JP2009252791A - Coil component and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil component that is less expensive by automation and can be reduced in height, and to provide a method of manufacturing the coil component. <P>SOLUTION: At a pin terminal 23, a groove 23a axially extended in the axial direction of the pin terminal 23 is formed over the entire axial direction of the pin terminal 23. By assembling the coil component with the width of the groove 23a slightly larger than the diameter of a conductor end 32D of second primary winding, the conductor end 32D of the second primary winding is engaged over the entire groove 23a. Although the second primary winding comprises an insulated and coated conductor 32H, no insulating cover is present between an inner surface of the groove 23a in the pin terminal 23 and the conductor 32H in the groove 23a and solder 33 is interposed, thus electrically connecting the conductor 32H to the pin terminal 23. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a coil component and a method for manufacturing the coil component, and more particularly to a coil component in which one end or the other end of a conductive wire constituting the coil is electrically connected to a pin terminal serving as an external electrode, and the coil component. The present invention relates to a method for manufacturing a coil component.

2. Description of the Related Art Conventionally, a coil component is known in which one end or the other end of a conductive wire constituting a coil of a coil component is electrically connected to a pin terminal serving as an external terminal constituting the coil component and connected. The electrical connection to the pin terminal at one end or the other end of the conducting wire is to tie one end or the other end of the conducting wire to the pin terminal and solder one end or the other end of the tangled conducting wire to the pin terminal. This is done by welding. Such a configuration in which one end or the other end of the conducting wire is entangled with the pin terminal is described in, for example, JP-A-10-125540 (Patent Document 1).
Japanese Patent Laid-Open No. 10-125540

  However, in the conventional coil component, as described above, one end or the other end of the conductive wire is entangled with the pin terminal, and this entanglement process is labor-intensive. On the other hand, if this tying process is automated and performed by a machine, a device having a complicated mechanism is required. Therefore, there is a problem that it is costly to perform the tying process whether it is performed manually or automatically.

  In addition, in order to tie one end or the other end of the conducting wire to the pin terminal, an area for tying one end or the other end of the conducting wire in the axial direction of the pin terminal must be secured, and the axial direction of the pin terminal In this case, a problem arises that the coil component becomes tall.

  SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a coil component and a method for manufacturing the coil component that can be automated and cost-effective and can be reduced in height.

  In order to achieve the above object, the present invention provides an insulating resin terminal block in which a pin terminal made of a conductor is implanted, and one end or the other end is fixed to the insulating resin terminal block by winding a conducting wire. The pin terminal is formed with a groove extending in the axial direction of the pin terminal over the entire axial direction of the pin terminal, and the groove has one end of the winding or The other end part engages over the whole groove | channel, The coil component by which this conducting wire and this pin terminal are electrically connected is provided.

  The pin terminal is formed with a groove extending in the axial direction of the pin terminal over the entire axial direction of the pin terminal, and one end or the other end of the winding is formed in the groove. Engaging all over and electrically connecting the lead wire and the pin terminal, it is not necessary to tie one end or the other end of the lead wire to the pin terminal, one end of the lead wire to the pin terminal The electrical connection of the part or the other end part can be automated, and the cost can be reduced.

  In addition, when one end or the other end of the conducting wire is entangled with the pin terminal, it is necessary to secure a region for tying one end or the other end of the conducting wire in the axial direction of the pin terminal. It is not necessary to secure such an area. For this reason, it is possible to reduce the height of the coil component in the axial direction of the pin terminal.

  In addition, the pin terminal can be made to correspond to various conductors having a conductor end having a large diameter or a conductor end having a small diameter. Further, the insertion can be made easier than the case where the conductor end portion is inserted into a cylindrical pin terminal. In addition, when the conductive wire end has a thick diameter, it is possible to use the thick conductive wire end as it is as an external electrode without using the pin terminal, but when the conductive wire end is thin, Since the strength is insufficient, the end portion of the conductor cannot be used as an external electrode as it is. Even in such a case, the thin conductor end can be reinforced and used as an external terminal by inserting the thin conductor end into the pin terminal groove. In addition, it is possible to insert a conductive wire with an insulating coating, and later supply solder to the groove of the pin terminal to discharge the insulating coating from the opening of the groove. Also, the solder can be filled in the groove without any gap.

  In addition, when the lead wire end and the pin terminal are electrically connected by caulking, part of the lead wire end can be escaped to the opening of the groove by caulking, and there is no place for the caulked lead wire end. As a result, it is possible to prevent a problem that the pin terminal is deformed.

  In addition, when a protrusion protruding from the peripheral surface of the pin terminal is provided in the opening of the groove, a welding ball composed of the protrusion and the conductor end is formed in the opening without changing the outermost dimension of the pin terminal. it can.

  Here, the conducting wire has a core wire made of a conductor and an insulating coating covering the peripheral surface of the core wire, and there is no insulating coating between the inner surface of the groove of the pin terminal and the core wire in the groove. It is preferable that a conductor is interposed.

  The conducting wire has a core wire made of a conductor and an insulation coating that covers the peripheral surface of the core wire, and there is no insulation coating between the inner surface of the groove of the pin terminal and the core wire in the groove. Since the body is interposed, the core wire and the pin terminal can be reliably electrically connected. Moreover, it can be set as the coil component by which insulation coating was discharged | emitted from the opening part.

  The conducting wire has a core wire made of a conductor and an insulating coating covering the peripheral surface of the core wire, and the pin terminal has a caulking portion that caulks the conducting wire when the pin terminal is caulked. The pin terminal and the conductive wire are preferably electrically connected at the caulking portion.

  The pin terminal has a caulking portion that caulks to the conducting wire by caulking the pin terminal, and the pin terminal and the conducting wire are electrically connected at the caulking portion. The terminal can be reliably electrically connected. Further, a part of the conductor end can be released to the opening of the groove by caulking, and the coil part can be prevented from being deformed due to the absence of the place of the caulked conductor end. .

  Moreover, it is preferable that the portion of the pin terminal that defines the inner surface of the groove has a melted portion that is melted and electrically connected to the conducting wire. Since the portion of the pin terminal that defines the inner surface of the groove has a melted portion that is melted and electrically connected to the conductive wire, the core wire and the pin terminal can be reliably electrically connected.

  Further, the present invention is a pin terminal made of a conductor, and is formed of a conductor in the groove of the insulating resin terminal block in which the pin terminal formed with a groove extending in the whole axial direction is formed. Inserting a conductive wire having a core wire and an insulating coating covering a peripheral surface of the core wire; and immersing one end portion of the pin terminal in molten solder to supply the solder into the groove; There is provided a method of manufacturing a coil component including the step of melting and removing the insulating coating of the conductive wire and electrically connecting the pin terminal and the core wire.

  A pin terminal made of a conductor having a groove extending in the entire axial direction thereof is formed in the groove of the insulating resin terminal block in which the pin terminal is implanted. A step of inserting a conductive wire having an insulating coating covering the surface, and dipping one end of the pin terminal into molten solder to supply the solder into the groove, thereby providing the insulating coating of the conductive wire in the groove Since it includes a step of melting and removing and electrically connecting the pin terminal and the core wire, the core wire and the pin terminal can be reliably electrically connected. Further, the insulating coating can be discharged from the opening.

  Further, the present invention is a pin terminal made of a conductor, and is formed of a conductor in the groove of the insulating resin terminal block in which the pin terminal formed with a groove extending in the whole axial direction is formed. Inserting a lead wire having a core wire and an insulating coating covering a peripheral surface of the core wire; and caulking a part of the pin terminal to the lead wire in the groove by caulking the pin terminal. A method of manufacturing a coil component including a step of electrically connecting a terminal and the core wire is provided.

  A pin terminal made of a conductor having a groove extending in the entire axial direction thereof is formed in the groove of the insulating resin terminal block in which the pin terminal is implanted. A step of inserting a lead wire having an insulating coating covering the surface; and a part of the pin terminal is caulked against the lead wire in the groove by caulking the pin terminal to connect the pin terminal and the core wire. Therefore, the core wire and the pin terminal can be reliably electrically connected. Further, it is possible to prevent a part of the end portion of the conducting wire from escaping to the opening of the groove by caulking and to prevent the pin terminal from being deformed due to the absence of the place of the caulking end portion of the conducting wire.

  Further, the present invention is a pin terminal made of a conductor, and a groove extending in the entire axial direction is formed, and a protrusion protruding from the peripheral surface of the pin terminal is provided in the opening of the groove. A step of inserting a conductor having a conductor core wire and an insulating coating covering a peripheral surface of the core wire into the groove of the insulating resin terminal block in which the pin terminal is implanted; and the projecting portion into the groove Bending and temporarily fixing the conductor in the groove by bringing the protrusion into contact with the conductor in the groove; and welding the protrusion and the conductor to the protrusion and the core wire And a method of manufacturing a coil component having a step of electrically connecting the two.

  A pin terminal made of a conductor, which is formed with a groove extending in the entire axial direction thereof, and having a protrusion protruding from the peripheral surface of the pin terminal at the opening of the groove. Inserting a conductive wire having a conductor core wire and an insulation coating covering the peripheral surface of the core wire into the groove of the insulated resin terminal block, and bending the protrusion into the groove to project the protrusion. A process of temporarily fixing the conductor in the groove by bringing the conductor into contact with the conductor in the groove, and electrically connecting the protrusion and the core wire by welding the protrusion and the conductor Therefore, the core wire and the pin terminal can be reliably electrically connected. Moreover, the welding ball which consists of a protrusion part and a conducting wire end part can be formed in an opening part, without changing the outermost dimension of a pin terminal.

  As described above, the present invention can provide a coil component and a method for manufacturing the coil component which can be automated and cost-effective and can be reduced in height.

  A coil component and a method of manufacturing the coil component according to the embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 1, the coil component 1 is more specifically a power transformer having a substantially rectangular parallelepiped shape, and its dimensions are about 32.6 mm in length, 32.0 mm in width, and about 14.5 mm in height. Meets the standard (UL 60950). As shown in FIG. 2, the coil component 1 includes three primary windings 22, 32, 52, a secondary winding 42, a first insulating resin bobbin 41, a second insulating resin bobbin 51, and a plate shape The insulating member 31, the insulating resin terminal block 21, the insulating resin cover 61, the first magnetic core 11, and the second magnetic core 12 are provided.

  Since the first magnetic core 11 and the second magnetic core 12 have the same shape, only the first magnetic core 11 will be described. More specifically, the first magnetic core 11 is a conductive ferrite core made of Mn—Zn. The first magnetic core 11 has a flat plate portion 11A having a substantially rectangular plate shape with a slightly constricted central portion, and extends from the upper surface of the flat plate portion 11A over a pair of short sides of the substantially rectangular flat plate portion 11A. Edge projecting portions 11B and 11B projecting upward in FIG. 2 are provided. In addition, a columnar central protruding portion 11C that protrudes upward from FIG. 2 from the upper surface is provided at the center position of the upper surface of the flat plate portion 11A. As the coil component 1 is assembled as shown in FIG. 1, the projecting end surface of the edge projecting portion 11B of the first magnetic core 11 and the projecting end surface of the end projecting portion 11B of the second magnetic core 12 are opposed to each other, The protruding end surface of the central protruding portion 11C of the first magnetic core 11 and the protruding end surface of the central protruding portion 11C of the second magnetic core 12 are configured to face each other.

  The insulating resin terminal block 21 has a terminal block plate-like portion 21A having a substantially rectangular plate shape having a circular portion 21B swelled in a circular shape at the center thereof, and in the center of the circular portion 21B, A circular terminal block through hole 21a that is coaxially opened with the circular portion 21B is formed. A terminal block opening wall that protrudes upward in FIG. 2 from the upper surface of the terminal block plate portion 21A over the entire periphery of the opening on the upper surface of the terminal block plate portion 21A and around the opening of the terminal block through hole 21a. 21C is provided. Further, the peripheral edge of the circular portion 21B, the entire short side of the substantially rectangular terminal block plate-shaped portion 21A, and the portion extending from the peripheral edge to the short side of the one side are formed from the upper surface of the terminal block plate-shaped portion 21A. Terminal block edge walls 21D projecting upward in FIG. 2 are provided.

  The portion corresponding to the lowermost corner portion of FIG. 2 of the substantially rectangular terminal block plate portion 21A and surrounded by the terminal block edge wall 21D is a first primary winding described later. 2 is higher than the upper surface of the circular portion 21B of the terminal block plate-like portion 21A by the approximate sum of the height in the vertical direction of FIG. 2 in FIG. 2 and the height in the vertical direction of FIG. It has a guide portion mounting surface 21E that is higher in the direction, and the entire portion of one short side of the pair of short sides of the substantially rectangular terminal base plate portion 21A forms a terminal electrode forming portion 21F. . Two small-diameter through holes 21b and 21c are formed in the guide portion mounting surface 21E. The upper ends of the pin terminals 23 and 24 are fixed to the openings on the lower side of FIG. 2 of the two through holes 21b and 21c, respectively.

  As shown in FIG. 4, the pin terminals 23, 24 have grooves extending in the axial direction of the pin terminals 23, 24 over the entire axial direction of the pin terminals 23, 24, that is, in the vertical direction of FIG. 4. 23a and 24a are formed. The widths of the grooves 23a and 24a are slightly larger than the diameters of conductor ends 32D and 32G of a second primary winding 32, which will be described later, and the coil component 1 is assembled as shown in FIG. , 24a is engaged with the conductive wire ends 32D and 32G of the second primary winding 32. As will be described later, the second primary winding 32 is composed of a core wire 32H with an insulation coating, but as shown in FIG. 5, between the inner surface of the groove 23a of the pin terminal 23 and the core wire 32H in the groove 23a. There is no insulation coating and the solder 33 is interposed, whereby the core wire 32H and the pin terminal 23 are electrically connected. The same applies to the pin terminal 24.

  At a position adjacent to the guide portion mounting surface 21E, a substantially quadrangular prism shape is formed, and the upper surface of the terminal block plate-like portion 21A is upward in FIG. 2, that is, first to third primary windings 22 described later, A first conducting wire end protecting portion 21H and a second conducting wire end protecting portion 22I extending in the axial direction of 32 and 52 are provided. Through holes 21e and 21d oriented in the extending direction are formed in the first conductor end protection part 21H and the second conductor end protection part 21I, respectively, and the through holes 21e and 21d are respectively provided in the through holes 21e and 21d. Conductor ends 52G and 52D of a third primary winding 52, which will be described later, pass through and protrude downward from the lower surface of the terminal block plate portion 21A to form an external terminal as shown in FIG. Conductor ends 52D and 52G of a third primary winding 52, which will be described later, pass through the through holes 21d and 21e, so that they are positioned above the upper surface of the terminal block plate portion 21A in FIG. The first conductor end protection portion 21H and the second conductor end protection portion 21I cover and protect substantially the entire conductor end portions 52D and 52G of the third primary winding 52. The first conducting wire end protecting portion 21H and the second conducting wire end protecting portion 21I correspond to the conducting wire end covering portion.

  Between the 1st conducting wire end part protection part 21H and the 2nd conducting wire end part protection part 21I, the flat surface of the same height as the upper surface of the circular part 21B of 21 A of terminal block plate-shaped parts is provided, and the said flat A through hole 21g through which the other conductor end 22G of the first primary winding 22 (described later) passes is formed on the surface. Further, on the side opposite to the flat surface with respect to the second conductor end protecting portion 21I, a terminal block plate is provided by a height approximately half of the height in the vertical direction of FIG. A flat surface that is higher in the upward direction in FIG. 2 than the upper surface of the circular portion 21B of the shape portion 21A is provided. A through hole 21f through which one conductor end 22D of a first primary winding 22 described later passes is formed on the flat surface. One conductor end 22D and the other conductor end 22G of the first primary winding 22 penetrating through the through holes 21f and 21g protrude from the lower surface of the terminal block plate-like portion 21A downward in FIG. As shown in FIG. 1, external terminals are formed.

  Of the pair of short sides of the terminal block plate-shaped portion 21A having a substantially rectangular shape, the other short side with respect to one short side provided with the first conductor end protector 21H, the second conductor end protector 21I, etc. The side is provided with a protruding edge 21J that protrudes upward in FIG. 2 from the upper surface of the terminal block plate-like portion 21A over the other short side. The entire portion of the other short side of the pair of short sides forms a terminal electrode forming portion 21G. The protruding end face of the protruding edge portion 21J has a vertical height in FIG. 2 of a first primary winding 22 described later, a vertical height in FIG. 2 of a plate-like insulating member 31 described later, and a second 1 described later. The terminal block plate portion 21A is substantially equal to the vertical height of the next winding 32 in FIG. 2 and the vertical height in FIG. 2 of the first bobbin plate portion 41A of the first insulating resin bobbin 41 described later. 2 is higher than the upper surface of the circular portion 21B.

  As shown in FIG. 2, through holes 21h and 21i through which one conductor end 42D and the other conductor end 42G of a secondary winding 42, which will be described later, pass, are formed on the protruding end surface of the protruding edge 21J. Has been. One conductor end portion 42D and the other conductor end portion 42G of the secondary winding 42 penetrating through the through holes 21h and 21i protrude from the lower surface of the terminal block plate portion 21A downward in FIG. Form external terminals as shown in b).

  The first and third primary windings 22 and 52, and the secondary winding 42 are each made of a conductor having a core wire made of a conductor and an insulating coating covering a peripheral surface of the core wire, the center of which is a shaft. As described above, it is wound by so-called alpha winding (or crosswise winding) so as to form a double structure in a planar and axial direction so that the diameter increases in the radial direction. Further, the second primary winding 32 is planar so that a conductor having a core wire 32H made of a conductor and an insulating coating covering the peripheral surface of the core wire 32H is enlarged in the radial direction about the axis. In addition, it is wound by so-called aligned winding so as to have a single structure in the axial direction.

  The first to third primary windings 22, 32, 52, and the secondary winding 42 are respectively wound around the winding portions 22A, 32A, 52A, 42A and the winding portions 22A, 32A, One end portions 22B, 32B, 52B, 42B drawn from 52A, 42A and the other end portions 22C, 32C, 52C, 42C are provided. The one end portions 22B, 32B, 52B, 42B and the other end portions 22E, 32E, 52E, 42E are substantially outward in the radial direction of the winding portions 22A, 32A, 52A, 42A from the winding portions 22A, 32A, 52A, 42A. Insulated from the extended ends of the drawn portions 22C, 32C, 52C, 42C, 22F, 32F, 52F, 42F and the drawn portions 22C, 32C, 52C, 42C, 22F, 32F, 52F, 42F drawn to extend It has the direction of the resin terminal part, ie, conducting wire end part 22D, 32D, 52D, 42D, 22G, 32G, 52G, 42G extended to the downward direction of FIG. The conductive wire ends 22D, 52D, 42D, 22G, 52G, and 42G of the first and third primary windings 22 and 52 and the secondary winding 42 are assembled with the coil component 1 as shown in FIG. Thus, as described above, it protrudes downward from the lower surface of the insulating resin terminal block 21 to form an external terminal, and the conductive wire end portions 32D, 32G of the second primary winding 32 are in the grooves 23a, 24a of the pin terminals 23, 24. Are electrically connected to the pin terminals 23, 24.

  The plate-like insulating member 31 has a disk-shaped portion 31A that has a substantially disk shape. The disk-shaped portion 31A corresponds to a primary insulating resin plate. A circular insulating member through-hole 31a that opens coaxially with the disk-shaped part 31A is formed at the center position of the disk-shaped part 31A. Further, an insulating member guide portion 31B that protrudes in a substantially radial direction of the disc-shaped portion 31A is provided at a part of the periphery of the disc-shaped portion 31A. The insulating member guide part 31B corresponds to a primary support part. A guide wall in which two notches 31b and 31c are formed is provided at the protruding end edge of the insulating member guide portion 31B so as to extend upward from the upper surface of the disk-shaped portion 31A in FIG. The notches 31b and 31c have wide openings, and even the thin conductors can be easily engaged with the notches 31b and 31c. The portions of the lead portions 32C and 32F connected to the conductor end portions 32D and 32G of the second primary winding 32 are engaged with the notches 31b and 31c, respectively, and the lead portion of the second primary winding 32 is engaged. 32C and 32F are configured to be supported.

  When the coil component 1 is assembled as shown in FIG. 1, the insulating member guide portion 31 </ b> B is placed on the guide portion placement surface 21 </ b> E of the terminal electrode forming portion 21 </ b> F of the insulating resin terminal block 21. Conductor end portions 32D and 32G of the primary winding 32 are inserted into the grooves 23a and 24a of the pin terminals 23 and 24 as described above. Thus, the insulating member guide portion 31B that supports the lead portions 32C and 32F of the second primary winding 32 is mounted on the guide portion mounting surface 21E of the terminal electrode forming portion 21F of the insulating resin terminal block 21. Therefore, the plate-like insulating member 31 provided with the insulating member guide portion 31B can be prevented from rotating around the axis of the second primary winding 32. For this reason, it is possible to prevent the second primary winding 32 from rotating about its axis.

  The first insulating resin bobbin 41 has a first bobbin plate-like portion 41A having a substantially disk shape, and the radius of the first bobbin plate-like portion 41A is slightly smaller than the radius of the circular portion 21B of the insulating resin terminal block 21. It is composed largely. The first bobbin plate portion 41A corresponds to an insulating resin plate or plate portion. A first bobbin guide portion 41B that protrudes outward in the radial direction of the first bobbin plate portion 41A is provided at a part of the periphery of the first bobbin plate portion 41A. The first bobbin guide portion 41B corresponds to a support portion. On the projecting end edge of the first bobbin guide portion 41B, a guide wall in which three notches 41a, 41b, 41c are formed is provided extending from the upper surface of the first bobbin guide portion 41B upward in FIG. . Of the three cutouts 41a, 41b, 41c, the cutouts 41a, 41b at both ends have a wide opening, and can be easily engaged with the cutouts 41a, 41b even if they are thin conductors. . The portions of the lead portions 42C and 42F connected to the conductor end portions 42D and 42G of the secondary winding 42 are engaged with the notches 41a and 41b at both ends, respectively, and the lead portions 42C and 42F of the secondary winding 42 are engaged. Is configured to be supported.

  A circular first bobbin through-hole 41d that opens coaxially with the first bobbin plate-like portion 41A is formed at the center position of the first bobbin plate-like portion 41A. The radius of the first bobbin through hole 41d is configured to be slightly smaller than the radius of the terminal block through hole 21a of the insulating resin terminal block 21. A lower surface of the first bobbin plate-like portion 41A and around the opening of the first bobbin through-hole 41d protrudes downward from the lower surface of the first bobbin plate-like portion 41A over the entire periphery of the opening in FIG. A one-bobbin opening lower wall 41C is provided. Further, on the upper surface of the first bobbin plate-like portion 41A and slightly outward of the first bobbin through hole 41d in the radial direction from the periphery of the opening of the first bobbin through hole 41d, the entire periphery of the opening is spread. A first bobbin opening upper wall 41D that protrudes upward in FIG. 2 from the upper surface of the first bobbin plate-like portion 41A is provided. Since the radius of the first bobbin through hole 41d is configured to be slightly smaller than the radius of the terminal block through hole 21a of the insulating resin terminal block 21, the assembly of the coil component 1 as shown in FIG. The first bobbin opening lower wall 41C is disposed on the inner side of the terminal block opening wall 21C in the radial direction of the first primary winding 22, and the outer peripheral surface of the first bobbin opening lower wall 41C is the inner periphery of the terminal block opening wall 21C. Opposite the surface.

  A portion of the periphery of the first bobbin plate-like portion 41A corresponding to the periphery of the circular portion 21B of the insulating resin terminal block 21 when the coil component 1 is assembled as shown in FIG. A first bobbin lower wall 41E that protrudes downward in FIG. 2 from the lower surface of the portion 21A is provided. Further, the first bobbin plate-like portion 41A protrudes upward in FIG. 2 from the upper surface of the first bobbin plate-like portion 41A at a position slightly inward in the radial direction of the first bobbin plate-like portion 41A slightly from the periphery of the first bobbin plate-like portion 41A. One bobbin upper wall 41F is provided over the entire circumference excluding the portion of the first bobbin guide portion 41B. The first bobbin upper wall 41F corresponds to a wall portion. Since the radius of the first bobbin plate-like portion 41A is slightly larger than the radius of the circular portion 21B of the insulating resin terminal block 21, the first bobbin plate-like portion 41A is assembled by the coil component 1 as shown in FIG. In the radial direction of the primary winding 22, the terminal base edge wall 21D at the periphery of the circular portion 21B is arranged on the inner side of the first bobbin lower wall 41E, and the terminal base edge wall 21D at the periphery of the circular portion 21B. Is opposed to the inner peripheral surface of the first bobbin lower wall 41E.

  The second insulating resin bobbin 51 has a second bobbin plate-like portion 51A having a substantially disk shape, and the radius of the second bobbin plate-like portion 51A is the same as the radius of the first bobbin plate-like portion 41A. The second bobbin plate portion 51A corresponds to a primary insulating resin plate. A part of the peripheral edge of the second bobbin plate-like portion 51A is provided with a second bobbin guide portion 51B that protrudes outward in the radial direction of the second bobbin plate-like portion 51A. The second bobbin guide portion 51B corresponds to a primary support portion. On the projecting end edge of the second bobbin guide portion 51B, a guide wall in which three notches 51a, 51b, 51c are formed extends from the upper surface of the second bobbin guide portion 51B upward in FIG. . Of the three cutouts 51a, 51b, 51c, the cutouts 51a, 51b at both ends have wide openings so that even thin conductors can be easily engaged with the cutouts 51a, 51b. . The portions of the lead portions 52C and 52F connected to the conductor end portions 52D and 52G of the third primary winding 52 are engaged with the notches 51a and 51b at both ends, respectively, and the third primary winding 52 is engaged. The drawer portions 52C and 52F are supported.

  A circular second bobbin through-hole 51d that opens coaxially with the second bobbin plate-like portion 51A is formed at the center position of the second bobbin plate-like portion 51A. The radius of the second bobbin through hole 51d is the same as the radius of the first bobbin through hole 41d. A lower surface of the second bobbin plate-like portion 51A and around the opening of the second bobbin through-hole 51d protrudes downward from the lower surface of the second bobbin plate-like portion 51A over the entire periphery of the opening. A two-bobbin opening lower wall 51C is provided. In addition, on the upper surface of the second bobbin plate-like portion 51A and slightly outside the second bobbin through hole 51d in the radial direction from the periphery of the opening of the second bobbin through hole 51d, the entire periphery of the opening is spread. A second bobbin opening upper wall 51D that protrudes upward in FIG. 2 from the upper surface of the second bobbin plate-like portion 51A is provided. Since the radius of the second bobbin through hole 51d is the same as the radius of the first bobbin through hole 41d, the coil part 1 is assembled as shown in FIG. The second bobbin opening lower wall 51C is disposed on the inner side of the first bobbin opening upper wall 41D, and the outer peripheral surface of the second bobbin opening lower wall 51C faces the inner peripheral surface of the first bobbin opening upper wall 41D.

  The outer periphery of the second bobbin plate-like portion 51A except the portion corresponding to the first bobbin guide portion 41B of the first insulating resin bobbin 41 when the coil component 1 is assembled as shown in FIG. Is provided with a second bobbin lower wall 51E that protrudes downward from the lower surface of the second bobbin plate-like portion 51A in FIG. Further, the second bobbin plate-like portion 51A protrudes upward in FIG. 2 from the upper surface of the second bobbin plate-like portion 51A at a position slightly inward in the radial direction of the second bobbin plate-like portion 51A slightly from the periphery of the second bobbin plate-like portion 51A. A two-bobbin upper wall 51F is provided over the entire circumference excluding the portion of the second bobbin guide portion 51B. Since the radius of the first bobbin plate-like portion 41A is the same as the radius of the second bobbin plate-like portion 51A, the coil component 1 is assembled as shown in FIG. In the radial direction, the first bobbin upper wall 41F is arranged inside the second bobbin lower wall 51E, and the outer peripheral surface of the first bobbin upper wall 41F faces the inner peripheral surface of the second bobbin lower wall 51E.

  The insulating resin cover 61 has a cover plate portion 61A having a substantially rectangular plate shape with a circular cover portion 61B swelled in a circular shape at the center, and the radius of the cover plate portion 61A is the second. It is the same as the radius of the bobbin plate-like portion 51A. In the center of the cover circular portion 61B, a circular cover through hole 61a that opens coaxially with the cover circular portion 61B is formed. The radius of the cover through hole 61a is the same as the radius of the second bobbin through hole 51d. A cover opening wall 61C is provided on the lower surface of the cover circular portion 61B and around the opening of the cover through hole 61a so as to protrude downward from the lower surface of the cover circular portion 61B over the entire periphery of the opening. . Since the radius of the cover through-hole 61a is the same as the radius of the second bobbin through-hole 51d, the coil component 1 is assembled as shown in FIG. The opening wall 61C is disposed inside the second bobbin opening upper wall 51D, and the outer peripheral surface of the cover opening wall 61C faces the inner peripheral surface of the second bobbin opening upper wall 51D.

  Further, a cover lower wall 61D that protrudes downward in FIG. 2 from the lower surface of the cover circular portion 61B is provided on the periphery of the cover circular portion 61B. Since the radius of the cover plate portion 61A is the same as the radius of the second bobbin plate portion 51A, when the coil component 1 is assembled as shown in FIG. 1, the entire inner peripheral surface of the cover lower wall 61D. Is configured to face the entire outer peripheral surface of the second bobbin upper wall 51F except for a portion corresponding to the second bobbin guide portion 51B of the second insulating resin bobbin 51.

  The pair of short sides of the cover plate-like portion 61A having a substantially rectangular plate shape has anti-rotation walls 61E and 61E extending from the upper surface of the cover plate-like portion 61A upward in FIG. Are provided. When the coil component 1 is assembled as shown in FIG. 1, the rotation prevention wall 61 </ b> E can come into contact with the constricted portion of the second magnetic core 12, and by this contact, the insulating resin cover 61 and the third The primary winding 52, the second insulating resin bobbin 51, the secondary winding 42, the first insulating resin bobbin 41, etc. rotate around the axis of the first to third primary windings 22, 32, 52 as the rotation axis. To prevent it.

  The coil component 1 described above has a circuit configuration as shown in FIG. The configuration is a power transformer in which the first to third primary windings 22, 32, 52 are arranged on the primary side, and the secondary winding 42 is arranged on the secondary side. Conductor ends 22D, 22G, 32D, 32G, 52D, 52G of the first to third primary windings 22, 32, 52, and the conductor ends 42D, 42G of the secondary winding 42 each constitute an external terminal, The conductor end 22G of the first primary winding 22 and 52G of the third primary winding 52 are electrically connected on the mounting board by a land pattern of the mounting board.

  The second primary winding 32 with respect to the first bobbin plate-like portion 41A and the first bobbin plate-like portion 41A disposed opposite to the second primary winding 32 in the axial direction of the second primary winding 32 Has a secondary winding 42 disposed coaxially with the second primary winding 32 and facing the first bobbin plate-like portion 41A on the opposite side, and is wound together with the second primary winding 32. Since the first insulating resin bobbin module 40, which will be described later, constituting the rotating unit is provided, the primary winding and the secondary winding in the axial direction of the primary winding and the secondary winding 42 by the first insulating resin bobbin module 40. 42 can be partitioned by one first bobbin plate-like portion 41A. For this reason, the height reduction in the axial direction of the primary winding 32 and the secondary winding 42 can be achieved. In addition, since a plurality of windings are not wound in one first insulating resin bobbin module 40, taping which has been conventionally performed for insulation between the plurality of windings is not performed. It can be set as the coil component 1 which satisfy | fills UL specification (UL60950).

  In addition, since the first insulating resin bobbin 41 has the first bobbin plate-like portion 41A and the first bobbin upper wall 41F, the first bobbin plate-like portion 51A is fitted with the second bobbin lower wall 51E. Can fit. Further, since the first bobbin upper wall 41F is disposed so as to face almost the entire peripheral surface of the secondary winding 42, the primary windings 32 and 52 are provided by the amount of the first bobbin upper wall 41F. And a creepage distance between the secondary winding 42 and the secondary winding 42 can be secured longer. Further, since it is possible to prevent the peripheral surface of the secondary winding 42 from being exposed, it is possible to prevent the peripheral surface of the secondary winding 42 from being damaged. Further, when the coil component 1 is mounted on a substrate (not shown), an insulating tape is wound around the entire surface of the coil component 1 for safety standards between the coil component 1 and other components on the mounting substrate. 1 may be protected, but it is possible to prevent the peripheral surface of the secondary winding 42 from being damaged when the insulating tape is wound in this way.

  In addition, since the first conductive wire end protection portion 21H and the second conductive wire end protection portion 21I are provided in the insulating resin terminal block 21 so as to extend in the axial direction of the primary winding 52, the conductive wire end portion 52D, Most of 52G can be protected. Further, since the exposure of the primary winding 52 can be reduced, insulation between the coil component 1 and other components on the mounting substrate can be achieved. Further, when the coil component 1 is mounted on the substrate, an insulating tape is wound around the entire surface of the coil component 1 for safety standards between the coil component 1 and other components on the mounting substrate to protect the coil component 1. However, when the insulating tape is wound in this way, it is possible to prevent the one end 52B and the other end 52E of the primary winding 52 from being damaged.

  Further, the insulating resin plate is disposed on the side of the winding portion 42A of the secondary winding 42 in the axial direction of the secondary winding 42 and closer to the insulating resin terminal block 21, and 1 in the axial direction of the primary windings 32 and 52. A disc-shaped portion 31A and a second bobbin plate-shaped portion 51A are provided on the side of the winding portions 32A and 52A of the next windings 32 and 52 closer to the insulating resin terminal block 21, and the disc-shaped portion 31A and the second bobbin plate-shaped are provided. The part 51A is provided with an insulating member guide part 31B and a second bobbin guide part 51B that extend substantially outward in the radial direction of the winding parts 32A and 52A, respectively, so that the lead part 42C of the secondary winding 42, 42F, primary winding lead portions 52C and 52F can be supported.

  The first bobbin guide portion 41B of the first insulating resin bobbin 41 and the second bobbin guide portion 51B of the second insulating resin bobbin 51 are respectively radially outward of the first bobbin plate-like portion 41A and the second bobbin plate-like portion 51A. Since the first bobbin upper wall 41F and the second bobbin upper wall 51F are not provided in this portion, the secondary winding 42 and the second and third primary windings are provided. The creepage distance between the lines 32 and 52 can be secured at a predetermined value.

  The pin terminals 23 and 24 are formed with grooves 23a and 24a extending in the axial direction of the pin terminals 23 and 24 over the entire axial direction of the pin terminals 23 and 24, and the grooves 23a and 24a have second grooves. Since the conductor end portions 32D and 32G of the primary winding 32 are engaged over the entire grooves 23a and 24a, the conductor end portions 32D and 32G and the pin terminals 23 and 24 are electrically connected. It is not necessary to tie the conductor ends 32D and 32G to the terminals 23 and 24, the electrical connection of the conductor ends 32D and 32G to the pin terminals 23 and 24 can be automated, and the cost can be reduced. .

  Further, when the conductor end portions 32D and 32G are entangled with the pin terminals 23 and 24, it is necessary to secure a region for entwining the conductor end portions 32D and 32G in the axial direction of the pin terminals 23 and 24. However, it is not necessary to secure such an area. For this reason, it is possible to reduce the height of the coil component 1 in the axial direction of the pin terminals 23 and 24.

  Further, the pin terminals 23 and 24 can be made to correspond to various conductors having conductor ends with a large diameter or conductors with a small diameter. Further, when the conducting wire end portion has a large diameter, it is possible to use the thick conducting wire end portion as it is as an external electrode without using the pin terminals 23 and 24, but as in the present embodiment. When the conductor end portions 32D and 32G are thin, the conductor end portions 32D and 32G cannot be used as external electrodes as they are because the strength is insufficient. Even in such a case, the thin conductor end portions 32D and 32G can be reinforced and used as external terminals by inserting the thin conductor end portions 32D and 32G into the grooves of the pin terminals 23 and 24. . Further, the insertion can be made easier than when the conductor end portions 32D and 32G are inserted into the cylindrical pin terminals 23 and 24. Also, the conductor end portions 32D and 32G with the insulating coating are inserted, and the solder 33 is supplied to the grooves 23a and 24a of the pin terminals 23 and 24 later to discharge the insulating coating from the openings of the grooves 23a and 24a. Can do. Also, the solder 33 can be filled in the grooves 23a and 24a without any gaps.

  In the coil component manufacturing method, first, the first to third primary windings 22, 32, 52 and the secondary winding 42 are manufactured by air-core winding a conductive wire made of an insulation-coated core wire. . Next, the winding portion 22A of the first primary winding 22 is placed on the upper surface of the circular portion 21B of the insulating resin terminal block 21, and the first primary winding 22 is stored in the insulating resin terminal block 21. The conductive wire end portions 22D and 22G of the first primary winding 22 are inserted into the through holes 21f and 21g so as to penetrate, and the conductive wire end portions 22D and 22G serve as pin terminals as external terminals. In this way, as shown in FIG. 3, the insulating resin terminal block module 20 including the insulating resin terminal block 21 and the first primary winding 22 is manufactured. In FIG. 3, the first magnetic core 11 is shown in combination with the insulating resin terminal block module 20 for convenience of explanation.

  Next, the winding portion 32A of the second primary winding 32 is placed on the upper surface of the disk-shaped portion 31A of the plate-like insulating member 31, and the guide wall of the insulating member guide portion 31B of the plate-like insulating member 31 is placed. The portions of the lead portions 32C and 32F connected to the conductor end portions 32D and 32G of the second primary winding 32 are engaged with the notches 31b and 31c, respectively, and the lead of the second primary winding 32 is pulled out. The parts 32C and 32F are supported. In this way, as shown in FIG. 3, the plate-like insulating member module 30 including the plate-like insulating member 31 and the second primary winding 32 is manufactured.

  Next, the winding portion 42A of the secondary winding 42 is placed on the upper surface of the first bobbin plate-like portion 41A of the first insulating resin bobbin 41, and the first bobbin guide portion 41B of the first insulating resin bobbin 41 is placed. The portions of the lead portions 42C and 42F connected to the conductor end portions 42D and 42G of the secondary winding 42 are engaged with the notches 41a and 41b at both ends of the guide wall, respectively. 42C and 42F are supported. In this manner, as shown in FIG. 3, the first insulating resin bobbin module 40 including the first insulating resin bobbin 41 and the secondary winding 42 is manufactured. The first insulating resin bobbin module 40 corresponds to a secondary winding module.

  Next, the winding portion 52A of the third primary winding 52 is placed on the upper surface of the second bobbin plate-like portion 51A of the second insulating resin bobbin 51, and the second bobbin guide of the second insulating resin bobbin 51 is placed. The notches 51a and 51b at both ends of the guide wall of the portion 51B are engaged with the portions of the lead portions 52C and 52F connected to the conductor end portions 52D and 52G of the third primary winding 52, respectively. The lead portions 52C and 52F of the primary winding 52 are supported. In this way, as shown in FIG. 3, the second insulating resin bobbin module 50 including the second insulating resin bobbin 51 and the third primary winding 52 is manufactured.

  Next, as shown in FIG. 3, the insulating member guide portion 31B is a terminal electrode forming portion so that the first primary winding 22 and the second primary winding 32 are in a coaxial positional relationship. The plate-like insulating member module 30 is laminated on the insulating resin terminal block module 20 so as to be disposed on the guide portion mounting surface 21E of 21F, and the plate-like insulating member module is placed in the grooves 23a and 24a of the pin terminals 23 and 24. The conductor end portions 32D and 32G of the 30 second primary windings 32 are inserted by press fitting. Next, the first insulating resin bobbin module 40 is laminated on the plate-like insulating member 31 so that the second primary winding 32 and the secondary winding 42 have a coaxial positional relationship, and the insulating resin terminal The conductor end portions 42D and 42G of the secondary winding 42 of the first insulating resin bobbin module 40 are inserted and penetrated into the through holes 21h and 21i on the protruding end surface of the protruding edge portion 21J of the base module 20, and the conductive wire end portions 42D and 42G are penetrated. Is a pin terminal which is an external terminal.

  Next, the second insulating resin bobbin module 50 is laminated on the first insulating resin bobbin module 40 so that the third primary winding 52 and the secondary winding 42 have a coaxial positional relationship, and the first The conductor end portions 52D and 52G of the third primary winding 52 of the second insulating resin bobbin module 50 are inserted into the through holes 21d and 21e of the first conductor end portion protection portion 21H and the second conductor end portion protection portion 21I and penetrated. The conductive wire end portions 52D and 52G are pin terminals that are external terminals. Next, by stacking the insulating resin cover 61 on the second insulating resin bobbin module 50, the insulating resin terminal block module 20, the plate-like insulating member module 30, the first insulating resin bobbin module 40, and the second insulating resin bobbin module. 50 and the insulating resin cover 61 are manufactured.

  Then, the protruding end surface of the edge protruding portion 11B of the first magnetic core 11 is brought into contact with the protruding end surface of the edge protruding portion 11B of the second magnetic core 12, and the central protruding portion 11C of the first magnetic core 11 and the second magnetic core 12 are contacted. The central protrusion 11C of the first magnetic core 11 passes through the terminal block through hole 21a, the insulating member through hole 31a, the first bobbin through hole 41d, the second bobbin through hole 51d, and the cover through hole 61a. The projecting end surface of the second magnetic core 12 is brought into contact with the projecting end surface of the central projecting portion 11C. As a result, the winding unit is sandwiched between the first magnetic core 11 and the second magnetic core 12, and finally the peripheral surfaces of the first magnetic core 11 and the second magnetic core 12 are wound with the tape 1 </ b> A (FIG. 1). , 24 is immersed in the solder bath to supply the solder 33 into the grooves 23a, 24a of the pin terminals 23, 24, thereby melting the insulation coating of the conductive wire constituting the second primary winding 32. 23a, 24a, and the pin terminals 23, 24 are inserted with only the solder 33 between the inner surfaces of the grooves 23a, 24a of the pin terminals 23, 24 and the conductor ends 32D, 32G of the second primary winding 32. The inner surfaces of the grooves 23a and 24a of the terminals 23 and 24 and the core wires 32H of the conductive wire ends 32D and 32G of the second primary winding 32 are electrically connected, and at the same time, the first and third primary windings 22 are connected. , 52 conducting wire ends 22D, 22G, 52D, 52G It is immersed in a solder bath, lead end 22D, peeled 22G, 52D, the insulating coating of the lower end of 52G, lead end 22D, 22G, 52D, to attach the solder to the lower end of 52G. Thus, the power transformer as the coil component 1 is manufactured.

  Except for the plate-like insulating member module 30, in the insulating resin terminal block module 20, the first insulating resin bobbin module 40, and the second insulating resin bobbin module 50, only the first and third primary windings 22, 52, Although the winding portions 22A, 52A, and 42A of the secondary winding 42 are exposed, the winding portions 22A, 52A, and 42A are hidden by stacking the modules as described above.

  Further, since the second primary winding 32 of the plate-like insulating member module 30 and the first primary winding 22 of the insulating resin terminal block module 20 are the same input side windings, the creepage distance is a concern. There is no need. For this reason, the plate-like insulating member 31 includes a first bobbin lower wall 41E, a first bobbin upper wall 41F, and a second bobbin lower wall as provided in the first insulating resin bobbin 41 and the second insulating resin bobbin 51. 51E, the second bobbin upper wall 51F, etc. need not be provided.

  Grooves 23a, 24a of insulating resin terminal block 21 in which pin terminals 23, 24, which are pin terminals 23, 24 made of conductors and formed with grooves 23a, 24a extending in the entire axial direction, are formed. And inserting the conductor end portions 32D and 32G into the grooves 23a and 24a by immersing the lower ends of the pin terminals 23 and 24 in the molten solder and supplying the solder 33 into the grooves 23a and 24a. The insulation coating of 32D and 32G is melted and removed, and the step of electrically connecting the pin terminals 23 and 24 and the core wire 32H is included, so that the core wire 32H of the conductor end portions 32D and 32G and the pin terminals 23 and 24 Can be reliably connected electrically. Further, the insulating coating can be discharged from the opening.

  The coil component and the method for manufacturing the coil component of the present invention are not limited to the above-described embodiments, and various modifications and improvements can be made within the scope described in the claims. For example, by dipping the lower ends of the pin terminals 23 and 24 in a solder bath, the solder 33 is supplied into the grooves 23a and 24a of the pin terminals 23 and 24, the insulating coating is melted, and discharged from the grooves 23a and 24a. , 24 between the inner surfaces of the grooves 23a, 24a and the conductor ends 32D, 32G of the second primary winding 32 with only the solder 33 interposed therebetween, and the grooves 23a, 24a of the pin terminals 23, 24 Although the inner surface and the conductor ends 32D and 32G of the second primary winding 32 are electrically connected, the electrical connection method is not limited to this method.

  For example, as shown in FIG. 7, the caulking portion 133 is provided by caulking a caulking tool against the peripheral surface of the pin terminal 123. As a result, the conductive wire end portion 32D of the second primary winding 32 is caulked by the inner surface of the groove 123a of the pin terminal 123, and the conductive wire end of the second primary winding 32 and the inner surface of the groove 123a of the pin terminal 123. The core 32H of the part 32D is electrically connected. Thus, it is good also as a coil component which has the crimping part 133. FIG.

  A conductor core wire 32H is formed in the groove 123a of the insulating resin terminal block 21 in which the pin terminal 123 formed with a groove 123a extending in the entire axial direction of the pin terminal 123 made of a conductor is formed. A step of inserting a conductor end portion 32D of a conductor having an insulation coating covering the peripheral surface of the core wire 32H, and a part of the pin terminal 123 by caulking the pin terminal 123 to the conductor end portion 32D in the groove 123a. Since there is a step of electrically connecting the pin terminal 123 and the core wire 32H of the conductive wire end portion 32D, the core wire 32H of the conductive wire end portion 32D and the pin terminal 123 can be reliably electrically connected. . Further, a part of the conductor end portion 32D can be escaped to the opening of the groove 123a by caulking, and the pin terminal 123 can be prevented from being deformed due to the absence of the place of the caulked conductor end portion 32D. it can.

  Alternatively, a protrusion 233 that protrudes from the peripheral surface of the pin terminal 223 is provided at the opening of the groove 223a (FIG. 8), the protrusion 233 is bent into the groove 223a, and the protrusion 233 is the second one in the groove 223a. By bringing the conductor end 32D into contact with the conductor end 32D of the next winding 32, the conductor end 32D is temporarily fixed in the groove 223a, and the protrusion 233 and the conductor end 32D are welded as shown in FIG. You may make it electrically connect the protrusion part 233 and the core wire 32H of 32 A of conductor wire ends. Thus, it is good also as a coil component which has the protrusion part 233. FIG.

  A pin terminal made of a conductor having a groove 223a extending in the entire axial direction thereof is formed, and a protrusion 233 protruding from the peripheral surface of the pin terminal is provided in the opening of the groove 223a. A step of inserting the conductor end portion 32D into the groove 223a of the insulated resin terminal block 21, and by bending the protruding portion 233 into the groove 223a and bringing the protruding portion 233 into contact with the conductor end portion 32D in the groove 223a. The method includes a step of temporarily fixing the conductor end portion 32D in the groove 223a and a step of electrically connecting the protrusion portion 233 and the core wire 32H by welding the protrusion portion 233 and the conductor end portion 32D. The core wire 32H of the part 32D and the pin terminal 223 can be reliably electrically connected. Moreover, the welding ball which consists of the protrusion part 233 and the conducting wire end part 32D can be formed in an opening part, without changing the outermost dimension of the pin terminal 223. FIG.

  Or it is good also as a structure which has the fusion | melting part in which the part of the pin terminal which prescribes | regulates the inner surface of a groove | channel fuses and is electrically connected with the core wire 32H of conducting wire. Thus, it is good also as a coil component which has a fusion | melting part.

  9 and 10, the pin terminals may be provided on the insulating resin terminal block 321 so that the grooves 323 a and 324 a of the pin terminals 323 and 324 open on the end surface of the insulating resin terminal block 321. By doing so, it is possible to fit the second primary winding 32 into the grooves 323a and 324a from the openings of the grooves 323a and 324a.

  In the coil component manufacturing method, the power transformer as the coil component 1 is manufactured by finally winding the peripheral surfaces of the first magnetic core 11 and the second magnetic core 12 with the tape 1A. However, the tape 1A is used. It is not limited. For example, the protruding end surface of the edge protruding portion 11B of the first magnetic core 11 and the protruding end surface of the edge protruding portion 11B of the second magnetic core 12 are bonded with an adhesive, and the protruding end surface of the central protruding portion 11C of the first magnetic core 11 You may adhere | attach the protrusion end surface of 11 C of center protrusion parts of the 2 magnetic core 12 with an adhesive agent.

  Moreover, although the groove | channels 23a and 24a were previously formed in the pin terminals 23 and 24, it is not limited to this. For example, the grooves 23a, 24a may be formed later on the metal bar by any other means such as grinding, cutting, laser processing, etching, etc., or the metal bars are punched with a mold to form the grooves 23a, 24a. Also good. Moreover, it is good also as a substantially cylindrical shape in which the groove | channels 23a and 24a extended in a longitudinal direction were formed by punching and rounding a plate-shaped metal plate with a metal mold | die.

  In addition, the conductor ends 32D and 32G of the second primary winding 32 of the plate-like insulating member module 30 are inserted by being inserted into the grooves 23a and 24a of the pin terminals 23 and 24, but the present invention is not limited thereto. For example, insert molding may be performed.

  In the present embodiment, the first to third primary windings 22, 32, 52, and the secondary winding 42 are manufactured by air-core winding, but the insulating resin terminal block 21 terminal block opening wall 21C Alternatively, the first and second insulating resin bobbins 41 and 51 may be manufactured by being wound directly on the first and second bobbin opening upper walls 41D and 51D.

  Moreover, although the 1st magnetic core 11 and the 2nd magnetic core 12 were comprised by the electroconductive ferrite core which consists of Mn-Zn, it is not limited to this. For example, it may be composed of a conductive core such as a metal dust core or a Ni-based ferrite core.

  In addition, a part of one end portion 52B and the other end portion 52E of the third primary winding 52 that is not covered with the first conductor end protection portion 21H and the second conductor end protection portion 21I. The resin coating may be used.

  In addition, the conductor end portions 52G and 52D of the third primary winding 52 pass through the through holes 21e and 21d of the first conductor end protection portion 21H and the second conductor end protection portion 21I, respectively. For example, a portion through which the conductor end portions 22G, 32G, 42G, 22D, 32D, and 42D of the first and second primary windings 22 and 32 and the secondary winding 42 penetrate is not limited to such a configuration. Further, protruding protective portions such as the first conductive wire end protection portion 21H and the second conductive wire end protection portion 21I may be provided.

  In addition, the solder 33 is interposed between the inner surface of the groove 23a of the pin terminal 23 and the core wire 32H in the groove 23a, but the present invention is not limited to the solder 33 and may be a conductor.

  Further, the lower ends of the pin terminals 23 and 24 are immersed in the solder bath, and at the same time, the lower ends of the conductive wire end portions 22D, 22G, 52D and 52G of the first and third primary windings 22 and 52 are immersed in the solder bath. However, the lower ends of the pin terminals 23 and 24 are immersed in the solder bath, and the lower ends of the conductor end portions 22D, 22G, 52D and 52G of the first and third primary windings 22 and 52 are immersed in the solder bath. Does not have to be performed at the same time.

  The coil component and the method for manufacturing the coil component of the present invention are particularly useful in the field of inductance components such as a transformer and a choke coil used in a power supply device.

The upper perspective view which shows the coil components by embodiment of this invention. The lower perspective view which shows the coil components by embodiment of this invention. The disassembled perspective view which shows the coil components by embodiment of this invention. The disassembled perspective view which shows the coil components by embodiment of this invention. The principal part perspective view which shows the part of the pin terminal of the coil components by embodiment of this invention. The principal part sectional drawing which shows the part of the pin terminal of the coil components by embodiment of this invention. The circuit diagram which shows the coil components by embodiment of this invention. The cross-sectional perspective view which shows the part of the pin terminal by the modification of the coil components by embodiment of this invention. The cross-sectional perspective view which shows the part of the pin terminal by the modification of the coil components by embodiment of this invention. The perspective view which shows the insulated resin terminal block by the modification of the coil components by embodiment of this invention. The principal part perspective view which shows the part of the pin terminal by the modification of the coil components by embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coil component 11 1st magnetic core 12 2nd magnetic core 21 Insulation resin terminal block 21H 1st conducting wire end part protection part 21I 2nd conducting wire end part protection part 22 1st primary winding 22A, 32A, 42A, 52A Winding part 22B, 32B, 42B, 52B One end 22E, 32E, 42E, 52E The other end 22C, 32C, 42C, 52C, 22F, 32F, 42F, 52F Drawer 22D, 32D, 42D, 52D, 22G, 32G, 42G, 52G Conductor end portions 23, 24 Pin terminals 23a, 24a Groove 32 Second primary winding 32H Core wire 33 Solder 40 First insulating resin bobbin module 41A First bobbin plate-like portion 41B First bobbin guide portion 41E First bobbin lower portion Wall 41F First bobbin upper wall 42 Secondary winding 50 Second insulating resin bobbin module 51B Second bobbin guide portion 51E Second bobbin lower 51F the second bobbin upper wall 52 third primary winding

Claims (7)

An insulating resin terminal block in which pin terminals made of conductors are implanted;
A wire wound around one end or the other end of which is fixed to the insulating resin terminal block;
The pin terminal is formed with a groove extending in the axial direction of the pin terminal over the entire axial direction of the pin terminal, and one end or the other end of the winding is formed in the groove. A coil component that is engaged throughout and is electrically connected to the lead wire and the pin terminal. The conducting wire has a core wire made of a conductor and an insulating coating that covers the peripheral surface of the core wire,
The coil component according to claim 1, wherein a conductor is interposed between the inner surface of the groove of the pin terminal and the core wire in the groove without an insulating coating. The conducting wire has a core wire made of a conductor and an insulating coating that covers the peripheral surface of the core wire,
The pin terminal has a caulking portion caulked to the conducting wire by caulking the pin terminal, and the pin terminal and the conducting wire are electrically connected at the caulking portion. The coil component according to claim 1.   2. The coil component according to claim 1, wherein a portion of the pin terminal that defines the inner surface of the groove has a melting portion that is melted and electrically connected to the conducting wire. A pin terminal made of a conductor having a groove extending in the entire axial direction thereof is formed in the groove of the insulating resin terminal block in which the pin terminal is implanted. Inserting a conductive wire having an insulating coating covering the surface;
By immersing one end of the pin terminal in molten solder and supplying the solder into the groove, the insulating coating of the conductive wire in the groove is melted and removed, and the pin terminal and the core wire are electrically connected. And a step of connecting to the coil part. A pin terminal made of a conductor having a groove extending in the entire axial direction thereof is formed in the groove of the insulating resin terminal block in which the pin terminal is implanted. Inserting a conductive wire having an insulating coating covering the surface;
And a step of caulking a part of the pin terminal to the conductive wire in the groove to electrically connect the pin terminal and the core wire by caulking the pin terminal. Manufacturing method. A pin terminal made of a conductor, which is formed with a groove extending in the entire axial direction thereof, and having a protrusion protruding from the peripheral surface of the pin terminal at the opening of the groove. Inserting a conductor having a core wire made of a conductor and an insulating coating covering a peripheral surface of the core wire into the groove of the insulated resin terminal block;
Temporarily fixing the conductor in the groove by bending the protrusion into the groove and bringing the protrusion into contact with the conductor in the groove;
A method of manufacturing a coil component, comprising: a step of electrically connecting the protruding portion and the core wire by welding the protruding portion and the conductive wire.

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