesive outflow prevention means.
[0089]
In addition, the description regarding the other partial core 16, the sheet 16s, the sheet portions 16s1, 16s2, and the adhesive 16a1 is replaced with the description of the partial core 15, the sheet 15s, the sheet portions 15s1, 15s2, and the adhesive 15a1, respectively. .
[0090]
FIG. 9A is a perspective view of a surface-mounted coil component 10 according to a second modified example of the first embodiment, FIG. 9B is a perspective view of one partial core 16 constituting the exterior core 14, and FIG. (C) is XIc-XIc arrow sectional drawing of the surface mount type coil component 10. FIG.
[0091]
In this example, the sheet 15 s is bonded to both the first partial core 15 and the drum core 12 on the surface facing the first partial core 15. Although the gap regulation is inferior to that in which the adhesive is interposed only on one surface side of the sheet 15s, the effect of the above-described downsizing and the suppression of the variation in coil characteristics of each component due to the division of the exterior core 14 are hindered. is not. In this example, it is not necessary to provide an adhesive for directly bonding the drum core 12 and the partial core 15 to a position different from the sheet 15s. Note that an adhesive can be applied to the other position as needed.
[0092]
In addition, the description about the other partial core 16 and the sheet 16s is replaced with the description of the partial core 15 and the sheet 15s, respectively.
[0093]
Next, the above-mentioned sheets (sheet parts) 15 and 16 will be described. Here, a sheet is represented by using the symbol S as a representative thereof.
[0094]
FIG. 10A is a front view of the sheet S when no adhesive is applied, FIG. 10B is a front view of a laminated body including the sheet S and the adhesive UA when only one surface is coated with the adhesive UA, FIG. 10C is a front view of a laminate including the sheet S and the adhesive when the adhesives UA and LA are applied to both surfaces.
[0095]
When the sheet S is made of a non-magnetic material, the sheet S itself does not affect the coil characteristics, so that it is possible to further suppress the variation in the coil characteristics for each component. An example of the sheet S is an insulating resin sheet, preferably an epoxy sheet.
[0096]
The epoxy sheet is prepared by dissolving a mixture of (1) an epoxy resin and (2) an epoxy curing agent in a solvent (3) to produce a curable epoxy resin composition, and (4) fabricating the curable epoxy resin composition. Impregnated.
[0097]
{Circle around (1)} Epoxy resins include tetraglycidyl ether type epoxy resin, bisphenol A type epoxy resin, bisphenol F type epoxy resin, novolak type epoxy resin, alicyclic epoxy resin, glycidyl ester type epoxy resin, glycidylamine type epoxy resin, Examples include a heterocyclic epoxy resin and a urethane-modified epoxy resin, and these can be used alone or in combination of two or more.
[0098]
(2) Epoxy curing agents include amine-based curing agents, polyaminoamide-based curing agents, acids and acid anhydrides, dicyandiamide, basic active hydrogen compounds such as organic acid dihydrazide, imidazoles, amineimides, Lewis acids, and branes. Stead acid salts, phenolic resins and the like can be mentioned, and these can be used alone or in combination of two or more.
[0099]
(3) Examples of the solvent include acetone, methyl ethyl ketone, toluene, methyl cellosolve, dimethylformamide and the like, and these can be used alone or as a mixture of two or more.
[0100]
{Circle over (4)} As the cloth, cloth of glass fiber or carbon fiber can be used.
[0101]
An appropriate thermosetting resin or epoxy resin can be used as the adhesive, and a polyimide sheet can be used as the sheet S.
[0102]
When the sheet S is not bonded to any of the partial core and the drum type core, the one shown in FIG. 10A is used, and when the sheet S is bonded to one of them, the one shown in FIG. 10B is used. When the sheet S is bonded to both the partial core and the drum core, the sheet shown in FIG. 10C is used.
[0103]
When the sheet S is adhered to both members, the gap regulation is inferior to that of the former, but the above-described downsizing and the variation in coil characteristics for each part due to the division of the outer core 14 are described. The effect of suppression is not hindered.
[0104]
(2nd Embodiment)
Next, a second embodiment of the surface mount type coil component 30 according to the present invention will be described with reference to FIGS. FIG. 11 is a perspective view of the coil component of the present embodiment, FIG. 12A is a plan view of the coil component, and FIG. 12B is a cross-sectional view taken along the line XIIb-XIIb in FIG. It is.
[0105]
The surface-mounted coil component 30 includes a drum-shaped core 12 in which a rectangular winding 11 is wound by a crosswise method, and a pair of a drum-shaped core 12 bonded to the drum-shaped core 12 through a substantially uniform core gap 18. And an exterior core 34 composed of a substantially U-shaped partial core 35, 36. The partial core 35 and the partial core 36 surround the drum-type core 12 from the side via gap portions 41 and 42 at opposing positions so as not to be joined to each other.
[0106]
Similarly to the first embodiment, by using the sheets 135s and 136s and an adhesive or the like, the core gap 18 can be made substantially constant in the circumferential direction. That is, the relationship between the sheets 135 s and 136 s, the partial cores 35 and 36, and the drum core 12 is the same as the relationship between the sheets 15 s and 16 s, the partial cores 15 and 16, and the drum core 12 in the first embodiment. And the description of the first embodiment will be replaced. In the figure, an example of the bonding method (applying an adhesive on both sides of the sheet) in the case of the second modified example of the first embodiment is shown, but regarding the bonding, this is the first embodiment and the first modified example. Can be read as the description of the modified example.
[0107]
The partial core 35 is formed with rectangular parallelepiped legs (opposing protrusions) 35a and 35b projecting in parallel toward the partial core 36, and the leg portions 35a and 35b are provided with a pair of caps. The electrodes 45 and 46 are attached. The cap-shaped electrodes 45, 46 include main bodies 45a, 46a fitted to the partial core 35, and projecting pieces (guide pieces) 45b, 46b provided in the main body and located in the gaps 41, 42. Prepare.
[0108]
The electrode body portions 45a and 46a include a quadrangular central portion located outside the leg portions 35a and 35b of each partial core, and hook portions 45h and 46h formed by bending strip-shaped pieces formed at upper and lower four corners thereof. Is provided. The cap-shaped electrodes 45, 46 are fitted to the legs 35a, 35b by sandwiching hooks 45h, 46h formed on the upper and lower sides in the height direction of the drum core 12.
[0109]
By using such cap-shaped electrodes 45 and 46, it is possible to easily attach the electrode to the partial core and to prevent accidental detachment. In addition, conduction with the printed wiring board is achieved through the lower hook portions 45h and 46h. Incidentally, such a cap-shaped electrode can be applied to the surface-mount type coil component of the first embodiment. In addition, the cap-shaped electrode may be arranged on the inside of the partial core with the quadrilateral region of the main body portion, and each hook portion may be bent outward to be attached to the leg portions 35a and 35b.
[0110]
The protruding pieces 45b and 46b are for holding the ends 11a and 11b of the winding between the electrode main body and the fixing piece, similarly to the first embodiment, to assist in fixing. The protruding piece 45b is configured to bend downward in the drawing to temporarily fix the winding, and conversely, the protruding piece 46b is bent upward to temporarily fix the winding.
[0111]
FIG. 11 shows a state before the winding is suppressed by the projecting pieces, and FIG. 12 shows a state in which the windings are temporarily fixed by bending the projecting pieces. The connection is completed by performing arc welding, soldering, or the like on the state of FIG.
[0112]
According to this embodiment, the same effect as that of the first embodiment can be obtained. That is, the ends 11a and 11b of the windings are connected to the cap-shaped electrodes 45 and 46 at the gaps 41 and 42 between the partial cores 45 and 46, respectively. That is, since the winding 11 does not bypass the upper side of the exterior core 34, the height of the winding 11 (further, the height of the protrusion by welding or soldering) can be reduced.
[0113]
Further, in the connection work between the winding 11 and the cap-shaped electrodes 45 and 46, it is not necessary to bend the winding 11 at the shoulder of the exterior core 34, so that the work can be performed easily. In addition, since the width direction of the rectangular winding 11 matches the height direction of the drum core 12 by using the crosswise method, the gap can be passed without twisting the winding. The connecting work is extremely easy.
[0114]
(Third embodiment)
Next, a third embodiment of the surface mount type coil component according to the present invention will be described with reference to FIG.
[0115]
FIG. 13A is a plan view of the surface-mount type coil component of the present embodiment, and FIG. 13B is a cross-sectional view of the surface-mount type coil component shown in FIG. 13A taken along arrows XIIIb-XIIIb. is there.
[0116]
In the surface-mount type coil component 50 of the present embodiment, the partial cores 55 and 56 constituting the exterior core 54 have the same U-shape. Therefore, the axial center of the drum core 12 is arranged in a straight line connecting the gap 61 and the gap 62 formed between the partial cores 55 and 56.
[0117]
The pair of electrodes 65 and 66 are bonded to both leg portions of the partial core 55 with an adhesive. The electrodes 65 and 66 are composed of main bodies 65a and 66a bonded to the partial core 55, and protruding pieces 65b and 66b connected to the main bodies. Then, similarly to the second embodiment, the terminals 11a and 11b of the rectangular winding are passed through the gap portions 61 and 62, and are temporarily fixed at the gap portions 61 and 62 by the protruding pieces 65b and 66b. From the state of FIG. 13, by performing arc welding, soldering, or the like so as to cover the vicinity of the protruding pieces 65b, 66b, the connection is completed.
[0118]
Similarly to the first embodiment, by using the sheets 155s and 156s and an adhesive or the like, the core gap 18 can be made substantially constant in the circumferential direction. That is, the relationship between the sheets 155 s and 156 s, the partial cores 55 and 56, and the drum-type core 12 is the same as the relationship between the sheets 15 s and 16 s, the partial cores 15 and 16, and the drum-type core 12 in the first embodiment. And the description of the first embodiment will be replaced. In the figure, an example of the bonding method (applying an adhesive on both sides of the sheet) in the case of the second modified example of the first embodiment is shown, but regarding the bonding, this is the first embodiment and the first modified example. Can be read as the description of the modified example.
[0119]
Also in the present embodiment, the winding is passed through the gap portions 61 and 62 as in the above-described embodiments, so that the height can be reduced substantially by the thickness of the winding. Furthermore, since the bending work at the shoulder of the armor core is not required, the work of connecting the winding and the electrode can be easily performed. In addition, since the width direction of the rectangular winding 11 coincides with the height direction of the drum core 12, the winding can be passed through the gap portion without twisting the winding. Has become. Further, in the present embodiment, since the partial cores 55 and 56 have the same shape, there is an advantage that a kind of partial core can be manufactured as compared with the second embodiment.
[0120]
(Fourth embodiment)
Next, a fourth embodiment of the surface mount type coil component according to the present invention will be described with reference to FIG.
[0121]
FIG. 14A is a plan view of the surface-mounted coil component of the present embodiment, and FIG. 14B is a cross-sectional view of the surface-mounted coil component shown in FIG. 14A taken along arrows XIVb-XIVb. is there.
[0122]
In the present embodiment, when a quadrilateral (indicated by a broken line in FIG. 14A) is imagined along the outer edge of the exterior core 54 when the surface mount type coil component is viewed in a plan view, a gap between the partial cores 55 and 56 is formed. 61 and 62 are located near two opposing vertices, respectively. The surfaces defining the gap portions 61 and 62 in the partial cores 55 and 56 are formed by the diagonal line l of the virtual square. ₁ It is parallel to. That is, the gap portions 61 and 62 have a constant width in the radial direction of the drum core 12.
[0123]
Similarly to the first embodiment, by using the sheets 155s and 156s and an adhesive or the like, the core gap 18 can be made substantially constant in the circumferential direction. That is, the relationship between the sheets 155 s and 156 s, the partial cores 55 and 56, and the drum core 12 is the same as the relationship between the sheets 15 s and 16 s, the partial cores 15 and 16, and the drum core 12 in the first embodiment. And the description of the first embodiment will be replaced. In the figure, an example of the bonding method (applying an adhesive on both sides of the sheet) in the case of the second modified example of the first embodiment is shown, but regarding the bonding, this is the first embodiment and the first modified example. Can be read as the description of the modified example.
[0124]
Also in this embodiment, the rectangular winding is passed through the gap portions 61 and 62 as in the above embodiments, so that the height can be reduced almost by the thickness of the winding. Furthermore, since the bending work at the shoulder of the armor core is not required, the work of connecting the winding and the electrode can be easily performed. However, since the gap portions 61 and 62 do not have a structure that expands outward, the first embodiment can be said to be a configuration superior to the present embodiment from the viewpoint of easiness of connection work.
[0125]
(Fifth embodiment)
Next, a fifth embodiment of the surface mount type coil component according to the present invention will be described with reference to FIG.
[0126]
15A is a plan view of the surface-mounted coil component of the present embodiment, and FIG. 15B is a cross-sectional view of the surface-mounted coil component shown in FIG. 15A taken along the line XVb-XVb. is there.
[0127]
In the present embodiment, in each of the partial cores 75 and 76 constituting the exterior core 74, the length of the leg toward the other core is different between left and right (up and down in FIG. 15A). In the partial core 75, the leg 75r is longer than the other leg 75l, and in the partial core 76, the leg 76r is longer than the other leg 76l. The partial core 75 and the partial core 76 have the same shape.
[0128]
Further, a pair of electrodes 65 and 66 are attached to both leg portions 75r and 75l of the partial core 75. The electrodes 65 and 66 have the same structure as that of the third embodiment, and include main bodies 65a and 66a bonded to the partial cores and protruding pieces 65b and 66b which are connected to the main bodies and located in the gaps 61 and 62. Is provided.
[0129]
Also in this embodiment, the rectangular winding is passed through the gap portions 61 and 62 as in the above embodiments, so that the height can be reduced almost by the thickness of the winding. Furthermore, since the bending work at the shoulder of the armor core is not required, the work of connecting the winding and the electrode can be easily performed.
[0130]
Similarly to the first embodiment, by using the sheets 175s and 176s and an adhesive or the like, the core gap 18 can be made substantially constant in the circumferential direction. That is, the relationship between the sheets 175 s and 176 s, the partial cores 75 and 76, and the drum core 12 is the same as the relationship between the sheets 15 s and 16 s, the partial cores 15 and 16, and the drum core 12 in the first embodiment. And the description of the first embodiment will be replaced. In the figure, an example of the bonding method (applying an adhesive on both sides of the sheet) in the case of the second modified example of the first embodiment is shown, but regarding the bonding, this is the first embodiment and the first modified example. Can be read as the description of the modified example.
[0131]
(Sixth embodiment)
Next, a sixth embodiment of the surface mount type coil component according to the present invention will be described with reference to FIG.
[0132]
In the surface-mounted coil component 90 of the present embodiment, the outer core 84 surrounding the drum core 12 is composed of a partial core 85 and a partial core 86. Only one gap 21 is formed between the partial core 85 and the partial core 86. Further, both ends 11a and 11b of the rectangular winding are passed through the one gap portion 21 and connected to the electrodes 25 and 26, respectively. As the electrode, for example, an electrode having a projecting piece as in the first embodiment can be used.
[0133]
In the case of such a configuration, the surface mounting type coil component can be temporarily fixed at one position of the gap portion 21 because the temporary fixing work of sandwiching the winding between the protruding pieces and the subsequent connecting work such as arc welding and soldering can be performed at one place of the gap portion 21. Production work becomes smoother, which leads to improved productivity.
[0134]
In this embodiment, only one gap portion is formed. However, when a plurality of gap portions are formed as in the first embodiment, both ends of the rectangular winding are passed through one of them. You may do so.
[0135]
Similarly to the first embodiment, by using the sheets 185s and 186s and an adhesive or the like, the core gap 18 can be made substantially constant in the circumferential direction. That is, the relationship between the sheets 185 s and 186 s, the partial cores 85 and 86, and the drum core 12 is the same as the relationship between the sheets 15 s and 16 s, the partial cores 15 and 16, and the drum core 12 in the first embodiment. And the description of the first embodiment will be replaced. In the figure, an example of the bonding method (applying an adhesive on both sides of the sheet) in the case of the second modified example of the first embodiment is shown, but regarding the bonding, this is the first embodiment and the first modified example. Can be read as the description of the modified example.
[0136]
(Seventh embodiment)
Next, a seventh embodiment of the surface mount type coil component according to the present invention will be described with reference to FIG.
[0137]
In the surface-mounted coil component 98 of the present embodiment, the outer core 94 surrounding the drum core 12 is composed of three parts: a partial core 95, a partial core 96, and a partial core 97. From a different point of view, the partial core 56 in the surface mount type coil component 50 shown in FIG. Because of the structure in which the exterior core is divided into three, three gap portions 91, 92, and 93 are formed between the respective partial cores. Providing a plurality of gaps has the advantage that the DC bias characteristics can be improved, that is, the change in inductance with respect to the current change can be reduced.
[0138]
A pair of electrodes 65 and 66 are attached to both legs of the partial core 95. Then, both ends 11a and 11b of the winding are passed through gap portions 91 and 92 and connected to the respective electrodes 65 and 66.
[0139]
As described above, even when the outer core is divided into three parts, the same effects as those of the above embodiments can be obtained. Further, although not shown, the same effect can be obtained when the exterior core is formed of four or more partial cores.
[0140]
As in the first embodiment, by using the sheets 195s, 196s1, 196s2 and an adhesive or the like, the core gap 18 can be made substantially constant in the circumferential direction. That is, regarding the relationship between the sheets 195s, 196s1, 196s2, the partial cores 95, 96, 97, and the drum core 12, the sheets 15s, 16s (considered to be divided) in the first embodiment with respect to their adhesion. This is the same as the relationship between the partial cores 15 and 16 (assumed to be divided) and the drum core 12, and the description of the first embodiment will be replaced. In the figure, an example of the bonding method (applying an adhesive on both sides of the sheet) in the case of the second modified example of the first embodiment is shown, but regarding the bonding, this is the first embodiment and the first modified example. Can be read as the description of the modified example.
[0141]
As described above, the invention made by the present inventors has been specifically described based on the embodiments. However, the present invention is not limited to the above embodiments. For example, in the embodiment shown in FIG. 13B (third embodiment), the leg portion of the partial core is formed in a tapered shape so that the cross-section is tapered inward (toward the drum-type core). Can be. At this time, if the upper and lower pieces of the electrode body are bent so as to approach each other, the electrode can be fitted into the partial core without using an adhesive.
[0142]
【The invention's effect】
As described above, according to the surface-mount type coil component and the method of manufacturing the same according to the present invention, it is possible to achieve downsizing and suppress variations in coil characteristics for each product.
[Brief description of the drawings]
FIG. 1A is a perspective view of a surface-mount type coil component 10 of the present embodiment, FIG. 1B is a perspective view of one partial core 16 constituting an exterior core 14, and FIG. FIG. 2 is a cross-sectional view of the surface mount type coil component 10 taken along an arrow Ic-Ic.
2A is a plan view of the surface-mounted coil component 10, FIG. 2B is a front view of the surface-mounted coil component 10, and FIG. 2C is a side view of the surface-mounted coil component 10. FIG.
FIG. 3 (a) is a diagram showing a state in which winding is started around a drum-type core, and FIGS. 3 (b) and 3 (c) show a state in which winding of the winding is completed. FIG.
FIG. 4 is a view showing one process of manufacturing the surface mount type coil component, and showing a state in which a drum core and a partial core are bonded.
FIG. 5 is a step subsequent to FIG. 4 and shows a state in which the winding is temporarily fixed by a protruding piece of an electrode.
FIG. 6 is a step subsequent to FIG. 5 and shows a state in which a leading end of the winding is cut.
FIG. 7 is a process subsequent to FIG. 6 and shows a state in which welding has been performed in the vicinity of the protruding piece of the electrode to complete the connection.
8A is a perspective view of the surface mount type coil component 10 of the present embodiment, FIG. 8B is a perspective view of one partial core 16 constituting the exterior core 14, and FIG. 8C. FIG. 7 is a sectional view taken along the arrow VIIIc-VIIIc of the surface-mounted coil component 10.
FIG. 9A is a perspective view of the surface-mounted coil component 10 of the present embodiment, FIG. 9B is a perspective view of one partial core 16 constituting the exterior core 14, and FIG. 9C. FIG. 4 is a cross-sectional view taken along the line IVc-IVc of the surface-mounted coil component 10.
FIG. 10A is a front view of the sheet S when no adhesive is applied, and FIG. 10B is a laminate including the sheet S and the adhesive UA when only one surface is coated with the adhesive UA. FIG. 10 (c) is a front view of a laminate composed of the sheet S and the adhesive when the adhesives UA and LA are applied to both surfaces.
FIG. 11 is a perspective view showing a second embodiment of the surface-mounted coil component according to the present invention.
FIG. 12A is a plan view of a surface-mounted coil component according to a second embodiment, and FIG. 12B is a cross-sectional view of the coil component shown in FIG. 12A taken along arrows XIIb-XIIb. FIG.
FIG. 13A is a plan view of a surface-mounted coil component according to a third embodiment, and FIG. 13B is a cross-sectional view of the coil component shown in FIG. 13A taken along arrows XIIIb-XIIIb. FIG.
FIG. 14A is a plan view of a surface-mounted coil component according to a fourth embodiment, and FIG. 14B is a cross-sectional view of the coil component shown in FIG. 14A taken along arrows XIVb-XIVb. FIG.
FIG. 15A is a plan view of a surface-mount type coil component according to a fifth embodiment, and FIG. 15B is a cross-sectional view of the coil component shown in FIG. 15A taken along the line XVb-XVb. FIG.
FIG. 16 is a plan view of a surface-mounted coil component according to a sixth embodiment.
FIG. 17 is a plan view of a surface-mounted coil component according to a seventh embodiment.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... Surface mount type coil parts, 11 ... Square winding, 11a, 11b ... End of winding, 12 ... Drum core, 12a ... Body, 12b, 12c ... Flange, 14 ... Outer core, 15, 16 ... Partial core, 18 core gap, 21, 22 gap portion, 25, 26 electrode, 25a, 26a electrode body, 25b, 26b electrode protruding piece, SA ₁ ... First surface defining the gap, SA ₂ ... Second surface defining a gap portion, 45, 46... Cap-shaped electrodes, 45h, 46h... Hook portions, 15s, 16s.

Claims (6)

A drum-type core having windings wound thereon, and a surface-mount type coil component including an exterior core surrounding the drum-type core around its axis, wherein between the drum-type core and the exterior core, A sheet is interposed, and the exterior core is divided into a plurality of partial cores so that the sheet comes into contact with the opposing surfaces of both the drum core and the exterior core. Type coil parts. The surface-mounted coil component according to claim 1, wherein the sheet is fixed to at least one of the opposing surfaces with an adhesive. The partial core includes first and second partial cores, and the sheet is adhered only to the first partial core on the facing surface of the first partial core, and the sheet is adhered to the first partial core. The surface-mounted coil component according to claim 1, wherein an adhesive is interposed between the first partial core and the drum-shaped core in a region other than the region. The partial core includes first and second partial cores, and the sheet includes first and second sheet portions separated along the axial direction of the drum-shaped core on the facing surface of the first partial core, The surface mount type coil component according to claim 1, wherein an adhesive is interposed between the first and second sheet portions. The partial core includes first and second partial cores, and the sheet is bonded to both the first partial core and the drum-shaped core on the facing surface of the first partial core. The surface-mounted coil component according to claim 1. A method for manufacturing a surface-mounted coil component, comprising: a drum-type core having windings wound thereon; and an outer core surrounding the drum-type core around its axis, wherein the outer core has first and second partial cores. At
(A) preparing a first partial core having a concave surface and a second partial core having a concave surface;
(B) interposing a sheet between the concave surface of the first partial core and the drum core;
(C) attaching the concave surface of the second partial core to the outer peripheral surface of the drum core;
A method for manufacturing a surface-mounted coil component, comprising:

Images