JP2005191403A - Coil component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil component wherein no drum core and no ring core are so integrated with each other by a bonding agent as to make unnecessary the consideration of the heat resistance of the bonding agent, and the disconnection of the lead wire of its coil is so suppressed as to improve its reliability. <P>SOLUTION: The coil component has a core 30 wherein a magnetic material is so powdered as to cover the surfaces of the resultant grains with insulating films and the resultant grains are so mixed with a binder as to be molded pressingly, a coil 31 wherein a wire is so wound spirally as to form it and it is buried in the core 30, and terminals 32 connected electrically with the coil 31. Further, each terminal 32 comprises a lead wire 33 of the coil 31 which is so protruded from the core 30 as to be subjected to a fold machining and a holding portion having a holding means for superimposing the holding portion on the lead wire 33 subjected to the fold machining. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a coil component used in various electronic devices, communication devices, and the like.

  Hereinafter, a conventional technique will be described with reference to the drawings.

  FIG. 9 is a block diagram showing the entire control system for controlling the fuel injection device of the automobile engine, FIG. 10 is a circuit diagram of a power supply unit in the control control unit of the control system, FIG. It is a perspective view of the conventional coil components used for the power supply part.

  In FIG. 9, in the control system for controlling the fuel injection device of the automobile engine, the control control unit 2 to which the driving current is supplied from the battery 1 controls the fuel injection device 3 of the engine. The control control unit 2 is provided with a CPU 4 that calculates and controls the injection amount and injection timing of the fuel injection device, and a power supply unit 5 that supplies current to the CPU 4.

  As shown in FIG. 10, the power supply unit includes a filter unit 8 including a coil component 6 and a capacitor component 7, and a DC / DC converter unit 11 including a coil component 6, a capacitor component 7, an IC 9, and a switching component 10. Are connected to each other, and the filter unit 8 is connected to the battery terminal 12 on the battery 1 side, and the DC / DC converter unit 11 is connected to the CPU terminal 13 on the CPU 4 side. In particular, the coil component 6 used in the DC / DC converter unit 11 is driven to be switched by the switching component 10. In the DC / DC converter unit 11, the 12 V voltage of the battery 1 is reduced to about 1.5 to 5 V for the CPU 4. ing.

  As one of the coil components used in the DC / DC converter unit 11, as shown in FIGS. 11 and 12, a drum-shaped drum magnetic core 21 having ridges at both ends of the winding shaft unit 20, and the drum magnetic core. A coil 22 wound around the winding shaft 20 of the ring 21, a ring-shaped ring magnetic core 23 combined with the drum magnetic core 21 so as to cover the coil 22, and a terminal portion 24 electrically connected to the coil 22; There is something with. The coil 22 is formed by spirally winding a conducting wire made of a round wire, and the lead wire 25 is wound around one end 26 of the L-shaped terminal portion 24.

  The drum magnetic core 21 and the ring magnetic core 23 are made of a ferrite material, and the drum magnetic core 21 and the ring magnetic core 23 are integrated by applying an adhesive 27.

As prior art document information relating to the invention of this application, for example, Patent Document 1 is known.
JP 2002-64024 A

  Since the conventional coil component is used for the DC / DC converter unit 11 in the vicinity of an automobile engine, heat resistance is required. However, in the coil component, since the drum magnetic core 21 and the ring magnetic core 23 are integrated by applying the adhesive 27, the adhesive 27 melts depending on the heat-resistant temperature of the adhesive 27 and the reliability deteriorates. It had the problem that.

  Further, since the lead wire 25 of the coil 22 is entangled with the L-shaped terminal portion 24, tension is easily applied between the terminal portion 24 and the lead wire 25 of the coil 22 due to the vibration of the engine of the automobile. There was a problem that the wire 25 may be broken.

  In order to solve the above problems, the present invention does not integrate the drum magnetic core and the ring magnetic core with an adhesive so that it is not necessary to consider the heat resistance of the adhesive. It aims at providing the coil component which suppressed and improved the reliability.

  In order to solve the above problems, the present invention has the following configuration.

  The invention of claim 1 of the present invention is formed by, in particular, forming a magnetic material in powder form, covering the surface with an insulating film, mixing a binder and press-molding, and winding a conductive wire in a spiral shape, A coil embedded in a magnetic core, and a terminal portion electrically connected to the coil, the terminal portion protruding from the magnetic core and bent, and the coil lead wire And a holding portion having holding means for holding the position and shape of the lead wire.

  With the above configuration, the terminal portion is composed of a coil lead wire bent from the magnetic core and a holding portion having holding means for holding the position and shape of the bent lead wire. The position and shape of the bent lead wire of the coil can be maintained, and the lead wire itself can be used as the terminal portion. Therefore, it is not necessary to tie the lead wire to the terminal portion, and the disconnection of the lead wire can be controlled to improve the reliability.

  In particular, in order to increase the number of turns of the coil, even if the thickness of the coil is reduced or the coil wire diameter is reduced, the lead wire itself is not easily bent or becomes independent. It is possible to improve reliability by suppressing disconnection.

  In addition, the coil is made of powdered magnetic material, covered with an insulating film, embedded in a magnetic core that has been pressed and mixed with a binder, so the magnetic core can be formed without using an adhesive and heat resistance is improved. it can.

  According to a second aspect of the present invention, the coil has an edgewise shape formed by spirally winding a flat conductive wire.

  With the above configuration, since the conducting wire is flat, the thickness of the conducting wire can be reduced, the space factor of the conducting wire can be improved, and the height can be reduced.

  According to a third aspect of the present invention, the coil is formed by bending an arc-shaped pattern formed on a metal flat plate.

  With the above configuration, since the conducting wire is formed by bending an arc-shaped pattern formed on a metal flat plate, the thickness of the conducting wire can be reduced, the space factor of the conducting wire can be improved, and the height can be reduced.

  According to a fourth aspect of the present invention, in particular, the holding portion is a flat plate having a self-supporting property capable of holding itself in a self-supporting manner, and the holding means is a lead wire for the coil obtained by bending the flat plate. It is the structure used as the means to hold | maintain in piles.

  With the above configuration, the holding part is a self-supporting flat plate that can hold the shape in a self-supporting manner, and the holding means holds the flat plate and the lead wire because the flat plate is superposed on the lead wire of the coil. can do. Having self-supporting here means a state in which when the flat plate is bent, the bent shape is maintained as it is and the holding force is such that it does not bend.

  The invention according to claim 5 of the present invention particularly has a configuration in which the flat plate is sandwiched between the magnetic core and the lead wire of the coil.

  With the above configuration, the flat plate can be sandwiched between the magnetic core and the lead wire of the coil, so that the lead wire can be accurately held. In particular, since the lead wire can be disposed outside the flat plate, solder connection with the mounting substrate can be facilitated during mounting.

  The invention described in claim 6 of the present invention has a configuration in which the lead wire of the coil is sandwiched between the magnetic core and the flat plate.

  With the above configuration, since the lead wire of the coil can be sandwiched between the magnetic core and the flat plate, the lead wire can be accurately held.

  The invention according to claim 7 of the present invention is particularly configured such that the width of the flat plate is wider than the width of the lead wire of the coil.

  With the above configuration, it is possible to easily perform solder connection with the mounting substrate at the time of mounting.

  The invention according to claim 8 of the present invention has a structure in which the flat plate and the lead wire of the coil are joined.

  With the above configuration, since the flat plate and the lead wire are joined, the flat plate and the lead wire are not displaced, and the lead wire can be held accurately.

  In the invention according to claim 9 of the present invention, in particular, the flat plate has a structure having electric conductivity.

  With the above configuration, since the flat plate has electrical conductivity, the lead wire and the flat plate can be electrically connected to each other, which is convenient for use as a terminal portion.

  In the invention according to claim 10 of the present invention, in particular, the flat plate has a structure in which one end is embedded in the magnetic core.

  With the above configuration, since the flat plate has one end embedded in the magnetic core, the flat plate can be easily attached.

  The eleventh aspect of the present invention has a configuration in which the end portion of the lead wire of the coil is crushed flat.

  With the above configuration, since the end portion of the lead wire is crushed flat, it is easy to connect to the flat plate.

  The invention described in claim 12 of the present invention is a configuration in which the end portion of the lead wire of the coil is particularly flattened and formed into a square shape.

  With the above configuration, the end portion of the lead wire is flattened into a flat shape so that it can be easily connected to a flat plate.

  According to the present invention, the coil is formed of a magnetic material powder, the surface is covered with an insulating film, and the magnetic core is formed without using an adhesive because the surface is covered with an insulating film and embedded in a pressure-molded magnetic core. it can.

  In addition, the terminal portion is composed of a coil lead wire that is bent from the magnetic core and a holding portion that has holding means for holding the position and shape of the bent lead wire. The position and shape of the processed coil lead wire can be maintained, and the lead wire itself can be used as a terminal portion. Therefore, it is not necessary to tie the lead wire to the terminal portion, and the disconnection of the lead wire can be controlled to improve the reliability.

  Thereby, it is not necessary to consider the heat resistance of the adhesive, and disconnection of the coil lead wire can be suppressed, and a coil component with improved reliability can be provided.

(Embodiment)
Hereinafter, all the claims of the present invention will be described with reference to the drawings using an embodiment.

  FIG. 1 is a sectional view of a coil component according to an embodiment of the present invention, FIG. 2 is a perspective view of the coil component, and FIG. 3 is a manufacturing process diagram of the coil component.

  1 and 2, a coil component according to an embodiment of the present invention includes a magnetic core 30 made of powdered magnetic material, the surface is covered with an insulating film, a binder is mixed and pressure-molded, and a conductive wire is spirally formed. A coil 31 formed by winding and embedded in the magnetic core 30 and a terminal portion 32 electrically connected to the coil 31 are provided.

  The coil 31 is formed of a thin round wire, and the lead wire 33 is formed in a rectangular shape while the end portion 34 is flattened.

  Further, the terminal portion 32 includes a lead wire 33 of the coil 31 that is bent from the magnetic core 30 and a holding portion that has a holding means that holds the lead wire 33 so as to overlap the bent lead wire 33. The holding portion is a flat plate 35 having a self-supporting property capable of being self-supporting and holding the shape, and the holding means is a means for holding and holding the lead wire 33 of the coil 31 by thermocompression bonding.

  In particular, the flat plate 35 is wider than the lead wire 33 of the coil 31 and is made of a metal having electrical conductivity, and one end 36 thereof is embedded in the magnetic core 30.

  The flat plate 35 is sandwiched between the magnetic core 30 and the lead wire 33 of the coil 31, and the flat plate 35 and the lead wire 33 of the coil 31 are bent from the side surface to the bottom surface of the magnetic core 30 along the magnetic core 30. doing.

  Next, the manufacturing process of this coil 31 component will be described.

  First, as shown in FIG. 3A, a coil 31 is formed by winding a round wire in a spiral shape and drawing out a lead wire 33 left and right.

  Secondly, as shown in FIG. 3B, the lead wire 33 of the coil 31 is crushed and cut along a broken line (AA), and the lead wire 33 is flattened and formed into a square shape.

  Third, as shown in FIG. 3 (c), a flat plate 35 having conductivity and capable of being self-supporting and maintaining its shape is connected to the lead wire 33 of the coil 31 by thermocompression bonding. Thus, the terminal portion 32 is formed.

  Fourth, as shown in FIG. 3 (d), a coil 31 is embedded in a magnetic core 30 that is made of a magnetic material, covered with an insulating film, mixed with a binder, and press-molded. At this time, the coil 31 is embedded so that the flat plate 35 and the lead wire 33 of the coil 31 protrude from the magnetic core 30.

  Fifth, the lead wire 33 of the coil 31 and the crimped flat plate 35 are both bent along the magnetic core 30 from the side surface of the magnetic core 30 toward the bottom surface of the magnetic core 30 to form the terminal portion 32. FIG. The coil 31 components shown in FIG.

  With the above configuration, the terminal portion 32 includes a lead wire 33 of the coil 31 that is bent from the magnetic core 30 and a holding portion that has holding means for holding the position and shape of the bent lead wire 33. Therefore, the position and shape of the lead wire 33 of the coil 31 bent by the holding portion can be held, and the lead wire 33 itself can be used as the terminal portion 32. Therefore, it is not necessary to entangle the lead wire 33 to the terminal portion 32, and disconnection of the lead wire 33 can be suppressed and reliability can be improved. In order to increase the number of turns of the coil 31, even if the thickness of the coil 31 is reduced or the wire diameter of the coil 31 is reduced, the lead wire 33 itself may be easily bent or become independent. Reliability can be improved by suppressing disconnection of the lead wire 33.

  In particular, since the holding portion is a self-supporting flat plate 35 that can stand and hold its shape, and the holding means is a means for holding the flat plate 35 so as to overlap the lead wire 33 of the coil 31 that has been bent, the flat plate 35 And the lead wire 33 can be easily held. In particular, since the end portion 34 of the lead wire 33 is flattened into a flat shape, the lead wire 33 can be easily connected to the flat plate 35.

  Further, since the flat plate 35 has one end 36 embedded in the magnetic core 30, the flat plate 35 can be easily attached, and the flat plate 35 has electrical conductivity, so that the lead wire 33 and the flat plate 35 can be electrically connected. The terminal unit 32 is easy to use. In particular, since the flat plate 35 is sandwiched between the magnetic core 30 and the lead wire 33 of the coil 31, the lead wire 33 can be accurately held. At this time, since the lead wire 33 is arranged outside the flat plate 35, it is possible to easily perform solder connection with the mounting substrate at the time of mounting.

  Further, since the coil 31 is made of a magnetic material powder, the surface is covered with an insulating film, and the magnetic core 30 is embedded in a pressure-molded magnetic core 30 mixed with a binder. it can.

  As described above, according to the embodiment of the present invention, it is not necessary to consider the heat resistance of the adhesive, and it is possible to provide a coil component with improved reliability by suppressing disconnection of the lead wire 33 of the coil 31. can do.

  In addition, having the self-supporting property in the embodiment of the present invention means a state in which when the flat plate 35 is bent, the bent shape is maintained as it is and the holding force is such that it does not bend. means.

  Further, as shown in FIG. 4, the lead wire 33 of the coil 31 is sandwiched between the magnetic core 30 and the flat plate 35, and as shown in FIG. 5, one end 36 of the flat plate 35 is not embedded in the magnetic core 30, and Even if the lead wire 33 of the coil 31 is joined, the lead wire 33 can be accurately held. For joining the lead wire 33 of the coil 31 and the flat plate 35, various joining methods such as resistance welding and solder joining may be used in addition to thermocompression bonding.

  Furthermore, instead of the coil 31 formed by spirally winding a round wire, as shown in FIGS. 6 and 7, an edgewise shape formed by spirally winding a flat wire. Alternatively, as shown in FIG. 8, an arc-shaped pattern 37 formed on a metal flat plate may be bent. In this case, the thickness of the conducting wire can be reduced, the space factor of the conducting wire can be improved, and the height can be reduced.

  In addition, various forms can be adopted without departing from the spirit of the present invention.

  As described above, according to the present invention, the present invention relates to a coil component used in various electronic devices, communication devices, etc., and it is not necessary to consider the heat resistance of the adhesive, and the coil lead wire is disconnected. It can suppress and use as a coil component which improved reliability.

Sectional drawing of the coil components in one embodiment of this invention Perspective view of the coil component Manufacturing process diagram of the coil parts Cross-sectional view of other coil parts Cross-sectional view of other coil parts Perspective view of other coil components using edgewise coils Cross-sectional view of other coil components using edgewise coils A plan view showing an arc-shaped pattern formed on a metal flat plate The block diagram which shows the whole control system which controls the fuel injection device of the automobile engine Circuit diagram of the power supply unit in the control unit of the control system Cross-sectional view of the coil component A perspective view of a conventional coil component used for the power supply unit

Explanation of symbols

30 Magnetic core 31 Coil 32 Terminal portion 33 Lead wire 34 End portion 35 Flat plate 36 One end 37 Pattern

Claims (12)

A magnetic material is powdered, the surface is covered with an insulating film, a magnetic core formed by pressing a binder and mixed, a coil formed by winding a conductive wire in a spiral shape, and a coil embedded in the magnetic core, and the coil electrically A terminal portion connected to the coil portion, the terminal portion including a lead wire of the coil that is bent by being protruded from the magnetic core, and a holding unit that holds a position and a shape of the lead wire of the coil that is bent. Coil parts consisting of a holding part. The coil component according to claim 1, wherein the coil has an edgewise shape formed by spirally winding a flat conductive wire. The coil component according to claim 1, wherein the coil is formed by bending an arc-shaped pattern formed on a metal flat plate. The said holding | maintenance part was made into the flat plate which has the self-supporting property which can be self-supported and can hold | maintain a shape, and the said holding means was a means to pile up and hold | maintain the said flat plate on the lead wire of the said coil bent. Coil parts. The coil component according to claim 4, wherein the flat plate is sandwiched between the magnetic core and a lead wire of the coil. The coil component according to claim 4, wherein a lead wire of the coil is sandwiched between the magnetic core and the flat plate. The coil component according to claim 4, wherein a width of the flat plate is wider than a width of the lead wire of the coil. The coil component according to claim 4, wherein the flat plate and the lead wire of the coil are joined. The coil component according to claim 4, wherein the flat plate has electrical conductivity. The coil component according to claim 4, wherein one end of the flat plate is embedded in the magnetic core. The coil component according to claim 4, wherein an end portion of the coil lead wire is flattened. The coil component according to claim 4, wherein an end portion of the coil lead wire is flattened and formed into a square shape.

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