JP2005340607A - Inductor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inductor in which it is possible to decrease a width dimension and a bent portion is not formed in the inductor using a flat wire. <P>SOLUTION: The inductor comprises a first core member 20 having a roller 21, and a second core member 30 which has an inner cylindrical part 31 surrounded by a peripheral wall and in which the first core member 20 is disposed in the inner cylindrical part 31. Flat wires 40 make a flat planar shape by extending a contact face along a longitudinal direction, and are laminated in a state of coming into contact with the contact face to be wound toward a diameter spreading direction of the roller 21. Further, a terminal member 50 is located on the side of the inner cylindrical part 31 and has an inner peripheral terminal 52 which joins a terminal 41 of the flat wire 40, and a planar face terminal 51 which is projected from an end face of the second core member 30 to be mounted at a mounting region. A terminal face 52a of the inner peripheral terminal 52 is directed to the diameter widening direction of the flat wire 40 in a wound state, to form a face joining between the terminal face 52a and the contact face of the flat wire 40. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an inductor applied to various electronic devices.

  In recent years, inductors have been required to be smaller and thinner in order to increase the mounting density of circuit boards and meet the demand for smaller electronic devices. As a type of conventional inductor, there is known a type in which a winding is wound around a drum core and a ring core is disposed in a state of being opposed to the drum core. In this type of inductor, in general, the binding terminal protrudes outward, and the end of the winding is connected to the binding terminal, and soldering is made to the binding part. ing.

  Patent Document 1 discloses a configuration in which a terminal of a winding is joined by soldering to a terminal member having a flat portion mounted on a circuit board without providing a binding terminal. Furthermore, Patent Document 2 discloses an inductor of a type using a rectangular wire as a winding.

JP 2003-109823 A (see paragraph number 0035, FIG. 3, FIG. 4 and FIG. 9) Japanese Patent Laid-Open No. 11-219839 (see abstract, FIG. 1 and others)

  By the way, in the inductor having the above-described binding terminal, extra dimensions are required for the binding terminal. Therefore, from the viewpoint of miniaturization, it is preferable not to provide the binding terminal as in the inductor disclosed in Patent Document 1. However, in the configuration disclosed in Patent Literature 1, the terminal is joined by soldering in a state where the terminal portion is extended to the outer peripheral wall portion of the terminal member. Therefore, it protrudes outward by the amount corresponding to the build-up part by soldering, and hinders the reduction of the width dimension.

  Further, as shown in Patent Document 2, a horizontal winding type flat wire (a flat wire of a type in which flat flat wire contact surfaces are laminated in the diameter-expanding direction in contact with each other) as shown in FIG. When used, the flat wire stacking direction (winding direction) and the flat wire drawing direction are perpendicular to each other. Therefore, when the end of the flat wire is fixed by soldering or the like, a twisted portion or a bent portion (hereinafter referred to as a bent portion) is formed in the flat wire drawing portion. In this way, when the bent portion is formed in the flat wire, the flat wire has a spring property, so that the connecting portion of the flat wire continues to apply a force in a direction away from the bonded state. Therefore, when an external action such as an impact load is applied, the bonding strength may be lowered.

  In addition, when the terminal portion of the rectangular wire is joined by soldering in a state where the bent portion is formed on the rectangular wire, there is a problem that a short circuit is likely to occur. That is, the bent portion is mainly formed at the end portion of the rectangular wire to be joined, but when soldering is performed at the tip portion of the end portion, the heat accompanying the soldering is applied to the bent portion. Is also communicated. In particular, since the rectangular wire has a conductor such as copper having excellent thermal conductivity, heat is immediately transmitted when the bent portion is close to the terminal.

  By the way, in the bent portion, the flat wire films may come into contact with each other due to twisting or bending. In such a contact state of the film, heat is transferred from the conductor inside each film, and the temperature rises easily. For this reason, in the bent portion, coupled with the stress load caused by bending, the film is melted and the conductor is easily exposed, and a short circuit where the conductors are in contact with each other is likely to occur. When such a short circuit occurs, the electrical characteristics deteriorate, causing a failure. Therefore, in an inductor using a rectangular wire, it is desired that no bent portion exists at the terminal.

  The present invention has been made on the basis of the above circumstances, and an object of the present invention is to provide an inductor in which a width portion can be reduced and a bent portion is not formed at a terminal in an inductor using a flat wire. .

  In order to solve the above-mentioned problem, the present invention has a first core member having a winding shaft and an inner cylinder part surrounded by a peripheral wall, and a second core member is arranged on the inner cylinder part. The core member and the contact surface have a flat shape along the length, and the rectangular wire laminated toward the diameter increasing direction of the winding shaft and the inner circumference located on the inner tube portion side and joining the ends of the rectangular wire And a terminal member having a flat terminal that protrudes from the end surface of the second core member and is mounted on the mounting portion, and the terminal surface of the inner peripheral terminal has a diameter expansion direction of the rectangular wire in a wound state. The terminal surface and the contact surface are surface-bonded.

  In this case, since the terminal surface of the inner peripheral terminal faces the diameter expansion direction of the rectangular wire, the terminal of the rectangular wire and the inner peripheral terminal wound around the winding shaft of the first core member. The terminal surface is in a state of facing each other at the time of joining. Therefore, the terminal of the flat wire and the terminal surface of the inner peripheral terminal can be surface-bonded in a state where the bent portion due to bending, twisting, or the like is not formed on the flat wire. Thereby, the joint portion between the terminal of the flat wire and the terminal surface of the inner peripheral terminal is not subjected to the stress due to the above-described bending portion formation, and it is possible to prevent the contact from being disconnected and causing poor contact. As described above, in order to prevent the above-described stress from being applied to the joint portion, for example, even when the inductor of the present invention is used in an environment in which the joint is easily detached such as a lot of vibration of an in-vehicle electronic device or the like, it can be used for a long time. Therefore, contact failure does not occur, and the function can be performed satisfactorily.

  Further, since the bent portion is prevented from being formed in the flat wire, the flat wire films are in contact with each other at the bent portion, and heat is transferred from both of the adjacent conductors. Can be prevented. Therefore, it is possible to prevent the situation where the film melts and the conductors come into contact with each other to cause a short circuit at the bent portion, and the electrical characteristics of the inductor are prevented from deteriorating for a long time. Can do. Moreover, a terminal member is joined to the terminal of a flat wire in the inner peripheral terminal arrange | positioned at the inner cylinder part of a 2nd core member. Therefore, the width dimension of the inductor can be reduced as compared with a configuration in which a connection terminal protruding to the outer diameter side is provided for joining with a flat wire. That is, the inductor can be made compact.

  Moreover, another invention has the 1st core member which has a winding axis, the 2nd core member which has an inner cylinder part enclosed by a surrounding wall, and arrange | positions a 1st core member in this inner cylinder part, Contact A flat wire that is flattened in the direction of diameter expansion of the winding shaft, an inner peripheral terminal that is positioned on the inner cylinder portion side and that joins the end of the flat wire, and a second A terminal member that has a flat terminal that protrudes from the end face of the core member and is mounted on the mounting portion, and a joint portion of the terminal of the rectangular wire to the inner peripheral terminal exists in the diameter-expanding direction of the winding shaft. Is.

  When configured in this way, since the joining portion of the terminal of the flat wire to the inner peripheral terminal exists in the diameter increasing direction of the winding shaft, the joining portion of the terminal of the flat wire is the first core member. The height position in the axial direction of the winding shaft does not change much compared with the stacking start portion of the flat wire on the winding shaft side. That is, since the height position at the joining portion does not change so much from the lamination start portion, it is not necessary to change the orientation of the flat wire by bending the flat wire or twisting the flat wire as in the conventional case. As a result, the joint portion between the terminal of the rectangular wire and the terminal surface of the inner peripheral terminal is not subjected to stress due to the bent portion formation such as the above-described bending or twisting, and it is possible to prevent contact failure due to disconnection. . As described above, in order to prevent the above-described stress from being applied to the joint portion, for example, even when the inductor of the present invention is used in an environment in which the joint is easily detached such as a lot of vibration of an in-vehicle electronic device or the like, it can be used for a long time. Therefore, contact failure does not occur, and the function can be performed satisfactorily.

  Further, since the bent portion is prevented from being formed in the flat wire, the flat wire films are in contact with each other at the bent portion, and heat is transferred from both of the adjacent conductors. Can be prevented. Therefore, it is possible to prevent the situation where the film melts and the conductors come into contact with each other to cause a short circuit at the bent portion, and the electrical characteristics of the inductor are prevented from deteriorating for a long time. Can do. Moreover, a terminal member is joined to the terminal of a flat wire in the inner peripheral terminal arrange | positioned at the inner cylinder part of a 2nd core member. Therefore, the width dimension of the inductor can be reduced as compared with a configuration in which a connection terminal protruding to the outer diameter side is provided for joining with a flat wire. That is, the inductor can be made compact.

  Further, according to another invention, in addition to the above-described inventions, the terminal surface is perpendicular to the diameter expansion direction. When configured in this manner, the terminal of the flat wire can be joined without being twisted or bent with respect to the terminal surface. For this reason, at the time of joining, it can prevent that a bent part is formed in a flat wire, and it can prevent more reliably that joining of a joined part comes off and a poor contact occurs.

  In addition to the above-described inventions, in another invention, the joining portion of the terminal of the flat wire to the inner peripheral terminal has a height position in the axial direction of the winding axis that is the same as that of the flat wire starting side. It is what is the position.

  When configured in this way, the joint portion of the end of the flat wire has a height position in the axial direction of the winding axis as compared to the lamination start side of the flat wire on the winding side of the first core member, It does not change. Thereby, the flat wire can be naturally brought into contact with the inner peripheral terminal in the diameter increasing direction, which is the direction in which the flat wire is unwound. Therefore, even if there is no bent portion due to bending or twisting in the flat wire, the flat wire terminal and the terminal surface of the inner peripheral terminal can be surface-bonded. As a result, the joint portion between the terminal of the flat wire and the terminal surface of the inner peripheral terminal is not subjected to the stress due to the formation of the bent portion described above, and the joint is detached and a contact failure occurs, or the film melts at the bent portion. It is possible to prevent a short circuit from occurring and electrical characteristics from deteriorating.

  Furthermore, in addition to the above-described inventions, in another invention, the terminal of the rectangular wire is given a biasing force toward the diameter expansion direction by winding the rectangular wire, and the terminal surface of the inner peripheral terminal is Surface contact is made with the contact surface of the terminal in a state of receiving this urging force.

  When configured in this way, the inner peripheral terminal is in a state in which a biasing force directed in the diameter-expanding direction is given by the end of the flat wire, and the inner peripheral terminal and the end of the flat wire are in that state. It is joined. Therefore, the inner peripheral terminal is joined in a state of receiving the urging force from the flat wire. As a result, a stress load due to the presence of the bent portion does not occur at the joint portion between the end of the rectangular wire and the terminal surface of the inner peripheral terminal, and a force is generated at the joint portion in the peeling direction. Absent. Therefore, it is possible to prevent contact failure due to disconnection.

  In addition to the above-described inventions, in another invention, the rectangular wire is wound in a state where two windings are overlapped along the winding axis of the winding frame portion, and the two windings are connected. The boundary portion is in contact with the outer peripheral surface of the winding shaft.

  In such a configuration, when the rectangular wire is wound around the winding shaft, if both the central portions of one rectangular wire are brought into contact with the outer peripheral surface of the winding shaft, both terminals are removed. It can be located on the radial side.

  Furthermore, in addition to each of the above-described inventions, the first core member is a drum core provided with a flange on each end in the axial direction of the winding shaft, and a ring core provided with an insertion hole. The drum core is inserted through the insertion hole.

  When configured in this manner, positioning at the time of winding of the rectangular wire can be easily performed by the flanges present on both end sides in the axial direction. Therefore, the joining portion of the end of the flat wire does not need to change the height position in the axial direction of the winding shaft as compared with the flat wire lamination start portion on the winding shaft side of the first core member, and is easier. Can be wound around. Thereby, it becomes possible to improve the manufacturing efficiency at the time of manufacturing the inductor.

  According to another invention, in addition to the above-described inventions, the first core member is a T-shaped core having a flange on one end side or the other end side in the axial direction of the winding shaft. In addition, the second core member is a pot core having a recessed portion, and the T-shaped core is located in the recessed portion.

  In such a configuration, since a pot core is used, leakage of magnetic flux can be reduced as compared with a case where a drum / ring core type inductor is used. Further, when the T-shaped core is fitted into the pot core, the T-shaped core is positioned, so that the positioning and fixing of the T-shaped core with respect to the pot core is facilitated. Therefore, it becomes possible to improve the manufacturing efficiency at the time of manufacturing the inductor.

  Further, according to another invention, in addition to the above-mentioned respective inventions, an inner peripheral concave portion that is recessed toward the outer diameter side from the other portion of the inner cylindrical portion in the inner cylindrical portion of the second core member. The inner circumferential terminal is fitted into the inner circumferential recess, and the inner circumferential terminal is located on the outer diameter side of the inner wall surface of the inner cylinder portion in the fitted state.

  When comprised in this way, it can prevent that an inner peripheral terminal protrudes in an inner diameter side rather than the inner wall face of an inner cylinder part by inserting an inner peripheral terminal in an inner peripheral recessed part. Therefore, even if the inner peripheral terminal is positioned on the inner cylinder part side, it does not interfere with the second core member.

  According to another invention, in addition to the above-described inventions, the terminal member is further provided with a fixing claw portion that engages with the outer peripheral wall surface of the second core member. When comprised in this way, the attachment attitude | position to the 2nd core member of a terminal member can be stabilized. Moreover, it can also adhere | attach between a fixed nail | claw part and a 2nd core member, and it also becomes possible to improve the attachment strength of the terminal member with respect to a 2nd core member.

  According to the present invention, the width dimension can be reduced in an inductor in which a rectangular wire is used. Moreover, it can prevent that a bending part is formed in the terminal of a flat wire.

(First embodiment)
Hereinafter, an inductor according to a first embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a perspective view showing an overall configuration of an inductor 10 according to a first embodiment of the present invention. FIG. 2 is a perspective view showing an internal configuration of the inductor 10 and shows a state where the drum core 20 and the ring core 30 are transmitted. Further, FIG. 3 is a side cross-sectional view of the inductor 10 showing a state in which the terminal member 50 is present at both longitudinal ends. FIG. 4 is a perspective view showing a state in which the terminal 41 of the flat wire 40 is joined to the inner peripheral terminal 52 of the terminal member 50.

  In the following description, the upper side (upper end side) refers to the side on which the upper flange portion 22 (described later) exists, and the lower side (lower end side) refers to the side on which the lower flange portion 23 (described later) exists. Shall point to. Moreover, let the direction which the flat wire 40 in a winding state unwinds be a diameter expansion direction.

  As shown in FIGS. 1 to 3, the inductor 10 is a surface mount type inductor, and includes a drum core 20, a ring core 30, a rectangular wire 40, and a terminal member 50.

  The drum core 20 and the ring core 30 are made of a magnetic material such as a nickel-based ferrite core. However, the material of the drum core 20 and the ring core 30 is not limited to the ferrite core, and may be other magnetic materials such as permalloy. The drum core 20 is disposed in an insertion hole 31 described later inside the ring core 30.

  As shown in FIG. 3, the drum core 20 as the first core member includes a cylindrical winding shaft 21 and upper flange portions 22 formed on both ends in the vertical direction of the winding shaft 21 and corresponding to the flange portions. And a lower flange portion 23 corresponding to the flange portion. In the present embodiment, the outer diameter of the upper flange portion 22 is substantially equal to the outer diameter of the lower flange portion 23. However, the outer diameter of the upper flange portion 22 may be made larger or smaller than the outer diameter of the lower flange portion 23.

  A rectangular wire 40 is wound around a portion surrounded by the winding shaft 21 and the upper flange portion 22 and the lower flange portion 23. In the following description, this portion around which the flat wire 40 is wound is referred to as a winding frame portion 24.

  The rectangular wire 40 wound around the winding frame portion 24 is a thin foil-like wire having an elongated flat cross section, and has a higher space factor than a winding having a circular cross section. It is possible. In addition, the rectangular wire 40 in this Embodiment is a type of rectangular wire in which horizontal winding (how to wind in a state in which the stacking direction is parallel to the winding axis of the rectangular wire 40) is performed. In the present embodiment, the width dimension of the flat wire 40 is smaller than half of the dimension in the height direction of the winding shaft 21 between the upper flange portion 22 and the lower flange portion 23.

  The flat wire 40 is subjected to a so-called double flat winding in which two upper and lower layers are stacked in the winding frame portion 24. In this winding, the rectangular wire 40 is in a state in which the height position changes only as the innermost peripheral portion in contact with the outer periphery of the winding shaft 21, that is, the central portion of the winding of the flat wire 40 advances in the circumferential direction. It has been passed over. And the flat wire 40 laminated | stacked on this innermost peripheral part is in an outer diameter side in the state which the height position in an up-down direction does not change, after contacting either one of the upper flange part 22 or the lower flange part 23. Laminated opposite. In this way, the flat wire 40 is in a so-called double flat winding state in which two upper and lower windings are stacked in a state where the horizontal winding is performed.

  In the above-described winding state, the rectangular wire 40 is laminated while being substantially parallel to the upper flange portion 22 and the lower flange portion 23. Thereby, the stacking start portion of the flat wire 40 and the height position of the terminal 41 are substantially the same.

  Of the flat wire 40, the terminal 41 on one end side and the terminal 41 on the other end side tend to move toward the outer diameter side due to the spring property of the flat wire 40. Due to this spring property, the terminal 41 is in a state of exerting a biasing force on the terminal member 50. However, the terminal 41 may not be in a state of exerting an urging force on the terminal member 50. For example, when the terminal 41 has a spring property that tends to move in the winding direction, the terminal 41 resists the urging force. The terminal 41 may be pulled out.

  1 to 3, a ring core 30 as a second core member is provided on the outer peripheral side of the drum core 20. The ring core 30 is disposed outside the drum core 20 so as to cover the outer periphery of the flat wire 40 and the outer periphery of the upper flange portion 22 and the lower flange portion 23. The ring core 30 is a substantially ring-shaped member. For this reason, the ring core 30 is provided with an insertion hole 31 constituting the ring shape at the center thereof. The drum core 20 is inserted through the insertion hole 31. Therefore, the insertion hole 31 functions as an inner cylinder part. In the state where the drum core 20 and the ring core 30 are attached and fixed, the upper and lower surfaces of the drum core 20 and the ring core 30 are substantially flush.

  Here, as shown in FIG. 1, the ring core 30 is not a circular ring shape, but three top portions of the four top portions of the square are notched so as to be parallel to the diagonal line of the square (hereinafter, referred to as “ring core 30”). The cutout portion is referred to as a ring outer peripheral small surface 32), and one apex portion is formed to draw an arc (hereinafter, this arc portion is referred to as an arc surface 33). In the following description, of the three ring outer peripheral small surfaces 32, the ring outer peripheral small surface 32 facing the circular arc surface 33 is referred to as a ring outer peripheral small surface 32a, and the other two ring outer peripherals adjacent to the circular arc surface 33 are used. The small surfaces 32 and 32 are referred to as ring outer peripheral small surfaces 32b and 32c, respectively.

  As shown in FIGS. 1 and 3, a mounting recess 34 is provided on the lower surface side of the ring outer peripheral small surfaces 32 b and 32 c of the ring core 30. The mounting recess 34 is a portion that is notched upward by a predetermined dimension from the other portion of the lower surface of the ring core 30. The mounting recess 34 is cut out from the outer diameter side of the ring core 30 toward the insertion hole 31. The notch dimension of the mounting recess 34 is such that when a flat terminal 51 described later is positioned in the mounting recess 34, the flat terminal 51 protrudes slightly downward from the lower surfaces of the ring core 30 and the drum core 20. It is provided with a size of about.

  In addition, an inner peripheral recess 35 is provided on the ring outer peripheral small surfaces 32b and 32c on the insertion hole 31 side. The inner circumferential recess 35 is a portion that is cut out (depressed) toward the outer diameter side by a predetermined dimension with respect to the other portion of the inner circumferential wall 31 a forming the insertion hole 31. In the present embodiment, the inner peripheral recess 35 is provided in a state of penetrating the inner peripheral wall surface 31 a over the entire vertical direction of the ring core 30. The notch dimension of the inner peripheral recess 35 is such that when an inner peripheral terminal 52 described later is positioned in the inner peripheral recess 35, the inner peripheral terminal 52 is located on the outer diameter side with respect to the other portions of the inner peripheral wall surface 31a. It is provided with dimensions that allow it to be retracted (does not jump out to the inner diameter side).

  Further, the terminal member 50 is fitted into the mounting recess 34 and the inner peripheral recess 35. The terminal member 50 is a component formed by bending or punching a plate-shaped metal member by pressing. The terminal member 50 includes a flat terminal 51, an inner peripheral terminal 52, and a fixed claw portion 53. Among these, the flat terminal 51 is a part having an adhesive surface bonded and fixed to the mounting recess 34 as a back surface. As shown in FIGS. 1 to 3, the planar terminal 51 is disposed on the lower surface side of the inductor 10, and when the inductor 10 is surface-mounted on a substrate (not shown), Become. The planar terminal 51 is electrically connected and fixed to the land of the substrate by reflow soldering.

  As shown in FIG. 2 to FIG. 4, the inner peripheral terminal 52 is bent in a state of making approximately 90 degrees from the flat terminal 51. The inner peripheral terminal 52 is located in the inner peripheral recess 35 described above. As a result, the terminal surface 52a of the inner peripheral terminal 52 is in a state of facing the diameter increasing direction of the rectangular wire 40 in the wound state.

  Further, the terminal surface 52a is surface-bonded to the terminal 41 in a state of receiving this urging force. In this joining, for example, a laser beam is irradiated after the rectangular wire 40 and the inner peripheral terminal 52 (terminal surface 52a) are in contact with each other. Then, the coating of the rectangular wire 40 is melted by the heat at the time of laser beam irradiation, and the conductor (not shown) of the rectangular wire 40 and the inner peripheral terminal 52 (terminal surface 52a) come into contact. At the same time, the film and the conductor are melted, and the inner peripheral terminal 52 (terminal surface 52a) is welded and fixed.

  In addition to the laser beam welding by laser beam irradiation, the flat wire 40 and the inner peripheral terminal 52 may be joined by a fixing method such as soldering or other various welding methods. Alternatively, a part of the flat wire 40 may be exposed, and the conductor and the inner peripheral terminal 52 may be in contact with each other and fixed with an adhesive or the like.

  Further, in the present embodiment, the protruding height of the inner peripheral terminal 52 is such that the inner peripheral terminal 52 is positioned in the inner peripheral recess 35 so that the inner peripheral terminal 52 is satisfactorily joined to the terminal 41 of the flat wire 40. It is provided so as to be approximately equal to or higher than the upper end of the winding frame portion 24. However, the inner peripheral terminal 52 is provided so as to be lower than the upper end of the upper flange portion 22. Further, in the present embodiment, the width dimension of the inner peripheral terminal 52 is provided so as to be smaller than the width dimension of the planar terminal 51 and the fixed claw portion 53.

  Similarly to the inner peripheral terminal 52 described above, the fixed claw portion 53 is bent in a state of making approximately 90 degrees from the planar terminal 51 and is in the same direction as the inner peripheral terminal 52 (upward in FIGS. 3 and 4). It extends towards. The fixed claw portion 53 is in a state of being closely opposed to the ring outer peripheral small surfaces 32b and 32c of the ring core 30 in a state where the flat terminal 51 and the inner peripheral terminal 52 are fitted in the mounting concave portion 34 and the inner peripheral concave portion 35, respectively. (See FIG. 3). That is, the fixed claw portion 53 is a portion for positioning the terminal member 50.

  In the present embodiment, there is a slight gap between the fixed claw portion 53 and the ring outer peripheral small surfaces 32b and 32c, and the terminal member 50 can be easily fitted into the mounting recess 34 and the inner periphery recess 35. doing. The terminal member 50 is bonded to the back surface of the flat terminal 51 by an adhesive or the like, but is bonded to the back surface of the inner peripheral terminal 52 (the surface opposite to the surface joined to the flat wire 40) by an adhesive or the like. Alternatively, an adhesive may be interposed in the gaps described above to bond them.

  When manufacturing the inductor 10 having the above configuration, first, the rectangular wire 40 is wound around the winding frame portion 24 in a double flat winding state. Then, only the portion (the central portion of the flat wire 40 corresponding to the first layer) wound on the innermost peripheral surface side of the winding frame portion 24 is crossed in the flat wire 40 and is laminated on the innermost peripheral portion. The flat wire 40 is brought into contact with either the upper flange portion 22 or the lower flange portion 23. Thereafter, the second layer (corresponding to the lamination start side) stacked on the first layer of the rectangular wire 40 is wound up to the terminal 41 on the outermost peripheral side in a state where the height position in the vertical direction does not change. In this manner, the flat wire 40 is in a so-called double flat winding state in which the horizontal winding is performed and stacked in two upper and lower layers.

  After the winding is completed, the terminal 41 of the flat wire 40 is joined to the inner peripheral terminal 52 by laser beam welding or the like. Thereby, the state shown in FIG. 4 is obtained. Thereafter, the drum core 20, the flat wire 40, and the terminal member 50 that have been integrated are inserted from the lower side of the insertion hole 31. At this time, an adhesive is applied in advance to at least the back surface of the flat terminal 51. Then, when the terminal member 50 is brought into contact with the mounting recess 34 and the inner peripheral recess 35, bonding is also performed at the same time.

  Further, the drum core 20 is bonded to the ring core 30 before and after the terminal member 50 is bonded. Such adhesion is realized, for example, by interposing an adhesive between the upper flange portion 22 or the lower flange portion 23 of the drum core 20 and the ring core 30 and curing the adhesive. As described above, the inductor 10 as shown in FIGS. 1 and 3 is manufactured.

  According to the inductor 10 having such a configuration, the terminal surface 52a of the inner peripheral terminal 52 is oriented in the diameter expansion direction of the rectangular wire 40. Therefore, the terminal 41 and the inner peripheral terminal 52 of the rectangular wire 40 in a wound state. The terminal surface 52a naturally faces each other. Therefore, when the terminal member 50 is joined, the terminal 41 of the rectangular wire 40 and the inner peripheral terminal 52 (terminal surface 52a) can be easily surface-joined without forming a bent portion by bending or twisting the rectangular wire 40. Can be made.

  By such surface bonding, the stress generated due to the presence of the above-described bent portion is not applied to the bonding portion between the terminal 41 of the rectangular wire 40 and the inner peripheral terminal 52 (terminal surface 52a). Therefore, even when the inductor 10 is used for a long period of time, it is possible to prevent a situation in which the junction is disconnected and a contact failure occurs. As described above, in order to prevent stress from being applied, even if the inductor 10 of the present invention is used in an environment in which the connection is likely to come off, for example, in a case where there is a lot of vibration in an in-vehicle electronic device or the like, contact failure will occur over a long period of time. It does not occur, and the function can be achieved satisfactorily.

  Further, since the bent portion is prevented from being formed in the flat wire 40, it is possible to prevent a situation in which the coatings of the flat wire 40 are in contact with each other and heat is transmitted from both of the conductors in close proximity to each other. Can do. Therefore, it is possible to prevent a situation in which the film melts and the conductors come into contact with each other to cause a short circuit at the bent portion, and the electrical characteristics of the inductor 10 are prevented from deteriorating for a long time. be able to.

  Further, in the case where laser beam welding is performed in the joining between the terminal 41 of the rectangular wire 40 and the inner peripheral terminal 52 as in the present embodiment, the coating is more than necessary even in the small-sized inductor 10. It is possible to perform reliable bonding while preventing melting. In addition, since the soldering is not performed, a build-up portion due to the soldering is not formed. Thereby, the width dimension of the inductor 10 can be reduced.

  The terminal member 50 is joined to the terminal 41 of the flat wire 40 in the insertion hole 31 of the ring core 30. Therefore, the width dimension of the inductor 10 can be reduced as compared with the conventional configuration in which the connection terminal protrudes to the outer diameter side for joining with the flat wire 40 as in the prior art. That is, the inductor 10 can be made compact.

  Further, in the present embodiment, the terminal member 50 is attached to the ring core 30 by forming the mounting recesses 34 and the like on the ring outer peripheral small surfaces 32b and 32c obtained by cutting out the square tops. Therefore, the width dimension of the inductor 10 can be further reduced. Further, since there is no protruding portion such as a binding terminal, the product strength of the inductor 10 such as drop strength is improved as compared with a configuration in which such a binding terminal exists. Moreover, since it does not become a special shape such as the presence of a protruding portion, the moldability of the ring core 30 is not deteriorated, and an increase in manufacturing cost can be prevented.

  Furthermore, the junction part of the terminal 41 and the terminal surface 52a exists in the diameter expansion direction. In addition, the height of the joining portion with respect to the axial direction of the winding shaft 21 is the same height position as the lamination start side of the flat wire 40. Therefore, the height position in the axial direction of the winding shaft 21 does not change much in the joining portion of the terminal 41 of the flat wire 40 compared to the lamination start side of the flat wire 40 on the winding shaft 21 side of the drum core 20. That is, it is not necessary to change the orientation of the flat wire 40 by bending the flat wire 40 or twisting the flat wire 40 as in the prior art. As a result, the stress caused by the above-described bending portion formation is not applied to the joint portion, and it is possible to prevent the joint from coming off and causing poor contact.

  Further, in the present embodiment, the terminal surface 52a is perpendicular to the diameter expansion direction. Therefore, the terminal 41 of the flat wire 40 can be surface-bonded in a state where there is no bent portion with respect to the terminal surface 52a, and it is possible to more surely prevent contact failure due to disconnection of the bonding portion. it can.

  Further, the terminal 41 of the flat wire 40 is given an urging force in the diameter increasing direction by the winding of the flat wire 40, and the terminal surface 52a of the inner peripheral terminal 52 is connected to the terminal 41 in a state of receiving the urging force. The surface is joined. Therefore, the inner peripheral terminal 52 is joined in a state of receiving the urging force from the flat wire 40. As a result, a stress load due to the presence of the bent portion does not occur in the joint portion between the terminal 41 of the flat wire 40 and the terminal surface 52a of the inner peripheral terminal 52, and the peeling direction is applied to the joint portion. No power is generated. Therefore, it is possible to prevent contact failure due to disconnection.

  Further, in the present embodiment, the flat wire 40 is wound in a state where two windings are overlapped along the winding shaft 21 of the winding frame portion 24, and a boundary portion connecting the two windings is a winding shaft. It is wound in a state of being in contact with the outer peripheral surface of 21. Therefore, both terminals 41 and 41 of one flat wire 40 can be positioned on the outer diameter side. That is, if the central portion of one rectangular wire 40 is brought into contact with the outer peripheral surface of the winding shaft 21, both terminals 41 and 41 can be positioned on the outer diameter side.

  Further, in the present embodiment, the drum core 20 is used as the first core member, and the ring core 30 is used as the second core member. Therefore, the positioning at the time of winding of the rectangular wire 40 can be easily performed by the upper flange portion 22 and the lower flange portion 23 present on both end sides in the axial direction of the drum core 20. Thereby, the manufacturing efficiency of the inductor 10 can be improved. Further, the joining portion of the terminal 41 of the flat wire 40 does not need to change the height position of the winding shaft 21 in the axial direction even when the flat wire 40 is wound around the winding frame portion 24.

  Further, the inner peripheral wall 31a of the ring core 30 is provided with an inner peripheral recess 35 that is recessed toward the outer diameter side from the other part of the inner peripheral wall 31a. 52 is fitted. Therefore, the inner peripheral terminal 52 is positioned on the outer diameter side with respect to the inner peripheral wall surface 31a in the fitted state, and the inner peripheral terminal 52 can be prevented from projecting toward the inner diameter side with respect to the inner peripheral wall surface 31a. Thereby, even if the inner peripheral terminal 52 is positioned on the insertion hole 31 side, the inner peripheral terminal 52 does not interfere with the drum core 20.

  The terminal member 50 is provided with a fixed claw portion 53. Therefore, the fixed claw portion 53 can be locked to the outer peripheral wall surface of the ring core 30, and the attachment posture of the terminal member 50 to the ring core 30 can be stabilized by such locking. In addition, adhesion can be performed between the fixed claw portion 53 and the ring core 30, and the attachment strength of the terminal member 50 to the ring core 30 can be improved.

(Second Embodiment)
Hereinafter, a second embodiment of the present invention will be described with reference to FIGS. FIG. 5 is a perspective view showing the overall configuration of inductor 100 according to the second embodiment of the present invention. FIG. 6 is a perspective view showing the internal configuration of the inductor 100 according to the second embodiment, and shows a state where the T-shaped core 200 and the pot core 300 are transmitted. Further, FIG. 7 is a side sectional view of the inductor 100 showing a state in which the terminal member 50 is present at both longitudinal ends.

  In the present embodiment, the same parts as those described in the first embodiment are denoted by the same reference numerals and description thereof is omitted.

  Inductor 100 in the present embodiment is a surface mount type inductor, similar to inductor 10 in the first embodiment described above. Here, the inductor 100 according to the present embodiment includes a T-shaped core 200 instead of the drum core 20, and includes a pot core 300 instead of the ring core 30. The details will be described below.

  As shown in FIG. 7, unlike the drum core 20 described above, the T-shaped core 200 as the first core member has only the lower flange portion 23 and does not have the upper flange portion 22. That is, the upper flange portion 22 does not exist above the winding frame portion 24 and is open. Therefore, the T-shaped core 200 has a T-shaped cross section.

  Unlike the ring core 30 described in the first embodiment, the pot core 300 as the second core member does not include the insertion hole 31 in the penetrating state and is recessed upward from the lower end surface. In this configuration, the concave portion 301 is provided. That is, the pot core 300 has a concave shape (a cross section is a U shape) in which a lid member is attached to the upper end portion of the ring core 30 in the first embodiment. Therefore, as shown in FIGS. 5 and 6, the T-shaped core 200 is not visible from the upper side and is covered with the pot core 300. The recessed portion 301 corresponds to the inner cylinder portion.

  Further, the upper end surface 21 a of the winding shaft 21 of the T-shaped core 200 comes into contact with the bottom portion 301 a of the recessed portion 301 of the pot core 300. However, the upper end surface 21a may be opposed to the bottom portion 301a with a slight gap.

  Further, the terminal member 50 in the present embodiment has the same shape as the terminal member 50 in the first embodiment described above. However, in this embodiment, in order to prevent the inner peripheral terminal 52 of the terminal member 50 from interfering with the bottom portion 301a, the inner peripheral terminal 52 is longer than the inner peripheral terminal 52 in the first embodiment described above. The dimensions are small.

  The other configuration of the inductor 100 according to the present embodiment is the same as that of the inductor 10 according to the first embodiment described above.

  Also in the inductor 100 having such a configuration, the terminal surface 52a faces the diameter expansion direction of the rectangular wire 40, and the terminal 41 and the terminal surface 52a are similar to the inductor 10 of the first embodiment described above. It will be in a state of facing nature. Therefore, it is possible to perform surface bonding in a state where there is no bent portion in the flat wire 40 at the time of bonding. Therefore, stress load can be prevented, and even if the inductor 100 of the present invention is used in an environment in which the joining is easily detached, for example, due to a lot of vibration of an in-vehicle electronic device or the like, poor contact may occur over a long period of time. The function can be achieved satisfactorily. Further, since the terminal member 50 is joined to the terminal 41 of the flat wire 40 in the recessed portion 301 of the pot core 300, the width dimension of the inductor 100 can be reduced and the inductor 100 can be made compact.

  In addition, in this embodiment, since the T-shaped core 200 and the pot core 300 are used, the T-shaped core 200 is covered with the pot core 300 on the upper side, and the space between the T-shaped core 200 and the pot core 300 is increased. There will be no gaps. Therefore, in this type of inductor 100, the leakage of magnetic flux can be reduced as compared with the case of using a drum / ring core type inductor. Further, when the T-shaped core 200 is fitted into the pot core 300, the T-shaped core 200 is positioned. Therefore, it becomes easy to attach and fix the T-shaped core 200 to the pot core 300, and the manufacturing efficiency of the inductor 100 can be improved.

  Although the first and second embodiments of the present invention have been described above, the present invention can be variously modified in addition to this. This will be described below.

  In the first and second embodiments described above, the case where the present invention is applied to the surface mount type inductors 10 and 100 has been described. However, the inductor of the present invention is not limited to the surface mount type, and may be an inductor including a terminal member having a mounting terminal protruding downward.

  Further, in the first embodiment described above, the type of inductor 10 in which the drum core 20 is covered with the ring core 30 is described. In the second embodiment, the inductor 100 of the type in which the T-shaped core 200 is covered with the pot core 300 is described. However, the inductor is not limited to such a type, and instead of the second core member, a case body made of a resin or the like of a non-conductive member is used, and the first core member is covered with this case body. There may be.

  Furthermore, in the first and second embodiments described above, the configuration including the fixed claw portion 53 and the substantially U-shaped terminal member 50 is described. However, the terminal member is not limited to the substantially U-shaped terminal member 50, and for example, an approximately L shape in which the fixed claw portion 53 is omitted may be used.

  Further, in the above-described embodiment, the flat wire 40 is wound in a state where two turns are stacked in the axial direction of the winding shaft 21. However, the winding of the flat wire 40 is not limited to this. For example, if the flat wire 40 is bent at a portion other than the joint portion of the inner peripheral terminal 52, only one turn may be used, or three or more turns may be stacked.

  Further, in the first and second embodiments described above, the drum core 20 or the T-shaped core 200 is described as the first core member, and the ring core 30 or the pot core 300 is described as the second core member. However, the first core member and the second core member are not limited to these. For example, the present invention may be applied by providing an attachment recess and an inner periphery recess for attaching a terminal member to an E-type core of a closed magnetic circuit type.

  In addition, for example, in a separate electronic member such as a transformer or a filter, a configuration in which the inner peripheral terminal of the terminal member is provided on the inner cylinder portion side may be employed.

  The inductor of the present invention can be used in the field of electrical equipment.

It is a perspective view which shows the external appearance shape of the inductor which concerns on the 1st Embodiment of this invention. It is a perspective view which shows the internal structure of the inductor of FIG. 1, and is a figure which shows the state which permeate | transmitted the drum core and the ring core. FIG. 2 is a side sectional view of the inductor according to the inductor of FIG. 1, showing a state in which terminal members exist at both longitudinal ends. FIG. 2 is a perspective view showing a state in which a flat wire terminal is joined to an inner peripheral terminal of a terminal member in the inductor of FIG. 1. It is a perspective view which shows the external appearance shape of the inductor which concerns on the 2nd Embodiment of this invention. FIG. 6 is a perspective view showing an internal configuration of the inductor of FIG. 5, and shows a state where a pot core and a T-shaped core are transmitted. FIG. 6 is a side sectional view of the inductor according to the inductor of FIG. 5, showing a state in which terminal members are present at both longitudinal ends.

Explanation of symbols

10, 100 ... Inductor 20 ... Drum core (corresponding to the first core member)
21 ... winding axis 22 ... upper flange (corresponding to the flange)
23 ... Lower flange (corresponding to the flange)
24 ... reel part 30 ... ring core (corresponding to the second core member)
31 ... Insertion hole (corresponding to the inner cylinder)
34 ... Mounting recess 35 ... Inner peripheral recess 40 ... Flat wire 41 ... Terminal 50 ... Terminal member 51 ... Planar terminal 52 ... Inner peripheral terminal 200 ... T-shaped core (corresponding to the first core member)
300 ... pot core (corresponding to the second core member)
301 ... Recessed part (corresponding to the inner cylinder part)

Claims (10)

A first core member having a winding shaft;
A second core member having an inner cylinder part surrounded by a peripheral wall, and arranging the first core member in the inner cylinder part;
The contact surface forms a flat shape along the length, and a flat wire laminated toward the diameter-enlarging direction of the winding shaft,
A terminal member that is located on the inner cylindrical portion side and that has an inner peripheral terminal that joins the terminal of the rectangular wire, and a flat terminal that protrudes from the end face of the second core member and is mounted on the mounting portion,
Comprising
The terminal surface of the inner peripheral terminal is oriented in the diameter expansion direction of the rectangular wire in a wound state, and the terminal surface and the contact surface are surface-bonded.
An inductor characterized by that. A first core member having a winding shaft;
A second core member having an inner cylinder part surrounded by a peripheral wall, and arranging the first core member in the inner cylinder part;
The contact surface forms a flat shape along the length, and a flat wire laminated toward the diameter-enlarging direction of the winding shaft,
A terminal member that is located on the inner cylindrical portion side and that has an inner peripheral terminal that joins the terminal of the rectangular wire, and a flat terminal that protrudes from the end face of the second core member and is mounted on the mounting portion,
Comprising
The joint portion of the terminal of the rectangular wire to the inner peripheral terminal exists in the diameter increasing direction of the winding shaft.
An inductor characterized by that.   The inductor according to claim 1, wherein the terminal surface is perpendicular to the diameter expansion direction.   The joint portion of the terminal of the rectangular wire with respect to the inner peripheral terminal has a height position in the axial direction of the winding shaft that is the same height position as the flattening start side of the rectangular wire. Item 4. The inductor according to any one of Items 1 to 3.   The terminal of the rectangular wire is given an urging force toward the diameter-expanding direction by winding of the rectangular wire, and the terminal surface of the inner peripheral terminal receives the urging force in the contact state of the terminal. The inductor according to any one of claims 1 to 4, wherein the inductor is surface-bonded.   The flat wire is wound in a state where two windings are overlapped along the winding axis of the winding frame portion, and a boundary portion connecting the two windings is in contact with the outer peripheral surface of the winding shaft. The inductor according to any one of claims 1 to 5, characterized in that:   The first core member is a drum core having flanges on both ends in the axial direction of the winding shaft, and the second core member is a ring core having an insertion hole, and the drum core is inserted into the insertion hole. The inductor according to any one of claims 1 to 6, wherein is inserted.   The first core member is a T-shaped core including a flange on one end side or the other end side in the axial direction of the winding shaft, and the second core member includes a recessed portion. The inductor according to any one of claims 1 to 6, wherein the inductor is a pot core, and the T-shaped core is located in the recessed portion.   The inner cylindrical portion of the second core member is provided with an inner peripheral recess that is recessed toward the outer diameter side with respect to the other portion of the inner cylindrical portion. The inductor according to any one of claims 1 to 8, wherein a peripheral terminal is fitted, and the inner peripheral terminal is positioned on an outer diameter side with respect to an inner wall surface of the inner cylinder portion in the fitted state.   The inductor according to any one of claims 1 to 9, wherein the terminal member is provided with a fixing claw portion that engages with an outer peripheral wall surface of the second core member.

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