JP2006121013A - Manufacturing method of coil component - Google Patents

Manufacturing method of coil component Download PDF

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JP2006121013A
JP2006121013A JP2004310047A JP2004310047A JP2006121013A JP 2006121013 A JP2006121013 A JP 2006121013A JP 2004310047 A JP2004310047 A JP 2004310047A JP 2004310047 A JP2004310047 A JP 2004310047A JP 2006121013 A JP2006121013 A JP 2006121013A
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terminal
winding
core
piece
coating
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Kozo Kajiwara
昂三 梶原
Yutaka Hatakeyama
豊 畠山
Kazumi Kobayashi
一三 小林
Naoto Togashi
直人 富樫
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TDK Corp
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TDK Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide the manufacturing method of a coil component wherein windings can properly be joined in a state that the windings and metallic terminals are surely electrically connected. <P>SOLUTION: The winding 30 clamped between second terminals 44, 54 and first side-parts 46, 56 is fixed to each of the metallic terminals 41, 42, 51, 52. The sheath of the winding 30 fixed to each of the metallic terminals 41, 42, 51, 52 and corresponding to at least second-side parts 47, 57 is removed by laser emission. The parts of the winding 30 from which the sheath is removed are clamped by second terminals 44, 54 and the second-side parts 47, 57, and then fixed to each of the metallic terminals 41, 42, 51, 52. The parts of the winding 30 from which the sheath is removed and each of the metallic terminals 41, 42, 51, 52 are welded to the second side-parts 47, 57 by laser emission or arc welding. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、コイル部品の製造方法に関する。   The present invention relates to a method for manufacturing a coil component.

この種のコイル部品として、巻芯部と当該巻芯部の端に位置する鍔部とを有するコアと、巻芯部に巻回された巻線と、巻線に電気的に接続されると共に鍔部に設けられた金属端子とを備えたものが知られている（例えば、特許文献１参照）。   As this type of coil component, a core having a core part and a flange part located at the end of the core part, a winding wound around the core part, and being electrically connected to the winding What is provided with the metal terminal provided in the collar part is known (for example, refer patent document 1).

特許文献１には、コアの巻芯部に絶縁被覆された導体線を巻回して巻線を形成し、当該巻線を鍔部に設けられた金属端子に溶接（例えば、レーザー溶接）により継線するコイル部品の製造方法が開示されている。特許文献１に記載の製造方法では、金属端子には仮固定用の係止部が形成されており、巻線の一部を係止部にて仮固定した後に巻線を金属端子に継線している。
特開２００３−２３４２１８号公報 In Patent Document 1, a conductor wire coated with insulation is wound around a core portion of a core to form a winding, and the winding is connected to a metal terminal provided on a collar portion by welding (for example, laser welding). A method of manufacturing a coiled wire component is disclosed. In the manufacturing method described in Patent Document 1, a temporary locking portion is formed on the metal terminal. After temporarily fixing a part of the winding at the locking portion, the winding is connected to the metal terminal. is doing.
JP 2003-234218 A

本発明は、巻線と金属端子とを確実に電気的に接続された状態で適切に継線することが可能なコイル部品の製造方法を提供することを課題とする。   An object of the present invention is to provide a method of manufacturing a coil component capable of appropriately connecting a winding and a metal terminal while being reliably electrically connected.

本発明者等は、巻線と金属端子とを確実に電気的に接続された状態で適切に継線し得るコイル部品の製造方法について鋭意研究を行った結果、以下のような事実を新たに見出した。   As a result of earnest research on a method of manufacturing a coil component that can be appropriately connected in a state where the winding and the metal terminal are securely connected to each other, the present inventors newly found the following facts. I found it.

通常、巻線には、絶縁被覆された導体線が用いられる。このため、巻線と金属端子とを電気的に接続するためには、巻線と金属端子とを継線する前に、被覆を除去しておく必要がある。そこで、本発明者等は、被覆を除去する方法として、以下の２つの方法を発案するに至った。第１の方法は、巻線を形成した際に金属端子に位置する部分の被覆を予め除去しておく方法、すなわち予め所望の位置の被覆が除去された導体線を用いて巻線を形成する方法である。第２の方法は、巻線を金属端子に溶接して継線する際に、熱により被覆を除去する方法である。   Usually, a conductor wire with insulation coating is used for the winding. For this reason, in order to electrically connect the winding and the metal terminal, it is necessary to remove the coating before connecting the winding and the metal terminal. Therefore, the present inventors have come up with the following two methods as a method for removing the coating. The first method is a method in which the coating of the portion located on the metal terminal is previously removed when the winding is formed, that is, the winding is formed using a conductor wire from which the coating at a desired position has been removed in advance. Is the method. The second method is a method in which the coating is removed by heat when the winding is welded to the metal terminal for connection.

しかしながら、いずれの方法も、以下のような問題点を含んでおり、巻線と金属端子とを確実に電気的に接続された状態で適切に継線し得るコイル部品の製造方法としては、不十分である。まず、第１の方法では、巻線を形成した際に、被覆を除去した部分と金属端子との位置ずれが生じてしまうことがあり、巻線と金属端子との電気的な接続が確実に行えなくなる懼れがある。一方、第２の方法では、巻線を形成した後に除去することから、上述した位置ズレの問題は生じ難い。しかしながら、被覆が炭化するなどして、適切に溶接できなくなる懼れがある。   However, each of the methods includes the following problems, and it is not possible to manufacture a coil component that can be appropriately connected in a state where the winding and the metal terminal are securely electrically connected. It is enough. First, in the first method, when the winding is formed, the position where the coating is removed and the metal terminal may be misaligned, and the electrical connection between the winding and the metal terminal is ensured. There is a drowning that can not be done. On the other hand, in the second method, since the winding is removed after the winding is formed, the above-described problem of positional deviation hardly occurs. However, there is a possibility that the coating cannot be appropriately welded due to carbonization of the coating.

以上のことを鑑みて、本発明に係るコイル部品の製造方法は、巻芯部と当該巻芯部の端に位置する鍔部とを有するコアと、巻芯部に巻回される巻線と、巻線に電気的に接続されると共に鍔部に設けられる金属端子と、を備えるコイル部品の製造方法であって、金属端子は、鍔部に対峙する端子部分と、当該端子部分から伸びる第１及び第２の片部分と、を有しており、巻線を端子部分と第１の片部分とで狭持して、金属端子に固定する工程と、金属端子に固定された巻線のうち少なくとも第２の片部分に対応する部分の被覆をレーザー照射により除去する工程と、巻線における被覆が除去された部分を端子部分と第２の片部分とで狭持して、金属端子に固定する工程と、巻線における被覆が除去された部分と金属端子とを第２の片部分へのレーザー照射又はアークにより溶接する工程と、を備えることを特徴とする。   In view of the above, the method for manufacturing a coil component according to the present invention includes a core having a core portion and a flange portion located at an end of the core portion, and a winding wound around the core portion. A coil part manufacturing method comprising: a metal terminal electrically connected to a winding and provided on a collar part, wherein the metal terminal extends from the terminal part facing the collar part. 1 and a second piece portion, and sandwiching the winding wire between the terminal portion and the first piece portion to fix the winding wire to the metal terminal, and the winding wire fixed to the metal terminal A step of removing at least a portion of the coating corresponding to the second piece by laser irradiation, and a portion of the winding from which the coating has been removed is sandwiched between the terminal portion and the second piece to form a metal terminal. The step of fixing, the portion of the winding from which the coating has been removed, and the metal terminal to the second piece portion Characterized in that it comprises a step of welding by Heather irradiation or arc, a.

本発明に係るコイル部品の製造方法では、まず、巻線が端子部分と第１の片部分とで狭持されて金属端子に固定された後、金属端子に固定された巻線のうち少なくとも第２の片部分に対応する部分の被覆がレーザー照射により除去される。そして、巻線における被覆が除去された部分が端子部分と第２の片部分とで狭持されて、金属端子に固定された後に、巻線における被覆が除去された部分と金属端子とが第２の片部分へのレーザー照射又はアークにより溶接される。したがって、巻線を形成した後に被覆が除去されることから、上述した第１の方法のように位置ズレが生じることはない。また、被覆が除去された状態で溶接が行われることから、巻線における被覆が除去された部分と金属端子とが適切に溶接される。これらの結果、巻線と金属端子とが確実に電気的に接続された状態で適切に継線されることとなる。   In the method for manufacturing a coil component according to the present invention, first, after the winding is sandwiched between the terminal portion and the first piece portion and fixed to the metal terminal, at least the first winding among the windings fixed to the metal terminal. The coating of the part corresponding to the one part of 2 is removed by laser irradiation. Then, after the portion of the winding from which the coating is removed is sandwiched between the terminal portion and the second piece portion and fixed to the metal terminal, the portion from which the coating is removed from the winding and the metal terminal are Welded by laser irradiation or arcing on one of the two parts. Therefore, since the coating is removed after the winding is formed, there is no positional deviation as in the first method described above. Moreover, since welding is performed in a state where the coating is removed, the portion of the winding from which the coating is removed and the metal terminal are appropriately welded. As a result, the winding and the metal terminal are appropriately connected in a state where the winding and the metal terminal are securely connected.

また、第２の片部分に対応する部分の被覆をレーザー照射により除去する工程では、互いに異なる複数の方向からのレーザー照射により被覆を除去することが好ましい。この場合、被覆をより一層確実に除去することができる。   In the step of removing the coating corresponding to the second piece by laser irradiation, it is preferable to remove the coating by laser irradiation from a plurality of different directions. In this case, the coating can be more reliably removed.

本発明によれば、巻線と金属端子とを確実に電気的に接続された状態で適切に継線することが可能なコイル部品の製造方法を提供することができる。   ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the coil components which can be appropriately connected in the state in which the coil | winding and the metal terminal were reliably electrically connected can be provided.

以下、添付図面を参照して、本発明の好適な実施形態について詳細に説明する。なお、説明において、同一要素又は同一機能を有する要素には、同一符号を用いることとし、重複する説明は省略する。本実施形態は、本発明をコモンモードフィルタに適用した例である。   Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the description, the same reference numerals are used for the same elements or elements having the same function, and redundant description is omitted. The present embodiment is an example in which the present invention is applied to a common mode filter.

まず、図１〜図６に基づいて、本実施形態に係るコモンモードフィルタ１の構成を説明する。図１は、本実施形態に係るコモンモードフィルタを示す斜視図である。図２及び図３は、本実施形態に係るコモンモードフィルタに含まれるコアを示す斜視図である。図４は、本実施形態に係るコモンモードフィルタに含まれる金属端子を示す斜視図である。図５及び図６は、本実施形態に係るコモンモードフィルタに含まれるコアの鍔部周辺の断面図である。   First, based on FIGS. 1-6, the structure of the common mode filter 1 which concerns on this embodiment is demonstrated. FIG. 1 is a perspective view showing a common mode filter according to the present embodiment. 2 and 3 are perspective views showing cores included in the common mode filter according to the present embodiment. FIG. 4 is a perspective view showing a metal terminal included in the common mode filter according to the present embodiment. FIG. 5 and FIG. 6 are cross-sectional views around the flange of the core included in the common mode filter according to the present embodiment.

コモンモードフィルタ１は、図１に示されるように、コア１０と、巻線３０と、金属端子４０とを備えている。   As shown in FIG. 1, the common mode filter 1 includes a core 10, a winding 30, and a metal terminal 40.

コア１０は、図２及び図３にも示されるように、巻芯部１２と、当該巻芯部１２の軸方向の両端に形成された一対の鍔部１３とを有している。コア１０は、いわゆるドラムコアである。コア１０は、磁性体（例えば、フェライト等）又は非磁性体（例えば、セラミック等）からなる。巻芯部１２は、四角柱形状を呈している。各鍔部１３は、直方体形状を呈している。巻芯部１２と鍔部１３とは、一体的に形成されている。コア１０は、その巻芯部１２の軸心方向に平行な断面での形状がＨ字状を呈している。以下、鍔部１３については、それぞれが略同一形状であるため、特に明記しない限り、片側のみで説明し、図２及び図３に示すように、巻芯部１２の長手方向をＸ軸方向、巻芯部１２の幅方向をＹ軸方向、Ｘ軸方向及びＹ軸方向に直交する方向をＺ軸方向と定義して説明する。   As shown in FIGS. 2 and 3, the core 10 includes a core portion 12 and a pair of flange portions 13 formed at both ends of the core portion 12 in the axial direction. The core 10 is a so-called drum core. The core 10 is made of a magnetic material (for example, ferrite) or a non-magnetic material (for example, ceramic). The core part 12 has a quadrangular prism shape. Each flange 13 has a rectangular parallelepiped shape. The core part 12 and the collar part 13 are integrally formed. The shape of the core 10 in a cross section parallel to the axial direction of the core portion 12 is H-shaped. Hereinafter, since the flanges 13 have substantially the same shape, unless otherwise specified, only one side will be described. As shown in FIGS. 2 and 3, the longitudinal direction of the core 12 is the X-axis direction, In the following description, the width direction of the winding core 12 is defined as the Y-axis direction, and the direction orthogonal to the X-axis direction and the Y-axis direction is defined as the Z-axis direction.

各鍔部１３は、巻芯部１２に連結する第１の部分１４と、当該第１の部分１４よりＹ軸方向に延出されている第２の部分１５と、第２の部分１５の反対方向に延出されている第２の部分１６と、を有している。これら第１の部分１４と第２の部分１５とは、巻芯部１２の軸芯を通るＺＸ平面に対して面対称な構成になっている。   Each flange 13 includes a first portion 14 connected to the core portion 12, a second portion 15 extending from the first portion 14 in the Y-axis direction, and the opposite of the second portion 15. And a second portion 16 extending in the direction. The first portion 14 and the second portion 15 are configured to be plane-symmetric with respect to the ZX plane passing through the axis of the winding core portion 12.

第１の部分１４は、Ｚ軸方向が長手方向であり且つＹ軸方向が幅方向であって、巻芯部１２と略同一の幅である略直方体形状を呈している。第１の部分１４は、一対の第１の側面１４ａ，１４ｂと、一対の第２の側面１４ｃ，１４ｄと、一対の第３の側面１４ｅ，１４ｆと、を有している。第１の側面１４ａ，１４ｂ同士は、Ｘ軸方向で見て互いに対向するように位置している。第２の側面１４ｃ，１４ｄ同士は、Ｚ軸方向で見て互いに対向し、且つ、各第１の側面１４ａ，１４ｂに交差する方向（本実施形態においては、直交する方向）に伸びるように位置している。第３の側面１４ｅ，１４ｆ同士は、Ｙ軸方向で見て互いに対向し、且つ、各第１の側面１４ａ，１４ｂ及び各第２の側面１４ｃ，１４ｄに交差する方向（本実施形態においては、直交する方向）に伸びるように位置している。各第１の側面１４ａ，１４ｂは巻芯部１２の軸心方向に直交することとなる。第１の側面１４ｂには、巻芯部１２が連結されることとなる。   The first portion 14 has a substantially rectangular parallelepiped shape in which the Z-axis direction is the longitudinal direction and the Y-axis direction is the width direction, and has substantially the same width as the core portion 12. The first portion 14 has a pair of first side surfaces 14a and 14b, a pair of second side surfaces 14c and 14d, and a pair of third side surfaces 14e and 14f. The first side surfaces 14a and 14b are positioned so as to face each other when viewed in the X-axis direction. The second side surfaces 14c and 14d face each other when viewed in the Z-axis direction, and are positioned so as to extend in a direction intersecting each first side surface 14a and 14b (in the present embodiment, a direction orthogonal). is doing. The third side surfaces 14e and 14f are opposed to each other when viewed in the Y-axis direction, and intersect with the first side surfaces 14a and 14b and the second side surfaces 14c and 14d (in this embodiment, It is positioned so as to extend in the direction perpendicular to the direction. The first side surfaces 14 a and 14 b are orthogonal to the axial direction of the core 12. The core part 12 will be connected with the 1st side surface 14b.

第２の部分１５は、第１の部分１４の第３の側面１４ｅからＹ軸方向に伸び、Ｚ軸方向が長手方向である略直方体形状を呈している。第２の部分１５は、一対の第１の側面１５ａ，１５ｂと、一対の第２の側面１５ｃ，１５ｄと、第３の側面１５ｅと、を有している。第１の側面１５ａ，１５ｂ同士は、Ｘ軸方向で見て互いに対向するように位置している。第２の側面１５ｃ，１５ｄ同士は、Ｚ軸方向で見て互いに対向し、且つ、各第１の側面１５ａ，１５ｂに交差する方向に伸びるように位置している。第３の側面１５ｅは、各第１の側面１５ａ，１５ｂ及び各第２の側面１５ｃ，１５ｄに交差する方向に伸びるように位置している。各第１の側面１５ａ，１５ｂは巻芯部１２の軸心方向に直交することとなる。第１の部分１４の第２の側面１４ｃ及び第３の側面１４ｅと、第２の部分１５の第２の側面１５ｃとで、段差が形成されており、第２の部分１５の第２の側面１５ｃは第１の部分１４の第２の側面１４ｃよりも低い位置にある。   The second portion 15 extends from the third side surface 14e of the first portion 14 in the Y-axis direction and has a substantially rectangular parallelepiped shape in which the Z-axis direction is the longitudinal direction. The second portion 15 has a pair of first side surfaces 15a and 15b, a pair of second side surfaces 15c and 15d, and a third side surface 15e. The first side surfaces 15a and 15b are positioned so as to face each other when viewed in the X-axis direction. The second side surfaces 15c and 15d are positioned so as to face each other in the Z-axis direction and extend in a direction intersecting with the first side surfaces 15a and 15b. The third side surface 15e is positioned so as to extend in a direction intersecting with the first side surfaces 15a and 15b and the second side surfaces 15c and 15d. The first side surfaces 15 a and 15 b are orthogonal to the axial direction of the core 12. A step is formed between the second side surface 14c and the third side surface 14e of the first portion 14 and the second side surface 15c of the second portion 15, and the second side surface of the second portion 15 is formed. 15 c is at a position lower than the second side surface 14 c of the first portion 14.

第２の側面１５ｃ，１５ｄは、第１〜第３の平面１７ａ〜１７ｃを含んでいる。第２の側面１６ｃ，１６ｄは、第１〜第３の平面１８ａ〜１８ｃを含んでいる。   The second side surfaces 15c and 15d include first to third planes 17a to 17c. The second side surfaces 16c and 16d include first to third planes 18a to 18c.

第２の側面１５ｃに含まれる第２の平面１７ｂは、巻芯部１２の軸心方向（Ｘ軸方向）に見て第１の平面１７ａよりも巻芯部１２（第１の側面１５ｂ）側に位置し且つ巻芯部１２の軸心方向（Ｘ軸方向）に直交する方向（Ｚ軸方向）に見て第１の平面１７ａよりも他方の第２の側面１５ｄ側に位置している。第２の側面１５ｃは、第１の平面１７ａから第２の平面１７ｂにわたって、段下がり形状を呈することとなる。第２の側面１５ｃに含まれる第３の平面１７ｃは、巻芯部１２の軸心方向に見て第１の平面１７ａよりも第１の側面１５ａ側に位置し且つ巻芯部１２の軸心方向に直交する方向に見て第１の平面１７ａよりも他方の第２の側面１５ｄ側に位置している。   The second flat surface 17b included in the second side surface 15c is closer to the core portion 12 (first side surface 15b) than the first flat surface 17a when viewed in the axial direction (X-axis direction) of the core portion 12. And the second side surface 15d on the other side of the first plane 17a as viewed in the direction (Z-axis direction) perpendicular to the axial center direction (X-axis direction) of the core part 12. The second side surface 15c exhibits a step-down shape from the first plane 17a to the second plane 17b. The third flat surface 17c included in the second side surface 15c is located closer to the first side surface 15a than the first flat surface 17a when viewed in the axial direction of the core portion 12, and the axial center of the core portion 12 is. When viewed in a direction orthogonal to the direction, the second side surface 15d is located on the other side of the first flat surface 17a.

第２の側面１５ｄに含まれる第２の平面１７ｂは、巻芯部１２の軸心方向（Ｘ軸方向）に見て第１の平面１７ａよりも巻芯部１２（第１の側面１５ｂ）側に位置し且つ巻芯部１２の軸心方向（Ｘ軸方向）に直交する方向（Ｚ軸方向）に見て第１の平面１７ａよりも他方の第２の側面１５ｃ側に位置している。第２の側面１５ｄは、第１の平面１７ａから第２の平面１７ｂにわたって、段下がり形状を呈することとなる。第２の側面１５ｄに含まれる第３の平面１７ｃは、巻芯部１２の軸心方向に見て第１の平面１７ａよりも第１の側面１５ａ側に位置し且つ巻芯部１２の軸心方向に直交する方向に見て第１の平面１７ａよりも他方の第２の側面１５ｃ側に位置している。第２の側面１５ｄに含まれる第２の平面１７ｂは、第１の部分１４の第２の側面１４ｄと同一平面上に位置する。   The second flat surface 17b included in the second side surface 15d is closer to the core portion 12 (first side surface 15b) than the first flat surface 17a when viewed in the axial direction (X-axis direction) of the core portion 12. And the second side surface 15c on the other side of the first flat surface 17a when viewed in the direction (Z-axis direction) perpendicular to the axial center direction (X-axis direction) of the core 12. The second side surface 15d exhibits a step-down shape from the first plane 17a to the second plane 17b. The third flat surface 17c included in the second side surface 15d is located closer to the first side surface 15a than the first flat surface 17a when viewed in the axial direction of the core portion 12, and is the axial center of the core portion 12. When viewed in a direction orthogonal to the direction, the second side surface 15c is located on the other side of the first flat surface 17a. The second plane 17b included in the second side surface 15d is located on the same plane as the second side surface 14d of the first portion 14.

第１〜第３の平面１７ａ〜１７ｃは、第１の側面１５ａ側から第１の側面１５ｂ側に向かって、第３の平面１７ｃ、第１の平面１７ａ、第２の平面１７ｂの順に位置している。第１の平面１７ａと第２の平面１７ｂとの間には傾斜面１７ｄが位置しており、第１の平面１７ａ、傾斜面１７ｄ及び第２の平面１７ｂとで段差が形成されている。第１の平面１７ａと第３の平面１７ｃとの間には、傾斜面１７ｅが位置しており、第１の平面１７ａ、傾斜面１７ｅ及び第３の平面１７ｃとで段差が形成されている。   The first to third planes 17a to 17c are located in the order of the third plane 17c, the first plane 17a, and the second plane 17b from the first side surface 15a side to the first side surface 15b side. ing. An inclined surface 17d is located between the first plane 17a and the second plane 17b, and a step is formed between the first plane 17a, the inclined plane 17d, and the second plane 17b. An inclined surface 17e is located between the first plane 17a and the third plane 17c, and a step is formed between the first plane 17a, the inclined surface 17e, and the third plane 17c.

第２の側面１５ｃ，１５ｄには、第１の平面１７ａと第２の平面１７ｂとの境界段差を跨ぐように凹部２０が設けられている。凹部２０の開口端は、第１の平面１７ａにおけるＸ軸方向での途中位置から、傾斜面１７ｄ及び第２の平面１７ｂにわたって伸びており、第２の平面１７ｂの第１の側面１５ｂ側の端まで至っている。凹部２０は、第２の側面１５ｃ，１５ｄにおけるＹ軸方向での略中央に位置している。   On the second side surfaces 15c and 15d, a recess 20 is provided so as to straddle the boundary step between the first plane 17a and the second plane 17b. The opening end of the recess 20 extends from the midway position in the X-axis direction of the first plane 17a over the inclined surface 17d and the second plane 17b, and is the end of the second plane 17b on the first side surface 15b side. Has reached. The recess 20 is located at the approximate center in the Y-axis direction on the second side surfaces 15c and 15d.

第１の平面１７ａには、当該第１の平面１７ａの第１の側面１５ａ側の端から凹部２０にわたるように、溝部２１が設けられている。溝部２１の深さは、凹部２０の深さよりも浅く設定されている。また、溝部２１の開口端の幅（Ｙ軸方向での長さ）は、凹部２０の開口端の幅（Ｙ軸方向での長さ）よりも小さく設定されている。   A groove portion 21 is provided in the first plane 17a so as to extend from the end of the first plane 17a on the first side surface 15a side to the recess 20. The depth of the groove 21 is set to be shallower than the depth of the recess 20. The width of the opening end of the groove 21 (length in the Y-axis direction) is set smaller than the width of the opening end of the recess 20 (length in the Y-axis direction).

第２の部分１６は、第１の部分１４の第３の側面１４ｆからＹ軸方向に伸び、Ｚ軸方向が長手方向である略直方体形状を呈している。第２の部分１６は、一対の第１の側面１６ａ，１６ｂと、一対の第２の側面１６ｃ，１６ｄと、第３の側面１６ｅと、を有している。第１の側面１６ａ，１６ｂ同士は、Ｘ軸方向で見て互いに対向するように位置している。第２の側面１６ｃ，１６ｄ同士は、Ｚ軸方向で見て互いに対向し、且つ、各第１の側面１６ａ，１６ｂに交差する方向に伸びるように位置している。第３の側面１６ｅは、各第１の側面１６ａ，１６ｂ及び各第２の側面１６ｃ，１６ｄに交差する方向に伸びるように位置している。各第１の側面１６ａ，１６ｂは巻芯部１２の軸心方向に直交することとなる。第１の部分１４の第２の側面１４ｃ及び第３の側面１４ｆと、第２の部分１６の第２の側面１６ｃとで、段差が形成されており、第２の部分１６の第２の側面１６ｃは第１の部分１４の第２の側面１４ｃよりも低い位置にある。   The second portion 16 extends from the third side surface 14f of the first portion 14 in the Y-axis direction, and has a substantially rectangular parallelepiped shape in which the Z-axis direction is the longitudinal direction. The second portion 16 has a pair of first side surfaces 16a and 16b, a pair of second side surfaces 16c and 16d, and a third side surface 16e. The first side surfaces 16a and 16b are positioned so as to face each other when viewed in the X-axis direction. The second side surfaces 16c and 16d are positioned so as to face each other when viewed in the Z-axis direction and to extend in a direction intersecting with the first side surfaces 16a and 16b. The third side surface 16e is positioned so as to extend in a direction intersecting with the first side surfaces 16a and 16b and the second side surfaces 16c and 16d. The first side surfaces 16 a and 16 b are orthogonal to the axial center direction of the core 12. A step is formed between the second side surface 14 c and the third side surface 14 f of the first portion 14 and the second side surface 16 c of the second portion 16, and the second side surface of the second portion 16. 16 c is at a position lower than the second side surface 14 c of the first portion 14.

第２の側面１６ｃに含まれる第２の平面１８ｂは、巻芯部１２の軸心方向（Ｘ軸方向）に見て第１の平面１７ａよりも巻芯部１２（第１の側面１６ｂ）側に位置し且つ巻芯部１２の軸心方向（Ｘ軸方向）に直交する方向（Ｚ軸方向）に見て第１の平面１８ａよりも他方の第２の側面１６ｄ側に位置している。第２の側面１６ｃは、第１の平面１８ａから第２の平面１８ｂにわたって、段下がり形状を呈することとなる。第２の側面１６ｃに含まれる第３の平面１８ｃは、巻芯部１２の軸心方向に見て第１の平面１８ａよりも第１の側面１６ａ側に位置し且つ巻芯部１２の軸心方向に直交する方向に見て第１の平面１８ａよりも他方の第２の側面１６ｄ側に位置している。   The second plane 18b included in the second side surface 16c is closer to the core 12 (first side 16b) than the first plane 17a when viewed in the axial direction (X-axis direction) of the core 12. And is located closer to the other second side surface 16d than the first flat surface 18a when viewed in the direction (Z-axis direction) perpendicular to the axial direction (X-axis direction) of the core 12. The second side surface 16c exhibits a step-down shape from the first plane 18a to the second plane 18b. The third flat surface 18c included in the second side surface 16c is located closer to the first side surface 16a than the first flat surface 18a when viewed in the axial direction of the core portion 12, and is the axial center of the core portion 12. When viewed in the direction orthogonal to the direction, the second side surface 16d is located on the other side of the first flat surface 18a.

第２の側面１６ｄに含まれる第２の平面１８ｂは、巻芯部１２の軸心方向（Ｘ軸方向）に見て第１の平面１８ａよりも巻芯部１２（第１の側面１６ｂ）側に位置し且つ巻芯部１２の軸心方向（Ｘ軸方向）に直交する方向（Ｚ軸方向）に見て第１の平面１８ａよりも他方の第２の側面１６ｃ側に位置している。第２の側面１６ｄは、第１の平面１８ａから第２の平面１８ｂにわたって、段下がり形状を呈することとなる。第２の側面１６ｄに含まれる第３の平面１８ｃは、巻芯部１２の軸心方向に見て第１の平面１８ａよりも第１の側面１６ａ側に位置し且つ巻芯部１２の軸心方向に直交する方向に見て第１の平面１８ａよりも他方の第２の側面１６ｃ側に位置している。第２の側面１６ｄに含まれる第２の平面１８ｂは、第１の部分１４の第２の側面１４ｄと同一平面上に位置する。   The second flat surface 18b included in the second side surface 16d is closer to the core portion 12 (first side surface 16b) than the first flat surface 18a when viewed in the axial direction (X-axis direction) of the core portion 12. And the second side surface 16c side of the first flat surface 18a as viewed in the direction (Z-axis direction) perpendicular to the axial direction (X-axis direction) of the core portion 12. The second side surface 16d exhibits a step-down shape from the first plane 18a to the second plane 18b. The third flat surface 18c included in the second side surface 16d is located closer to the first side surface 16a than the first flat surface 18a when viewed in the axial direction of the core portion 12, and the axial center of the core portion 12 is. The second side surface 16c is located on the other side of the first plane 18a when viewed in the direction orthogonal to the direction. The second plane 18b included in the second side surface 16d is located on the same plane as the second side surface 14d of the first portion 14.

第１〜第３の平面１８ａ〜１８ｃは、第１の側面１６ａ側から第１の側面１６ｂ側に向かって、第３の平面１８ｃ、第１の平面１８ａ、第２の平面１８ｂの順に位置している。第１の平面１８ａと第２の平面１８ｂとの間には傾斜面１８ｄが位置しており、第１の平面１８ａ、傾斜面１８ｄ及び第２の平面１８ｂとで段差が形成されている。第１の平面１８ａと第３の平面１８ｃとの間には、傾斜面１８ｅが位置しており、第１の平面１８ａ、傾斜面１８ｅ及び第３の平面１８ｃとで段差が形成されている。   The first to third planes 18a to 18c are located in the order of the third plane 18c, the first plane 18a, and the second plane 18b from the first side surface 16a side to the first side surface 16b side. ing. An inclined surface 18d is located between the first plane 18a and the second plane 18b, and a step is formed between the first plane 18a, the inclined surface 18d, and the second plane 18b. An inclined surface 18e is located between the first plane 18a and the third plane 18c, and a step is formed between the first plane 18a, the inclined surface 18e, and the third plane 18c.

第２の側面１６ｃ，１６ｄには、第１の平面１８ａと第２の平面１８ｂとの境界段差を跨ぐように凹部２２が設けられている。凹部２２の開口端は、第１の平面１８ａにおけるＸ軸方向での途中位置から、傾斜面１８ｄ及び第２の平面１８ｂにわたって伸びており、第２の平面１８ｂの第１の側面１６ｂ側の端まで至っている。凹部２２は、第２の側面１６ｃ，１６ｄにおけるＹ軸方向での略中央に位置している。   The second side surfaces 16c and 16d are provided with a recess 22 so as to straddle the boundary step between the first plane 18a and the second plane 18b. The opening end of the recess 22 extends from the midway position in the X-axis direction on the first plane 18a over the inclined surface 18d and the second plane 18b, and is the end of the second plane 18b on the first side face 16b side. Has reached. The recess 22 is located at the approximate center in the Y-axis direction on the second side surfaces 16c and 16d.

第１の平面１８ａには、当該第１の平面１８ａの第１の側面１６ａ側の端から凹部２２にわたるように、溝部２３が設けられている。溝部２３の深さは、凹部２２の深さよりも浅く設定されている。また、溝部２３の開口端の幅（Ｙ軸方向での長さ）は、凹部２２の開口端の幅（Ｙ軸方向での長さ）よりも小さく設定されている。   The first flat surface 18a is provided with a groove 23 so as to extend from the end of the first flat surface 18a on the first side surface 16a side to the recess 22. The depth of the groove 23 is set shallower than the depth of the recess 22. Further, the width of the opening end of the groove 23 (length in the Y-axis direction) is set smaller than the width of the opening end of the recess 22 (length in the Y-axis direction).

巻線３０は、２本の導体線３１を含んでいる。２本の導体線３１は、絶縁被覆されており、巻芯部１２に巻回されている。２本の導体線３１は、互いに電気的に絶縁されると共に、互いに磁気結合する。各導体線３１として、絶縁被膜銅線（例えば、ポリウレタン銅線、ポリアミドイミド銅線等）を用いることができる。   The winding 30 includes two conductor wires 31. The two conductor wires 31 are covered with insulation and are wound around the core portion 12. The two conductor wires 31 are electrically insulated from each other and magnetically coupled to each other. As each conductor wire 31, an insulation coating copper wire (for example, polyurethane copper wire, polyamide imide copper wire, etc.) can be used.

金属端子４０は、第１の金属端子４１，４２と、第２の金属端子５１，５２とを含んでいる。第１の金属端子４１，４２は、鍔部１３の第２の部分１５にそれぞれ装着されている。第２の金属端子５１，５２は、鍔部１３の第２の部分１６にそれぞれ装着されている。第１の金属端子４１及び第２の金属端子５１には、一方の導体線３１が電気的に接続されている。第１の金属端子４２及び第２の金属端子５２には、他方の導体線３１が電気的に接続されている。   The metal terminal 40 includes first metal terminals 41 and 42 and second metal terminals 51 and 52. The first metal terminals 41 and 42 are respectively attached to the second portion 15 of the flange 13. The second metal terminals 51 and 52 are respectively attached to the second portion 16 of the flange portion 13. One conductor wire 31 is electrically connected to the first metal terminal 41 and the second metal terminal 51. The other conductor wire 31 is electrically connected to the first metal terminal 42 and the second metal terminal 52.

第１の金属端子４１，４２は、図４にも示されるように、第１の端子部分４３と、当該第１の端子部分４３の各端部から伸びる一対の第２の端子部分４４，４５と、第２の端子部分４４から伸びる第１及び第２の片部分４６，４７を有している。第１の端子部分４３と、一対の第２の端子部分４４，４５と、第１及び第２の片部分４６，４７とは、金属板を折り曲げ加工することにより形成される。第１の端子部分４３は、鍔部１３の第２の部分１５の第１の側面１５ａに対峙する。第２の端子部分４４は、鍔部１３の第２の部分１５の第２の側面１５ｃに対峙する。第２の端子部分４５は、鍔部１３の第２の部分１５の第２の側面１５ｄに対峙する。一対の第２の端子部分４４，４５のそれぞれの先端部は、巻芯部１２方向に折り曲げられている。   As shown in FIG. 4, the first metal terminals 41, 42 include a first terminal portion 43 and a pair of second terminal portions 44, 45 extending from each end of the first terminal portion 43. And first and second piece portions 46 and 47 extending from the second terminal portion 44. The first terminal portion 43, the pair of second terminal portions 44 and 45, and the first and second piece portions 46 and 47 are formed by bending a metal plate. The first terminal portion 43 faces the first side surface 15 a of the second portion 15 of the flange portion 13. The second terminal portion 44 faces the second side surface 15 c of the second portion 15 of the flange portion 13. The second terminal portion 45 faces the second side surface 15 d of the second portion 15 of the flange portion 13. The distal ends of the pair of second terminal portions 44 and 45 are bent in the direction of the core portion 12.

第２の端子部分４４には、凸部４８が第２の側面１５ｃに設けられた凹部２０に対応する位置に設けられている。凸部４８は、第２の端子部分４５に向かって突出している。第２の端子部分４５には、凸部４９が第２の側面１５ｄに設けられた凹部２０に対応する位置に設けられている。凸部４９は、第２の端子部分４４に向かって突出している。   On the second terminal portion 44, a convex portion 48 is provided at a position corresponding to the concave portion 20 provided on the second side surface 15c. The convex part 48 protrudes toward the second terminal part 45. On the second terminal portion 45, a convex portion 49 is provided at a position corresponding to the concave portion 20 provided on the second side surface 15d. The protrusion 49 protrudes toward the second terminal portion 44.

第１及び第２の片部分４６，４７は導体線３１を継線するためのものであり、第２の端子部分４４とで導体線３１を挟持する。第１及び第２の片部分４６，４７は、第２の端子部分４４におけるＹ軸方向での一方の端部から伸びている。第１の片部分４６は、導体線３１を固定するための係止片であり、図４にて示された状態から曲げられることにより、第２の端子部分４４とで導体線３１を挟持する。第２の片部分４７は、レーザー溶接により主に溶融状態とされるための係止片であり、図４にて示された状態から曲げられることにより、第２の端子部分４４とで導体線３１を挟持する。図１では、図示を省略するが、第１及び第２の片部分４６，４７と第２の端子部分４４とで導体線３１を挟持した状態でレーザー溶接を行うことにより、第１の金属端子４１と導体線３１とが機械的及び電気的に接続される。図４に示されるように、曲げられる前の状態では、第１の片部分４６と第２の端子部分４４とが成す角度は略４５°であり、第２の片部分４７と第２の端子部分４４とが成す角度は略９０°である。   The first and second piece portions 46 and 47 are for connecting the conductor wire 31, and sandwich the conductor wire 31 with the second terminal portion 44. The first and second piece portions 46 and 47 extend from one end portion of the second terminal portion 44 in the Y-axis direction. The first piece portion 46 is a locking piece for fixing the conductor wire 31 and is bent from the state shown in FIG. 4 so as to sandwich the conductor wire 31 with the second terminal portion 44. . The second piece portion 47 is a locking piece mainly made into a molten state by laser welding, and is bent from the state shown in FIG. 31 is pinched. Although not shown in FIG. 1, the first metal terminal is formed by performing laser welding in a state where the conductor wire 31 is sandwiched between the first and second piece portions 46 and 47 and the second terminal portion 44. 41 and the conductor wire 31 are mechanically and electrically connected. As shown in FIG. 4, in the state before bending, the angle formed between the first piece portion 46 and the second terminal portion 44 is approximately 45 °, and the second piece portion 47 and the second terminal are formed. The angle formed by the portion 44 is approximately 90 °.

図４に示されるように、第１の金属端子４１，４２が鍔部１３に装着されていない状態で、第１の端子部分４３と、一対の第２の端子部分４４，４５とがそれぞれ成す角度は、いずれも鋭角（例えば、８６°程度）である。また、第１の金属端子４１，４２が鍔部１３に装着されていない状態で、第１の端子部分４３のＺ軸方向の長さは第１の側面１５ａのＺ軸方向の長さよりも僅かに大きく、一対の第２の端子部分４４，４５の端部のＺ軸方向での間隔は、第１の側面１５ａのＺ軸方向の長さよりも僅かに小さい。   As shown in FIG. 4, the first terminal portion 43 and the pair of second terminal portions 44 and 45 are formed in a state where the first metal terminals 41 and 42 are not attached to the flange portion 13. The angles are all acute angles (for example, about 86 °). In addition, the length of the first terminal portion 43 in the Z-axis direction is slightly smaller than the length of the first side surface 15a in the Z-axis direction when the first metal terminals 41 and 42 are not attached to the flange portion 13. In particular, the distance between the ends of the pair of second terminal portions 44 and 45 in the Z-axis direction is slightly smaller than the length of the first side surface 15a in the Z-axis direction.

第１の金属端子４１，４２は、図５にも示されるように、凸部４８，４９が凹部２０に入った状態で一対の第２の端子部分４４，４５により一対の第２の側面１５ｃ，１５ｄを狭持することにより、鍔部１３の第２の部分１５に設けられる。第１の金属端子４１，４２を鍔部１３の第２の部分１５にそれぞれ装着する場合、第１の金属端子４１，４２は、一対の第２の端子部分４４，４５の間隔が広げられながら、第２の部分１５の第１の側面１５ａ側から第２の部分１５に外挿される。このとき、凸部４８，４９は、第２の側面１５ｃ，１５ｄに設けられた溝部２１に係合し、第１の金属端子４１，４２の導入方向を規定する。   As shown in FIG. 5, the first metal terminals 41, 42 are paired with the pair of second side surfaces 15 c by the pair of second terminal portions 44, 45 in a state where the convex portions 48, 49 are in the concave portion 20. , 15d is provided in the second portion 15 of the collar portion 13. When the first metal terminals 41 and 42 are respectively attached to the second portion 15 of the flange portion 13, the first metal terminals 41 and 42 are expanded while the interval between the pair of second terminal portions 44 and 45 is widened. The second portion 15 is extrapolated to the second portion 15 from the first side surface 15a side. At this time, the convex portions 48 and 49 are engaged with the groove portions 21 provided on the second side surfaces 15c and 15d to define the introduction direction of the first metal terminals 41 and 42.

第２の金属端子５１，５２は、図４にも示されるように、第１の端子部分５３と、当該第１の端子部分５３の各端部から伸びる一対の第２の端子部分５４，５５と、第２の端子部分５４から伸びる第１及び第２の片部分５６，５７を有している。第１の端子部分５３と、一対の第２の端子部分５４，５５と、第１及び第２の片部分５６，５７とは、金属板を折り曲げ加工することにより形成される。第１の端子部分５３は、鍔部１３の第２の部分１６の第１の側面１６ａに対峙する。第２の端子部分５４は、鍔部１３の第２の部分１６の第２の側面１６ｃに対峙する。第２の端子部分５５は、鍔部１３の第２の部分１６の第２の側面１６ｄに対峙する。一対の第２の端子部分５４，５５のそれぞれの先端部は、巻芯部１２方向に折り曲げられている。   As shown in FIG. 4, the second metal terminals 51 and 52 include a first terminal portion 53 and a pair of second terminal portions 54 and 55 extending from each end portion of the first terminal portion 53. And first and second piece portions 56 and 57 extending from the second terminal portion 54. The first terminal portion 53, the pair of second terminal portions 54 and 55, and the first and second piece portions 56 and 57 are formed by bending a metal plate. The first terminal portion 53 faces the first side surface 16 a of the second portion 16 of the flange portion 13. The second terminal portion 54 faces the second side surface 16 c of the second portion 16 of the flange portion 13. The second terminal portion 55 faces the second side surface 16 d of the second portion 16 of the flange portion 13. The distal ends of the pair of second terminal portions 54 and 55 are bent in the direction of the core portion 12.

第２の端子部分５４には、凸部５８が第２の側面１６ｃに設けられた凹部２２に対応する位置に設けられている。凸部５８は、第２の端子部分５５に向かって突出している。第２の端子部分５５には、凸部５９が第２の側面１６ｄに設けられた凹部２２に対応する位置に設けられている。凸部５９は、第２の端子部分５４に向かって突出している。   On the second terminal portion 54, a convex portion 58 is provided at a position corresponding to the concave portion 22 provided on the second side surface 16c. The convex portion 58 protrudes toward the second terminal portion 55. In the second terminal portion 55, a convex portion 59 is provided at a position corresponding to the concave portion 22 provided in the second side surface 16d. The protrusion 59 protrudes toward the second terminal portion 54.

第１及び第２の片部分５６，５７は導体線３１を継線するためのものであり、第２の端子部分５４とで導体線３１を挟持する。第１及び第２の片部分５６，５７は、第２の端子部分５４におけるＹ軸方向での他方の端から伸びている。第１の片部分５６は、導体線３１を固定するための係止片であり、図４にて示された状態から曲げられることにより、第２の端子部分５４とで導体線３１を挟持する。第２の片部分５７は、レーザー溶接により主に溶融状態とされるための係止片であり、図４にて示された状態から曲げられることにより、第２の端子部分５４とで導体線３１を挟持する。図１では、図示を省略するが、第１及び第２の片部分５６，５７と第２の端子部分５４とで導体線３１を挟持した状態でレーザー溶接を行うことにより、第２の金属端子５１と導体線３１とが機械的及び電気的に接続される。図４に示されるように、曲げられる前の状態では、第１の片部分５６と第２の端子部分５４とが成す角度は略４５°であり、第２の片部分５７と第２の端子部分５４とが成す角度は略９０°である。   The first and second piece portions 56 and 57 are for connecting the conductor wire 31, and sandwich the conductor wire 31 with the second terminal portion 54. The first and second piece portions 56 and 57 extend from the other end of the second terminal portion 54 in the Y-axis direction. The first piece portion 56 is a locking piece for fixing the conductor wire 31 and is bent from the state shown in FIG. 4 so as to sandwich the conductor wire 31 with the second terminal portion 54. . The second piece portion 57 is a locking piece that is mainly brought into a molten state by laser welding, and is bent from the state shown in FIG. 31 is pinched. Although not shown in FIG. 1, the second metal terminal is obtained by performing laser welding in a state where the conductor wire 31 is sandwiched between the first and second piece portions 56 and 57 and the second terminal portion 54. 51 and the conductor wire 31 are mechanically and electrically connected. As shown in FIG. 4, in the state before being bent, the angle formed by the first piece portion 56 and the second terminal portion 54 is approximately 45 °, and the second piece portion 57 and the second terminal are formed. The angle formed by the portion 54 is approximately 90 °.

図４に示されるように、第２の金属端子５１，５２が鍔部１３に装着されていない状態で、第１の端子部分５３と、一対の第２の端子部分５４，５５とがそれぞれ成す角度は、いずれも鋭角（例えば、８６°程度）である。また、第２の金属端子５１，５２が鍔部１３に装着されていない状態で、第１の端子部分５３のＺ軸方向の長さは第１の側面１６ａのＺ軸方向の長さよりも僅かに大きく、一対の第２の端子部分５４，５５の端部のＺ軸方向での間隔は、第１の側面１６ａのＺ軸方向の長さよりも僅かに小さい。   As shown in FIG. 4, the first terminal portion 53 and the pair of second terminal portions 54 and 55 are formed in a state where the second metal terminals 51 and 52 are not attached to the flange portion 13. The angles are all acute angles (for example, about 86 °). Further, the length of the first terminal portion 53 in the Z-axis direction is slightly smaller than the length of the first side surface 16a in the Z-axis direction when the second metal terminals 51 and 52 are not attached to the flange portion 13. The distance between the ends of the pair of second terminal portions 54, 55 in the Z-axis direction is slightly smaller than the length of the first side surface 16a in the Z-axis direction.

第２の金属端子５１，５２は、図６にも示されるように、凸部５８，５９が凹部２２に入った状態で一対の第２の端子部分５４，５５により一対の第２の側面１６ｃ，１６ｄを狭持することにより、鍔部１３の第２の部分１６に設けられる。第２の金属端子５１，５２を鍔部１３の第２の部分１６にそれぞれ装着する場合、第２の金属端子５１，５２は、一対の第２の端子部分５４，５５の間隔が広げられながら、第２の部分１６の第１の側面１６ａ側から第２の部分１６に外挿される。このとき、凸部５８，５９は、第２の側面１６ｃ，１６ｄに設けられた溝部２３に係合し、第２の金属端子５１，５２の導入方向を規定する。   As shown in FIG. 6, the second metal terminals 51 and 52 are formed by a pair of second terminal portions 54 and 55 in a state where the convex portions 58 and 59 are in the concave portion 22. , 16d is provided in the second portion 16 of the collar portion 13. When the second metal terminals 51 and 52 are respectively attached to the second portion 16 of the flange portion 13, the second metal terminals 51 and 52 are expanded while the interval between the pair of second terminal portions 54 and 55 is widened. The second portion 16 is extrapolated to the second portion 16 from the first side surface 16a side. At this time, the convex portions 58 and 59 are engaged with the groove portions 23 provided on the second side surfaces 16c and 16d to define the introduction direction of the second metal terminals 51 and 52.

次に、図７〜図１４に基づいて、本実施形態に係るコモンモードフィルタ１の製造過程について説明する。図７〜図１４は、本実施形態に係るコモンモードフィルタの製造過程を説明するための図である。   Next, a manufacturing process of the common mode filter 1 according to the present embodiment will be described with reference to FIGS. 7-14 is a figure for demonstrating the manufacturing process of the common mode filter which concerns on this embodiment.

まず、コア１０と、金属端子４０（第１の金属端子４１，４２及び第２の金属端子５１，５２）とを用意する。そして、図７に示されるように、コア１０に各金属端子４１，４２，５１，５２を装着する（端子装着工程）。ここでは、各金属端子４１，４２，５１，５２を、上述したように、鍔部１３の各対応する部分１５，１６の第１の側面１５ａ，１６ａ側から各凸部４８，４９，５８，５９が対応する凹部２０，２２に嵌る位置まで外挿する。その後、第２の端子部分４４，４５，５４，５５の各先端部を、巻芯部１２方向に折り曲げる。   First, the core 10 and the metal terminals 40 (first metal terminals 41 and 42 and second metal terminals 51 and 52) are prepared. Then, as shown in FIG. 7, the metal terminals 41, 42, 51, 52 are mounted on the core 10 (terminal mounting process). Here, as described above, the metal terminals 41, 42, 51, 52 are connected to the corresponding convex portions 48, 49, 58, 58 from the first side surfaces 15 a, 16 a side of the corresponding portions 15, 16 of the flange portion 13. Extrapolate to the position where 59 fits into the corresponding recesses 20 and 22. Thereafter, the tip portions of the second terminal portions 44, 45, 54, and 55 are bent in the direction of the core portion 12.

次に、１本の導体線３１を用意し、図８に示されるように、巻芯部１２に巻回する（巻線工程）。そして、図９に示されるように、導体線３１の所望の位置を第１の片部分４６，５６と第２の端子部分４４，５４とで挟持し、導体線３１を各金属端子４１，５２に固定する（第１の仮固定工程）。その後、導体線３１を各金属端子４１，５２に固定した後、導体線３１を切断する（切断工程）。   Next, one conductor wire 31 is prepared and wound around the core 12 as shown in FIG. 8 (winding step). Then, as shown in FIG. 9, the desired position of the conductor wire 31 is sandwiched between the first piece portions 46 and 56 and the second terminal portions 44 and 54, and the conductor wire 31 is connected to the metal terminals 41 and 52. (First temporary fixing step). Then, after fixing the conductor wire 31 to each metal terminal 41 and 52, the conductor wire 31 is cut | disconnected (cutting process).

次に、１本の導体線３１を用意し、巻芯部１２に巻回する（巻線工程）。そして、図１０に示されるように、導体線３１の所望の位置を第１の片部分４６，５６と第２の端子部分４４，５４とで挟持し、導体線３１を各金属端子５１，４２に固定する（第１の仮固定工程）。その後、導体線３１を各金属端子５１，４２に固定した後、導体線３１を切断する（切断工程）。これらにより、巻線３０が形成されることとなる。各第１の片部分４６，５６は、曲げられる前の状態では第２の端子部分４４，５４との成す角度が略４５°であり、第１の片部分４６，５６を容易に曲げることができる。なお、図８〜１０において、導体線３１は既に切断した状態で示されている。   Next, one conductor wire 31 is prepared and wound around the core 12 (winding step). Then, as shown in FIG. 10, the desired position of the conductor wire 31 is sandwiched between the first piece portions 46 and 56 and the second terminal portions 44 and 54, and the conductor wire 31 is connected to the metal terminals 51 and 42. (First temporary fixing step). Then, after fixing the conductor wire 31 to each metal terminal 51 and 42, the conductor wire 31 is cut | disconnected (cutting process). As a result, the winding 30 is formed. Each of the first piece portions 46 and 56 has an angle of approximately 45 ° with the second terminal portions 44 and 54 in a state before being bent, so that the first piece portions 46 and 56 can be easily bent. it can. 8-10, the conductor wire 31 is shown in a state where it has already been cut.

次に、図１１に示されるように、巻線３０（各導体線３１）の被覆を除去する（被覆除去工程）。被覆の除去は、各金属端子４１，４２，５１，５２に固定された巻線３０のうち少なくとも第２の片部分４７，５７に対応する部分の被覆をレーザー照射により行う。ここでは、互いに異なる複数の方向（本実施形態では、異なる２方向）Ｄ１，Ｄ２からのレーザー照射により被覆を除去する。第２の片部分４７，５７と第２の端子部分４４，５４とが成す角度は略９０°であるので、第２の片部分４７，５７はレーザー照射に対して障害とはなり難い。レーザーには、例えばＹＡＧレーザーを用いることができる。レーザー照射は、異なる２方向Ｄ１，Ｄ５から行ってもよく、また、異なる２方向Ｄ３，Ｄ４から行ってもよい。方向Ｄ１と方向Ｄ２とでは、１３５°程度ずれている。方向Ｄ１と方向Ｄ５、及び、方向Ｄ３と方向Ｄ４とでは、それぞれ１８０°程度ずれている。   Next, as shown in FIG. 11, the coating of the winding 30 (each conductor wire 31) is removed (coating removing step). For removal of the coating, at least a portion corresponding to the second piece portions 47 and 57 of the winding 30 fixed to each metal terminal 41, 42, 51 and 52 is coated by laser irradiation. Here, the coating is removed by laser irradiation from a plurality of different directions (two different directions in this embodiment) D1 and D2. Since the angle formed between the second piece portions 47 and 57 and the second terminal portions 44 and 54 is approximately 90 °, the second piece portions 47 and 57 are unlikely to be an obstacle to laser irradiation. For example, a YAG laser can be used as the laser. Laser irradiation may be performed from two different directions D1 and D5, or from two different directions D3 and D4. The direction D1 and the direction D2 are shifted by about 135 °. The direction D1 and the direction D5, and the direction D3 and the direction D4 are each shifted by about 180 °.

次に、図１に示されるように、第２の片部分４７，５７を曲げて、巻線３０における被覆が除去された部分を第２の端子部分４４，５４と第２の片部分４７，５７とで狭持する。これにより、巻線３０の両端部が各金属端子４１，４２，５１，５２に固定されることとなる（第２の仮固定工程）。   Next, as shown in FIG. 1, the second piece portions 47 and 57 are bent, and the portions of the winding 30 from which the coating is removed are replaced with the second terminal portions 44 and 54 and the second piece portions 47 and 57. Hold it at 57. Thereby, the both ends of the coil | winding 30 will be fixed to each metal terminal 41,42,51,52 (2nd temporary fixing process).

次に、図１２に示されるように、巻線３０における被覆が除去された部分と各金属端子４１，４２，５１，５２とを第２の片部分４７，５７へのレーザー照射により溶接する。これにより、巻線３０が各金属端子４１，４２，５１，５２に継線されることとなる（継線工程）。レーザー光の照射領域ＬＡは、図１３に示されるように、第２の片部分４７，５７と巻線３０とを含むように設定されることが好ましい。レーザーには、被覆除去工程と同様に、例えばＹＡＧレーザーを用いることができる。巻線３０における被覆が除去された部分と各金属端子４１，４２，５１，５２との溶接には、レーザー照射による溶接の代わりに、アークによる溶接を用いることができる。   Next, as shown in FIG. 12, the portion of the winding 30 from which the coating is removed and the metal terminals 41, 42, 51, 52 are welded to the second piece portions 47, 57 by laser irradiation. Thereby, the coil | winding 30 will be connected to each metal terminal 41,42,51,52 (connection process). As shown in FIG. 13, the laser light irradiation area LA is preferably set so as to include the second piece portions 47 and 57 and the winding 30. As the laser, for example, a YAG laser can be used as in the coating removal step. For welding the portion of the winding 30 from which the coating has been removed and each of the metal terminals 41, 42, 51, 52, welding by arc can be used instead of welding by laser irradiation.

これらの工程を経て、上述した構成を有するコモンモードフィルタ１が得られることとなる。   Through these steps, the common mode filter 1 having the above-described configuration is obtained.

以上のように、本実施形態においては、まず、巻線３０が第２の端子部分４４，５４と第１の片部分４６，５６とで狭持されて各金属端子４１，４２，５１，５２に固定された後、各金属端子４１，４２，５１，５２に固定された巻線３０のうち少なくとも第２の片部分４７，５７に対応する部分の被覆がレーザー照射により除去される。そして、巻線３０における被覆が除去された部分が第２の端子部分４４，５４と第２の片部分４７，５７とで狭持されて、各金属端子４１，４２，５１，５２に固定された後に、巻線３０における被覆が除去された部分と各金属端子４１，４２，５１，５２とが第２の片部分４７，５７へのレーザー照射により溶接される。したがって、巻線３０を形成した後に被覆が除去されることから、巻線３０における被覆が除去された部分と各金属端子４１，４２，５１，５２との間に位置ズレが生じることはない。また、被覆が除去された状態で溶接が行われることから、巻線３０における被覆が除去された部分と各金属端子４１，４２，５１，５２とが適切に溶接される。これらの結果、巻線３０と各金属端子４１，４２，５１，５２とが確実に電気的に接続された状態で適切に継線されることとなる。   As described above, in the present embodiment, first, the winding 30 is sandwiched between the second terminal portions 44 and 54 and the first piece portions 46 and 56, and the respective metal terminals 41, 42, 51, 52. After being fixed to the metal terminals 41, 42, 51, 52, at least the portions corresponding to the second piece portions 47, 57 of the winding 30 fixed to the metal terminals 41, 42, 51, 52 are removed by laser irradiation. The portion of the winding 30 from which the coating is removed is sandwiched between the second terminal portions 44 and 54 and the second piece portions 47 and 57 and fixed to the metal terminals 41, 42, 51 and 52. After that, the portions of the winding 30 from which the coating has been removed and the respective metal terminals 41, 42, 51, 52 are welded to the second piece portions 47, 57 by laser irradiation. Therefore, since the coating is removed after the winding 30 is formed, there is no positional deviation between the portion of the winding 30 where the coating is removed and the metal terminals 41, 42, 51, 52. Further, since welding is performed in a state where the covering is removed, the portion of the winding 30 where the covering is removed and the respective metal terminals 41, 42, 51, 52 are appropriately welded. As a result, the winding 30 and each of the metal terminals 41, 42, 51, 52 are appropriately connected in a state where the winding 30 is reliably electrically connected.

また、本実施形態において、被覆除去工程では、互いに異なる複数の方向Ｄ１，Ｄ２からのレーザー照射により被覆を除去している。これにより、被覆をより一層確実に除去することができる。レーザー照射方向は、互いに１３５°程度以上ずれていることが好ましい。   In the present embodiment, in the coating removal step, the coating is removed by laser irradiation from a plurality of different directions D1 and D2. Thereby, a coating | cover can be removed still more reliably. The laser irradiation directions are preferably shifted from each other by about 135 ° or more.

次に、図９、図１０、及び図１４〜図１７に基づいて、本実施形態に係るコモンモードフィルタの製造過程の変形例について説明する。図１４〜図１７は、本実施形態に係るコモンモードフィルタの製造過程の変形例を説明するための図である。   Next, a modified example of the manufacturing process of the common mode filter according to the present embodiment will be described with reference to FIGS. 9, 10, and 14 to 17. 14-17 is a figure for demonstrating the modification of the manufacturing process of the common mode filter which concerns on this embodiment.

まず、端子装着工程については、上述した実施形態における端子装着工程と同じであり、説明を省略する。   First, the terminal mounting process is the same as the terminal mounting process in the above-described embodiment, and a description thereof will be omitted.

次に、１本の導体線３１を用意し、図１４に示されるように、導体線３１の所望の位置を一方の第１の金属端子４１の第１の片部分４６と第２の端子部分４４とで挟持し、導体線３１を一方の第１の金属端子４１に固定する（第１の仮固定工程）。そして、図１５に示されるように、導体線３１を巻芯部１２に巻回する（巻線工程）。続いて、図９に示されるように、導体線３１の所望の位置を他方の第２の金属端子５２の第１の片部分５６と第２の端子部分５４とで挟持し、導体線３１を他方の第２の金属端子５２に固定する（第１の仮固定工程）。その後、導体線３１を切断する（切断工程）。これにより、巻線３０が形成されることとなる。なお、図１４及び図１５において、導体線３１は既に切断した状態で示されている。   Next, one conductor wire 31 is prepared, and as shown in FIG. 14, the desired position of the conductor wire 31 is set to the first piece portion 46 and the second terminal portion of one first metal terminal 41. 44, and the conductor wire 31 is fixed to one first metal terminal 41 (first temporary fixing step). And as FIG. 15 shows, the conductor wire 31 is wound around the core part 12 (winding process). Subsequently, as shown in FIG. 9, the desired position of the conductor wire 31 is sandwiched between the first piece portion 56 and the second terminal portion 54 of the other second metal terminal 52, and the conductor wire 31 is It fixes to the other 2nd metal terminal 52 (1st temporary fixing process). Thereafter, the conductor wire 31 is cut (cutting step). As a result, the winding 30 is formed. 14 and 15, the conductor wire 31 is shown in a state where it has already been cut.

次に、１本の導体線３１を用意し、図１６に示されるように、導体線３１の所望の位置を一方の第２の金属端子５１の第１の片部分５６と第２の端子部分５４とで挟持し、導体線３１を一方の第２の金属端子５１に固定する（第１の仮固定工程）。そして、図１７に示されるように、導体線３１を巻芯部１２に巻回する（巻線工程）。続いて、図１０に示されるように、導体線３１の所望の位置を他方の第１の金属端子４２の第１の片部分４６と第２の端子部分４４とで挟持し、導体線３１を他方の第１の金属端子４２に固定する（第１の仮固定工程）。その後、導体線３１を切断する（切断工程）。これにより、巻線３０が形成されることとなる。なお、図１６及び図１７において、導体線３１は既に切断した状態で示されている。   Next, one conductor wire 31 is prepared, and as shown in FIG. 16, the desired position of the conductor wire 31 is set to the first piece portion 56 and the second terminal portion of one second metal terminal 51. 54, and the conductor wire 31 is fixed to one second metal terminal 51 (first temporary fixing step). And as FIG. 17 shows, the conductor wire 31 is wound around the core part 12 (winding process). Subsequently, as shown in FIG. 10, the desired position of the conductor wire 31 is sandwiched between the first piece portion 46 and the second terminal portion 44 of the other first metal terminal 42, and the conductor wire 31 is It fixes to the other 1st metal terminal 42 (1st temporary fixing process). Thereafter, the conductor wire 31 is cut (cutting step). As a result, the winding 30 is formed. 16 and 17, the conductor wire 31 is shown in a state where it has already been cut.

被覆除去工程、第２の仮固定工程及び継線工程については、上述した実施形態における各工程と同じであり、説明を省略する。これらの工程によっても、上述した構成を有するコモンモードフィルタ１が得られることとなる。   The coating removal process, the second temporary fixing process, and the connecting process are the same as the processes in the above-described embodiment, and a description thereof is omitted. Also by these steps, the common mode filter 1 having the above-described configuration is obtained.

以上のように、上記変形例においても、上述した本実施形態と同様に、巻線３０を形成した後に被覆が除去されることから、巻線３０における被覆が除去された部分と各金属端子４１，４２，５１，５２との間に位置ズレが生じることはない。また、被覆が除去された状態で溶接が行われることから、巻線３０における被覆が除去された部分と各金属端子４１，４２，５１，５２とが適切に溶接される。これらの結果、巻線３０と各金属端子４１，４２，５１，５２とが確実に電気的に接続された状態で適切に継線されることとなる。   As described above, also in the modified example, the coating is removed after the winding 30 is formed, as in the above-described embodiment. Therefore, the portion of the winding 30 where the coating is removed and each metal terminal 41. , 42, 51, 52 are not misaligned. Further, since welding is performed in a state where the covering is removed, the portion of the winding 30 where the covering is removed and the respective metal terminals 41, 42, 51, 52 are appropriately welded. As a result, the winding 30 and each of the metal terminals 41, 42, 51, 52 are appropriately connected in a state where the winding 30 is reliably electrically connected.

以上、本発明の好適な実施形態について説明してきたが、本発明は必ずしもこれらの実施形態に限定されるものではない。例えば、コア１０は、上述した形状のコアに限られない。また、コモンモードフィルタ１は、当該コモンモードフィルタ１の上面を平坦面として、自動装着機の吸着ノズルで吸着可能にするために、板状コアを備えていてもよい。板状コアの代わりに、セラミック製の板や樹脂製の板を備えていてもよく、コモンモードフィルタ１を樹脂モールドしてもよい。   The preferred embodiments of the present invention have been described above, but the present invention is not necessarily limited to these embodiments. For example, the core 10 is not limited to the core having the shape described above. Further, the common mode filter 1 may include a plate-like core so that the upper surface of the common mode filter 1 is a flat surface and can be sucked by the suction nozzle of the automatic mounting machine. Instead of the plate-like core, a ceramic plate or a resin plate may be provided, and the common mode filter 1 may be resin-molded.

本実施形態において、各第１の片部分４６，５６は、曲げられる前の状態では第２の端子部分４４，５４との成す角度が略４５°に設定されているが、これに限られるものではなく、例えば、図１８に示されるように略９０°に設定されていてもよい。また、各第２の片部分４７，５７の形状は、図４等に示された形状に限られることなく、図１９に示されるように、第１の片部分４６，５６と同様な形状であってもよい。   In the present embodiment, the angle between the first piece portions 46 and 56 and the second terminal portions 44 and 54 in the state before being bent is set to approximately 45 °, but is not limited thereto. Instead, for example, it may be set to approximately 90 ° as shown in FIG. Further, the shape of each of the second piece portions 47 and 57 is not limited to the shape shown in FIG. 4 and the like, and as shown in FIG. 19, the shape is the same as that of the first piece portions 46 and 56. There may be.

本実施形態では、コア１０としてドラムコアを採用しているが、これに限られるものではない。例えば、コア１０は、図２０に示されるように、一対の巻芯部１２と、当該一対の巻芯部１２の軸方向の両端に形成された一対の鍔部１３とを有する形状であってもよい。図２０に示されたコモンモードフィルタ１では、各巻芯部１２に１本の導体線３１が巻回されている。   In the present embodiment, a drum core is employed as the core 10, but the present invention is not limited to this. For example, as shown in FIG. 20, the core 10 has a shape having a pair of core portions 12 and a pair of flange portions 13 formed at both ends of the pair of core portions 12 in the axial direction. Also good. In the common mode filter 1 shown in FIG. 20, one conductor wire 31 is wound around each core portion 12.

本実施形態では、本発明をコモンモードフィルタ１に適用しているが、これに限られることなく、コモンモードフィルタ以外のコイル部品（例えば、巻線３０が１本あるいは３本以上有するインダクタ部品等）に本発明を適用してもよい。   In the present embodiment, the present invention is applied to the common mode filter 1. However, the present invention is not limited to this, and other coil components than the common mode filter (for example, inductor components having one or more windings 30) The present invention may be applied to:

本実施形態に係るコモンモードフィルタを示す斜視図である。It is a perspective view which shows the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタに含まれるコアを示す斜視図である。It is a perspective view which shows the core contained in the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタに含まれるコアを示す斜視図である。It is a perspective view which shows the core contained in the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタに含まれる電極を示す斜視図である。It is a perspective view which shows the electrode contained in the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタに含まれるコアの鍔部周辺の断面図である。It is sectional drawing of the collar part periphery of the core contained in the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタに含まれるコアの鍔部周辺の断面図である。It is sectional drawing of the collar part periphery of the core contained in the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの製造過程を説明するための図である。It is a figure for demonstrating the manufacturing process of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの製造過程を説明するための図である。It is a figure for demonstrating the manufacturing process of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの製造過程を説明するための図である。It is a figure for demonstrating the manufacturing process of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの製造過程を説明するための図である。It is a figure for demonstrating the manufacturing process of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの製造過程を説明するための図である。It is a figure for demonstrating the manufacturing process of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの製造過程を説明するための図である。It is a figure for demonstrating the manufacturing process of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの製造過程を説明するための図である。It is a figure for demonstrating the manufacturing process of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの製造過程の変形例を説明するための図である。It is a figure for demonstrating the modification of the manufacturing process of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの製造過程の変形例を説明するための図である。It is a figure for demonstrating the modification of the manufacturing process of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの製造過程の変形例を説明するための図である。It is a figure for demonstrating the modification of the manufacturing process of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの製造過程の変形例を説明するための図である。It is a figure for demonstrating the modification of the manufacturing process of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの変形例を説明するための斜視図である。It is a perspective view for demonstrating the modification of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの変形例を説明するための斜視図である。It is a perspective view for demonstrating the modification of the common mode filter which concerns on this embodiment. 本実施形態に係るコモンモードフィルタの変形例を説明するための斜視図である。It is a perspective view for demonstrating the modification of the common mode filter which concerns on this embodiment.

符号の説明Explanation of symbols

１…コモンモードフィルタ、１０…コア、１２…巻芯部、１３…鍔部、３０…巻線、３１…導体線、４０…電極、４１，４２…第１の金属端子、４３…第１の端子部分、４４，４５…第２の端子部分、４６…第１の片部分、４７…第２の片部分、５１，５２…第２の金属端子、５３…第１の端子部分、５４，５５…第２の端子部分、５６…第１の片部分、５７…第２の片部分。   DESCRIPTION OF SYMBOLS 1 ... Common mode filter, 10 ... Core, 12 ... Core part, 13 ... Gutter part, 30 ... Winding, 31 ... Conductor wire, 40 ... Electrode, 41, 42 ... 1st metal terminal, 43 ... 1st Terminal portion, 44, 45 ... second terminal portion, 46 ... first piece portion, 47 ... second piece portion, 51, 52 ... second metal terminal, 53 ... first terminal portion, 54, 55 ... 2nd terminal part, 56 ... 1st piece part, 57 ... 2nd piece part.

Claims (2)

巻芯部と当該巻芯部の端に位置する鍔部とを有するコアと、前記巻芯部に巻回される巻線と、前記巻線に電気的に接続されると共に前記鍔部に設けられる金属端子と、を備えるコイル部品の製造方法であって、
前記金属端子は、前記鍔部に対峙する端子部分と、当該端子部分から伸びる第１及び第２の片部分と、を有しており、
前記巻線を前記端子部分と前記第１の片部分とで狭持して、前記金属端子に固定する工程と、
前記金属端子に固定された前記巻線のうち少なくとも前記第２の片部分に対応する部分の被覆をレーザー照射により除去する工程と、
前記巻線における被覆が除去された前記部分を前記端子部分と前記第２の片部分とで狭持して、前記金属端子に固定する工程と、
前記巻線における被覆が除去された前記部分と前記金属端子とを前記第２の片部分へのレーザー照射又はアークにより溶接する工程と、を備えることを特徴とするコイル部品の製造方法。 A core having a core part and a collar part located at the end of the core part, a winding wound around the core part, and electrically connected to the winding and provided in the collar part A metal terminal, and a method of manufacturing a coil component comprising:
The metal terminal has a terminal portion facing the flange portion, and first and second piece portions extending from the terminal portion,
Sandwiching the winding between the terminal portion and the first piece portion and fixing the winding to the metal terminal;
Removing the coating of at least the portion corresponding to the second piece of the winding fixed to the metal terminal by laser irradiation;
Sandwiching the portion of the winding from which the coating has been removed between the terminal portion and the second piece portion, and fixing to the metal terminal;
And a step of welding the portion of the winding from which the coating has been removed and the metal terminal to the second piece by laser irradiation or arcing. 前記第２の片部分に対応する前記部分の被覆をレーザー照射により除去する工程では、互いに異なる複数の方向からのレーザー照射により被覆を除去することを特徴とする請求項１に記載のコイル部品の製造方法。
2. The coil component according to claim 1, wherein in the step of removing the coating of the portion corresponding to the second piece portion by laser irradiation, the coating is removed by laser irradiation from a plurality of different directions. Production method.
JP2004310047A 2004-10-25 2004-10-25 Manufacturing method of coil component Pending JP2006121013A (en)

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