JP2009272446A - Method of manufacturing coil part - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a coil part which inhibits variations of Q-characteristics by inhibiting quantitative variations in an adhesive adhering to a core and prevents the core from being broken. <P>SOLUTION: In the method of manufacturing the coil part, an elastic plate 102 comprised of silicon rubber is placed on the upper surface of metal frame 101. Subsequently, a kapton tape is cut off to form a kapton sheet and the kapton sheet is placed on the elastic plate 102. Then, an adhesive is applied to the kapton sheet. Positions in which the adhesive is applied are approximate centers in the longitudinal and width directions of the kapton sheet, and only a minimum necessary amount of the adhesive is applied to secure the kapton sheet to a drum core with the adhesive. Then, the drum core around which a conductive wire is wound is pressed one by one to the kapton sheet on the elastic plate 102 via the adhesive to manufacture the coil part 1. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a coil component, and more particularly to a method of manufacturing a coil component having a suction surface for suctioning a nozzle of the automatic machine when the coil component is mounted on a mounting substrate by an automatic machine.

  Conventionally, the coil component has been provided with a suction surface on which the nozzle of the automatic machine can be sucked when the coil part is mounted on the mounting substrate by the automatic machine. For example, a flat plate having a core part and flanges provided at both ends of the core part, a conductor is wound around the core part and spanning the flange parts at both ends of the core part. A coil component provided with a core is known, and is configured so that a nozzle of an automatic machine can be adsorbed to the flat plate-like core portion.

A method for manufacturing such a coil component is described in, for example, Japanese Patent Application Laid-Open No. 2007-221022 (Patent Document 1). In the coil component manufacturing method described in the publication, the core around which the conductive wire is wound is held in the through-hole of the holding plate in which the through-hole is formed, and the core is protruded from the through-hole by pressing the core with a pressing pin. Let Also, an application table is prepared, and an adhesive is applied on the application table. Then, the holding plate is moved onto the application table, the core is pressed by the pressing pin, and the core is brought into contact with and pressed against the application table to which the adhesive is applied. This causes the adhesive to adhere to the core. Then, the core is pressed against the plate-shaped core via the adhesive, and the plate-shaped core is bonded to the core.
JP 2007-22102 A

  However, in the conventional method for manufacturing a coil component described above, the adhesive is attached to the core by abutting and pressing the core on the application table on which the adhesive is applied. The adhesive adheres to the entire bonding surface of the core to which the plate-shaped core is bonded. When the core is bonded to the plate-shaped core, the adhesive may protrude from the bonding surface.

  Further, the plate-like core is housed in the plate-like core housing jig, and the core is pressed against the plate-like core in the state of being housed in the plate-like core housing jig via an adhesive, but the plate-like core is housed. Since the plate-shaped core housing jig does not have elasticity, if the core shape varies, the amount of the adhesive cannot be adjusted to follow the core shape, and therefore adheres. Variations in the amount of adhesive occur. In particular, in a high-frequency coil using a ceramic core, the dielectric constant changes due to variations in the amount of adhesive, and as a result, so-called Q characteristics of the coil components vary.

  Moreover, since the plate-shaped core accommodation jig for accommodating the plate-shaped core does not have elasticity, pressing the core against the plate-shaped core made of ferrite or the like may damage the core or the plate-shaped core.

  Therefore, an object of the present invention is to provide a method for manufacturing a coil component that suppresses variations in Q characteristics by suppressing variations in the amount of adhesive adhering to the core and prevents damage to the core.

  In order to achieve the above object, the present invention provides an adherend member arranging step of arranging an adherend member having a flat adhesive surface on an elastic plate, and applying an adhesive to a part of the adhesive surface to apply the adhesive. A step of providing a coating portion; and a core around which the conductor is wound is disposed opposite to the adhesive coating portion so that the member to be bonded is sandwiched between the core and the elastic plate, and the elastic plate and the core are connected to each other. There is provided a method of manufacturing a coil component, which includes a bonding step of relatively pressing and fixing the member to be bonded to the core via the adhesive.

  The member to be bonded is disposed on the elastic plate with the member to be bonded having a flat bonding surface, the step of applying an adhesive to a part of the bonding surface to provide an adhesive application portion, and the conductive wire is wound. The core is disposed opposite to the adhesive application portion, the member to be bonded is sandwiched between the core and the elastic plate, and the elastic plate and the core are pressed relative to each other, and the member to be bonded is fixed to the core via the adhesive. Therefore, it is possible to apply the minimum necessary adhesive to the bonding surface of the member to be bonded. For this reason, it is possible to prevent the adhesive from being applied excessively, to prevent the adhesive from protruding from the bonding surface of the member to be bonded, which is the part to which the adhesive should be attached, and to reliably cover the adhesive. The adhesive member can be fixed to the core. Further, by pressing the elastic body plate and the core relative to each other, the elastic body plate can be deformed so as to follow the outer peripheral shape of the core, and the necessary minimum adhesive is spread substantially uniformly on the bonding surface. be able to. In addition, the elasticity of the elastic plate can prevent excessive pressing force on the core when the elastic plate and the core are pressed relative to each other, thereby preventing the core from being damaged. it can.

  Here, the portion of the elastic plate on which the member to be bonded is disposed has adhesiveness, and in the step of arranging the member to be bonded, the member to be bonded is placed by placing the member to be bonded on the elastic plate. It is preferable to adhere the member to the elastic plate.

  The portion of the elastic plate on which the adherend member is disposed has adhesiveness, and in the adhering member arrangement step, the adherend member is adhered to the elastic plate by placing the adherend member on the elastic plate. The core can be fixed to the elastic plate due to the adhesiveness, and when the elastic plate and the core are pressed relative to each other in the bonding process, the bonded member slides on the elastic plate. It is possible to prevent the position of the adherend member from being shifted.

  The adherend member is made of a flexible resin sheet, and in the adhering step, the elastic member plate and the core are pressed relative to each other to bring the adherend member into the outer peripheral shape of the core. It is preferable to follow and bend.

  Since the adherend member is made of a flexible resin sheet, in the bonding process, the elastic member plate and the core are pressed relative to each other to bend the adherend member in accordance with the outer peripheral shape of the core. It can be securely bonded.

  In the bonding step, it is preferable to press the adhesive until the thickness of the adhesive between the core and the member to be bonded is the same as the thickness of the filler constituting the adhesive.

  In the bonding process, since the thickness of the adhesive between the core and the member to be bonded is pressed until the thickness of the filler constituting the adhesive is the same, the minimum required amount of adhesive is almost uniform on the bonding surface Therefore, the core and the member to be bonded can be bonded more reliably and accurately.

  As described above, the present invention can provide a method for manufacturing a coil component that suppresses variations in Q characteristics by suppressing variations in the amount of adhesive attached to the core and prevents damage to the core.

  A method for manufacturing a coil component according to an embodiment of the present invention will be described. First, the coil component manufactured by the manufacturing method of a coil component is demonstrated based on FIG. The coil component 1 is used for high frequency, and as shown in FIG. 1, includes a drum core 2 having a core portion 3, a conductive wire 7 wound around the core portion 3, and a Kapton sheet 8. ing.

  The drum core 2 is made of ceramic alumina, and has a core portion 3 having a substantially rectangular cross section perpendicular to the longitudinal direction, and flanges 4 and 4 provided at both ends in the longitudinal direction of the core portion 3 and having substantially the same shape. It is configured. One conducting wire 7 is wound around the core portion 3. Hereinafter, since the flange portions 4 located on both sides of the drum core 2 have the same shape, only one side will be described unless otherwise specified.

  Here, the longitudinal direction of the winding core portion 3 is the X-axis direction, the direction from the lower left side to the upper right side in FIG. 1 is the X axis plus direction, and the direction from the upper right side to the lower left side in FIG. It is defined and explained. Further, the width direction of the core part 3 is defined as the Y-axis direction, the direction from the lower right side to the upper left side in FIG. 1 is defined as the Y axis plus direction, and the direction from the upper left side in FIG. It is defined as a direction. The direction orthogonal to the X-axis direction and the Y-axis direction is the Z-axis direction, the direction from the upper side to the lower side in FIG. 1 is the Z-axis plus direction, and the direction from the lower side to the upper side in FIG. It is defined as a minus direction. Therefore, the upper surface 3A and the lower surface 3B of the core part 3 have a positional relationship parallel to the XY plane defined by the X axis and the Y axis.

  The pair of flange portions 4 and 4 are provided integrally with the core portion 3 at both ends of the core portion 3 in the X-axis direction. The flange portion 4 has a substantially rectangular parallelepiped shape, and the width of the flange portion 4 in the Y-axis direction is the same as the width of the core portion 3 in the same direction, and the flange portion is only in the Z-axis plus direction and the Z-axis minus direction. 4 protrudes from the upper surface 3A and the lower surface 3B of the core part 3, respectively.

  The collar portion 4 has six surfaces 4A to 4F. The electrode forming surface 4A and the Kapton bonding surface 4B face each other in the Z-axis direction. The first side surface 4C and the second side surface 4D face each other in the Y-axis direction. In addition, the outer end surface 4E and the inner side surface 4F face each other in the X-axis direction. The inner side surface 4F is a surface located on the core part 3 side. The electrode forming surface 4 </ b> A of the flange portion 4 is in a positional relationship parallel to the upper surface 3 </ b> A of the core portion 3. The dimensions of the coil component 1 are about 1.6 mm in the X-axis direction, about 0.8 mm in the Y-axis direction, and about 0.8 mm in the Z-axis direction.

  A first terminal electrode 5 and a second terminal electrode 6 are provided on the flange portions 4 and 4. The first terminal electrode 5 and the second terminal electrode 6 are formed from the entire electrode forming surface 4A to a part of the outer end surface 4E and the inner side surface 4F to the vicinity of the electrode forming surface 4A, respectively. It is applied and baked, Ni plating is applied thereon, and Sn plating is further applied thereon.

  The conducting wire 7 is wound around the core part 3. The conducting wire 7 is a high heat-resistant wire made of a copper wire, the periphery of which is insulated with a heat-resistant material made of polyamideimide (AIW), and has a winding portion 7A and a connecting portion (not shown). The winding part 7 </ b> A is a part that is wound around the core part 3 from the one collar part 4 toward the other collar part 4. The connecting portion is a portion forming one end portion and the other end portion of the conducting wire 7 constituting the coil component 1, and is connected to the first terminal electrode 5 and the second terminal electrode 6 by thermocompression bonding or the like. Part.

  The Kapton sheet 8 is flexible and has a plate-like rectangular shape, and a drum core is formed by a thermosetting resin as an epoxy-based adhesive 9 (FIG. 4) applied to the central position in the X-axis direction of the core 3. 2 is fixed. As shown in FIG. 1, the Kapton sheet 8 is arranged on the Kapton bonding surface 4 </ b> B and the core part 3 of the collars 4, 4 so as to span the collars 4, 4. The upper surface 8A shown is a flat suction surface that can be sucked by a nozzle (not shown) of the automatic machine when the coil component 1 is mounted on a mounting board (not shown) by an automatic machine (not shown), and the lower surface 8B is a drum core. 2 to form a flat adhesive surface. Between the lower surface 8B of the Kapton sheet 8 and the Kapton adhesion surface 4B of the flange 4 of the drum core 2, the inorganic filler contained in the thermosetting resin is present on both the lower surface 8B of the Kapton sheet 8 and the Kapton adhesion surface 4B. For this reason, the thickness of the adhesive 9 between the lower surface 8B of the Kapton sheet 8 and the Kapton bonding surface 4B of the flange 4 of the drum core 2 is the same as the thickness of the inorganic filler. The thickness of the inorganic filler is about 10 μm to 30 μm. The Kapton sheet 8 corresponds to a member to be bonded.

  Next, a jig used in the coil component manufacturing method will be described. A jig used in the method of manufacturing a coil component includes a metal frame 101, an elastic plate 102, a push pin 103, a post-process pallet 104, and a core suction nozzle (not shown). The metal frame 101 has a substantially plate shape and is formed so that a large number of through holes 101a penetrate in a direction connecting the upper surface and the lower surface of the metal frame 101 shown in FIG. The through hole 101a is formed at a position where the Kapton sheet 8 to which the coil component 1 is bonded is placed as will be described later.

  The elastic plate 102 is made of silicon rubber having a substantially plate-like adhesive property, and coincides with the through hole 101a of the metal frame 101 when the elastic plate 102 is placed on the upper surface of the metal frame 101 as will be described later. A through hole 102a that penetrates in the direction connecting the upper surface and the lower surface of the elastic plate 102 shown in FIG. 2B is formed at the position. The thickness of the elastic plate 102 is about 1 mm. Since the elastic plate 102 is made of silicon rubber having a substantially plate-like adhesive property, the drum core 2 can be fixed to the elastic plate 102 due to the adhesive property, and the drum core 2 is attached to the elastic plate 102 in the bonding process described later. When pressing, it is possible to prevent the Kapton sheet 8 from sliding on the elastic plate 102 and shifting the position of the Kapton sheet 8 with respect to the elastic plate 102.

  As shown in FIG. 6B, the push pin 103 can pass through the through hole 101a of the metal frame 101 and the through hole 102a of the elastic plate 102, and is a coil component that adheres to the elastic plate 102 as described later. One Kapton sheet 8 (FIG. 1) is pushed through the through holes 101a and 102a so that the coil component 1 can be separated from the elastic plate 102.

  The post-process pallet 104 has a substantially plate shape, and a large number of recesses 104a are formed so as to be recessed from the upper surface of the post-process pallet 104 shown in FIG. A large number of recesses 104 a can accommodate the lower part of the coil component 1 shown in FIG. 1 and accommodate each coil component 1 taken out from the elastic plate 102.

  The core suction nozzle (not shown) is configured so as to be able to suck the drum core 2 around which the lead wire 7 is wound around the core portion 3, and is housed in a drum core housing container (not shown) and is connected to the core portion 3. Is wound around the drum core 2 so that the drum core 2 can be pressed against the Kapton sheet 8 via an adhesive 9 as will be described later.

  Next, the manufacturing method of a coil component is demonstrated. In the method of manufacturing a coil component, first, Ag is formed on the entire electrode forming surface 4A of the flanges 4 and 4 of the drum core 2 and on the outer end surface 4E and a part of the inner side surface 4F that reaches the vicinity of the electrode forming surface 4A. Apply paste and bake. Next, Ni plating is performed on the Ag paste, and Sn plating is further performed thereon to provide the first terminal electrode 5 and the second terminal electrode 6. Next, the conducting wire 7 is wound around the core part 3 of the drum core 2 and accommodated in a drum core container (not shown).

  Next, as shown in FIG. 2, an elastic plate 102 made of silicon rubber is placed on the upper surface of the metal frame 101 so that the through holes 101a and 102a coincide with the through direction. Next, an adherend member arranging step is performed. In the bonded member arranging step, a wide Kapton tape is arranged opposite to the upper surface of the elastic plate 102, and is cut into the same shape as the Kapton sheet 8 constituting each coil component 1 by punching, as shown in FIG. As shown, the silicon rubber through holes 102a are placed on the elastic plate 102 in 7 rows and 17 columns so as to block each one. At this time, since the elastic plate 102 has adhesiveness, by placing the Kapton sheet 8 on the elastic plate 102, an upper surface 8A of the Kapton sheet 8 shown in FIG. 1 (FIG. 3B). (The surface located on the lower side of the figure) adheres to the elastic plate 102.

  Next, as shown in FIG. 4, the lower surface 8B of the Kapton sheet 8 shown in FIG. 1 placed on the elastic plate 102 (the surface located on the upper side in FIG. 4B). ) Is applied with a thermosetting resin as the adhesive 9. As shown in FIG. 4, the position where the adhesive 9 is applied is a substantially central position in the longitudinal direction and the width direction of the Kapton sheet 8, and is not applied to both ends in the longitudinal direction and the width direction. Is applied only in the minimum amount necessary for bonding and fixing the Kapton sheet 8 to the drum core 2. For this reason, it is possible to prevent the adhesive 9 (FIG. 4) from protruding from the lower surface 8B (FIG. 1) of the Kapton sheet 8 when the drum core 2 is pressed against the elastic plate 102 as described later. In addition, the Kapton sheet 8 can be securely bonded to the drum core 2. Further, since the minimum amount of adhesive 9 is applied on the Kapton sheet 8, for example, when the adhesive 9 is applied to the core part 3 and the Kapton sheet 8 is applied, the core part 3 is applied. Although the adhesive 9 enters between the wound conductive wires 7 more than necessary, it is possible to prevent such a problem from occurring. The part of the Kapton sheet 8 to which the adhesive 9 is applied forms an adhesive application part.

  Next, an adhesion process is performed. In the bonding step, the drum cores 2 accommodated in a drum core storage container (not shown) and having already been wound around the core 3 are sucked and conveyed one by one by a core suction nozzle (not shown), and the drum core 2 is bonded. As shown in FIG. 5, the coil component 1 is pressed against the lower surface 8 </ b> B (FIG. 1) of the Kapton sheet 8 on the elastic plate 102 via the adhesive 9 (FIG. 4). As a result, the Kapton sheet 8 is bent following the outer peripheral shape of the drum core 2, and at the same time, the elastic plate 102 is deformed following the outer peripheral shape of the drum core 2, so that the minimum necessary adhesive 9 is substantially uniform on the bonding surface. Spread to. The spread adhesive 9 is spread between the entire Kapton bonding surface 4B (FIG. 1) of the flange 4 of the drum core 2 and the Kapton sheet 8. At this time, the elasticity of the elastic plate 102 prevents the pressing force from acting on the drum core 2 when the drum core 2 is pressed against the elastic plate 102, and prevents the drum core 2 from being damaged.

  The pressing of the drum core 2 against the lower surface 8B of the Kapton sheet 8 is such that the thickness of the adhesive 9 between the Kapton adhesive surface 4B of the collar 4 of the drum core 2 and the Kapton sheet 8 is the thickness of the inorganic filler constituting the adhesive 9. Until it is the same. For this reason, it is possible to spread the adhesive 9 having the minimum necessary coating amount to the maximum with a substantially uniform thickness on the lower surface 8B of the Kapton sheet 8 serving as the bonding surface, and more reliably the drum core 2 and the Kapton sheet 8. Can be bonded with high accuracy. Next, the adhesive 9 is heated and cured. The above is the bonding process.

  Next, as shown in FIG. 6B, the coil component 1 as the drum core 2 on the elastic plate 102 to which the Kapton sheet 8 is bonded and fixed is respectively opposed to each recess 104a of the post-process pallet 104 (not shown). Let Then, the push pin 103 passes through the through hole 101a of the metal frame 101 and the through hole 102a of the elastic body plate 102 to separate the coil component 1 from the elastic body plate 102, and as shown in FIG. The coil component 1 is pushed into the recess 104a. The coil component 1 is manufactured through the above steps.

  The coil component according to the present invention is not limited to the above-described embodiment, and various modifications and improvements can be made within the scope described in the claims. For example, although the member to be bonded is constituted by the Kapton sheet 8, it is not limited to this. The elastic plate 102 is made of silicon rubber, but is not limited to this.

  In addition, the drum core 2 is pressed against the elastic plate 102 with the Kapton sheet 8 interposed therebetween, but the invention is not limited thereto, and the elastic plate 102 may be pressed against the drum core 2 with the Kapton sheet 8 interposed therebetween. Further, the bonding and fixing to the drum core 2 around which the conductive wire 7 is wound is not limited to the Kapton sheet 8. For example, a plate-like core may be bonded and fixed to the drum core 2 instead of the Kapton sheet 8.

  In addition, the thickness of the elastic plate 102 is about 1 mm, but is not limited to this value, and if the thickness value is appropriately selected at 0.3 mm or more according to the accuracy of the outer dimensions of the coil component. Good.

  The coil component of the present invention is extremely useful in the field of small coil components that are required to have little variation in Q characteristics.

The perspective view which shows the coil components manufactured by the manufacturing method of the coil components by this Embodiment. It is a figure which shows a mode that the elastic body board has been arrange | positioned on the metal frame in the manufacturing method of the coil components by this Embodiment, (a) is a top view, (b) is a partial cross section front view. It is a figure which shows the to-be-adhered member arrangement | positioning process of the manufacturing method of the coil components by this Embodiment, (a) is a top view, (b) is a front view. It is a figure which shows a mode that the adhesive agent was apply | coated on the Kapton sheet in the manufacturing method of the coil components by this Embodiment, (a) is a top view, (b) is a front view. It is a figure which shows the adhesion process of the manufacturing method of the coil components by this Embodiment, (a) is a top view, (b) is a front view. It is a figure which shows a mode that a coil component is spaced apart from on an elastic body board in the manufacturing method of the coil component by this Embodiment, (a) is a top view, (b) is a partial cross section front view. It is a figure which shows a mode that the coil components were accommodated in the post process pallet in the manufacturing method of the coil components by this Embodiment, (a) is a top view, (b) is a partial cross section front view.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coil components 2 Drum core 3 Core part 4 Collar part 4B Kapton adhesive surface 7 Conductor 8 Kapton sheet 8B Lower surface 9 Adhesive 102 Elastic body board

Claims (4)

An adherend member placement step of placing an adherend member having a flat adhesive surface on the elastic plate;
Applying an adhesive to a part of the adhesive surface to provide an adhesive application part;
The core around which the conductive wire is wound is disposed opposite to the adhesive application portion, and the elastic plate and the core are pressed relative to each other so that the adherend member is sandwiched between the core and the elastic plate, And a bonding step of fixing the member to be bonded to the core via an adhesive. The portion of the elastic plate where the adherend member is disposed has adhesiveness,
2. The method of manufacturing a coil component according to claim 1, wherein in the bonding member arranging step, the bonding member is adhered to the elastic plate by placing the bonding member on the elastic plate. . The adherend member is made of a flexible resin sheet,
2. The coil component according to claim 1, wherein, in the bonding step, the member to be bonded is bent following the outer peripheral shape of the core by pressing the elastic plate and the core relative to each other. Production method.   2. The coil component according to claim 1, wherein in the bonding step, pressing is performed until the thickness of the adhesive between the core and the member to be bonded is the same as the thickness of the filler constituting the adhesive. Manufacturing method.

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