JP2015192023A - coil component and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil component and a method of manufacturing the same capable of reducing the number of components and manufacturing man hours.SOLUTION: A coil component 11 comprises: a first core (a lower core) 13 that has a first coil insertion portion 19 and that consists of a magnetic body; an outer package 21 formed by molding integrally with the first core 13 and that consists of an insulator covering an outer periphery of the first core 13; a cylindrical portion 22 formed by integral molding, and that consists of an insulator covering a lateral face of the first coil insertion portion 19; a coil 14 that consists of a conductor inserted into the first coil insertion portion 19 via the cylindrical portion 22; a second core (an upper core) 12 that has a second coil insertion portion 19 inserted into the coil 14 from an opposite side to the first coil insertion portion 19, and that consists of a magnetic body; a filler 17 filling between the outer package 21 and the second core 12; and a terminal portion 18 connected with both ends of the coil 14 and extracted to the outside of the outer package 21.

Description

  The present invention relates to a coil component used in various electronic devices and electric machines, and a manufacturing method thereof.

  As a coil component, for example, a reactor used for a booster circuit of a motor drive device of an electric vehicle or various power motors is known. The reactor includes a core made of a magnetic material and a coil made of a conductor, and performs electrical transformation using inductive reactance, blocking of harmonic current, and smoothing of direct current.

  6A is a perspective view of a conventional coil component 1, FIG. 6B is a cross-sectional view taken along line BB of FIG. 6A, and FIG. 7 is an exploded perspective view in the manufacturing process of the conventional coil component 1. . A conventional coil component 1 includes a core 2 made of a plurality of magnetic bodies, a coil 3 made of a spiral conductor, a plate insulator 4 and a tubular insulator for ensuring insulation between the core 2 and the coil 3. 5 (bobbin), a ceramic gap plate 6 for securing the magnetic characteristics of the coil 3, a box-like case 7 made of metal, and insulation between the coil 3 and the case 7 inside the case 7 are secured. And a filler 8 containing a resin and a filler, and a terminal portion 9 connected to both ends of the coil 3 and led out of the case 7.

  In the conventional coil component 1, a core assembly in which a plurality of cores 2, a coil 3, a plate insulator 4, a cylindrical insulator 5, and a gap plate 6 are bonded together is manufactured, and the core assembly is a case. 7, the filler 8 was filled in the gap and cured. FIG. 7 is an exploded perspective view in the manufacturing process of the coil component 1 before filling with the filler 8.

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

JP 2010-267932 A

  However, since the above-described conventional coil component 1 is filled with resin in the case 7 after the core 2 and the coil 3 are assembled, the number of components is large and the number of manufacturing steps is also large. An object of this invention is to provide the coil component which can reduce a number of parts and a manufacturing man-hour, and can simplify a manufacturing process, and its manufacturing method.

  In order to achieve the above object, a coil component of the present invention has a first coil insertion portion, is formed by integral molding with a first core made of a magnetic material, and the first core. An insulating exterior covering the outer periphery of the core, an insulative cylindrical portion formed by integral molding and covering a side surface of the first coil insertion portion, and the first through the cylindrical portion. A coil made of a conductor inserted into the coil insertion part, a second coil insertion part inserted into the coil from the side opposite to the first coil insertion part, and a second core made of a magnetic material; And a filler filling the space between the outer body and the second core, and terminal portions connected to both ends of the coil and led out of the outer body.

  The coil component manufacturing method of the present invention includes a step of preparing a first core made of a magnetic material having a first coil insertion portion, and an insulation covering the outer periphery of the first core by integral molding. Forming an insulating cylindrical portion covering the side surface of the outer casing and the first coil insertion portion, and inserting a coil made of a conductor into the first coil insertion portion via the cylindrical portion. A step of inserting a second core made of a magnetic body into the coil from a side opposite to the first coil insertion portion, the exterior body, and the second coil insertion portion. And a step of filling with an insulating filler between the core.

  By having said structure, the coil components and its manufacturing method of this invention can reduce a number of parts and a manufacturing man-hour, and can simplify a manufacturing process.

(A), (b) The perspective view and sectional drawing of the coil components in one embodiment of this invention (A)-(d) Manufacturing process diagram of the coil component (A), (b) Manufacturing process diagram of the coil component (A), (b) Manufacturing process diagram of the coil component (A), (b) Manufacturing process diagram of the coil component (A), (b) The perspective view and sectional drawing of the conventional coil components Exploded perspective view of a conventional coil component manufacturing process

  FIG. 1A is a perspective view of a coil component 11 according to an embodiment of the present invention, and FIG. 1B is a cross-sectional view taken along the line AA in FIG. 1A and 1B, the coil component 11 includes an upper core 12 and a lower core 13 made of a magnetic material, a coil 14 formed by winding a conductor, and between the upper core 12 and the lower core 13. An insulating gap plate 15 disposed between the lower core 13 and the lower core molded body 16 integrally formed with the gap plate 15, the lower core molded body 16, the coil 14, and the upper core 12. And a terminal portion 18 made of a conductor.

  The upper core 12 and the lower core 13 use soft magnetic powder having an average particle size of about 10 to 100 μm mainly composed of iron, and after insulating the soft magnetic powder surface, an organic binder is added as necessary. They are mixed, pressure-molded at a predetermined pressure, and heat-treated or sintered as necessary. And an outer portion 20 constituting a magnetic circuit outside.

  The upper core 12 and the lower core 13 are opposed to each other via the gap plate 15 inside and outside the coil 14. Note that the gap plate 15 may not be provided between the upper core 12 and the lower core 13.

  The coil 14 is formed in a spiral shape by edgewise bending a flat conductive wire made of a metal mainly composed of copper. The coil 14 may be a flat copper wire that is flat-wise bent or may be a copper round wire that is wound.

  The gap plate 15 is made of ceramic such as alumina or resin, and is disposed between the upper core 12 and the lower core 13.

  The lower core molded body 16 is manufactured by integrally molding the lower core 13 to which the gap plate 15 is bonded by placing the lower core 13 inside the mold and performing injection molding using a PPS resin (polyphenylene sulfide resin). As a molding material for the lower core molded body 16, in addition to the PPS resin, a PBT resin (polybutylene terephthalate resin) or a liquid crystal polymer may be used. The lower core molded body 16 includes an exterior body 21 that covers the outer periphery and the back surface of the lower core 13, a cylindrical portion 22 that covers the side surface of the coil insertion portion 19 of the lower core 13, and an outer portion 20 of the lower core 13. Has a wall portion 23 that covers the inner surface facing the coil insertion portion 19.

  The exterior body 21 preferably covers the outer periphery and the back surface of the lower core 13 and has an extending portion 24 extending upward so as to surround the outer periphery of the upper core 12. The exterior body 21 may expose a part of the outer periphery and the back surface of the lower core 13. This exposed portion is a contact portion between the lower core 13 and the mold when the lower core molded body 16 is molded. By providing the exposed portions at the plurality of side surfaces and the bottom surface of the lower core 13, the position of the lower core 13 can be accurately fixed in the mold when the lower core molded body 16 is formed. The lower core molded body 16 can be integrally molded with high positional accuracy.

  The cylindrical portion 22 covers the side surface of the coil insertion portion 19 of the lower core 13 and ensures insulation between the coil insertion portion 19 of the lower core 13 and the coil 14. The cylindrical portion 22 preferably has an extending portion 25 extending between the coil insertion portion 19 of the upper core 12 and the coil 14.

  The wall portion 23 covers a side surface where the outer portion 20 of the lower core 13 faces the coil insertion portion 19, and ensures insulation between the outer portion 20 of the lower core 13 and the coil 14. The wall 23 preferably has an extension 26 extending between the outer portion 20 of the upper core 12 and the coil 14.

  The filler 17 is an insulator that contains an epoxy resin and a filler and hardens, and fills the space between the lower core molded body 16, the coil 14, and the upper core 12. In addition to the epoxy resin, the resin constituting the filler 17 may be a silicone resin or a urethane resin.

  The terminal portion 18 is connected to both ends of the coil 14 and led out of the filler 17 to obtain an electrical connection with an external circuit (not shown).

  The coil component 11 of the present invention configured as described above is used as a reactor in a booster circuit of a motor drive device of an electric vehicle and various power motors.

  Next, the manufacturing process of the coil component 11 of this invention is demonstrated, referring FIGS. 2A to 2D, FIG. 3A, FIG. 4A, and FIG. 5A are perspective views showing manufacturing steps of the coil component 11. FIG. FIGS. 3B, 4B, and 5B are cross-sectional views taken along line AA in FIGS. 3A, 4A, and 5A, respectively.

  First, as shown in FIG. 2 (a), the surface of the soft magnetic powder containing iron as a main component is subjected to insulation treatment, and then mixed with an organic binder, press-molded at a predetermined pressure, and the upper core 12 and The lower core 13 is produced. Each of the upper core 12 and the lower core 13 includes a coil insertion portion 19 inserted into the coil 14 and an outer portion 20 constituting a magnetic circuit outside the coil 14.

  Next, as shown in FIG. 2 (b), a rectangular copper wire is edgewise bent to produce a spiral coil. Terminal portions 18 are provided at both ends of the coil 14.

  Next, as shown in FIG. 2C, a ceramic plate made of alumina is processed to produce an insulating gap plate 15.

  Next, as shown in FIG. 2 (d), the gap plate 15 is bonded to the upper surface of the lower core 13.

  Next, the lower core 13 to which the gap plate 15 is bonded is placed in a mold (not shown) and injection molded using PPS resin, as shown in FIGS. 3 (a) and 3 (b). Then, the lower core molded body 16 is produced. The lower core molded body 16 includes an exterior body 21 that covers the outer periphery and the back surface of the lower core 13, a cylindrical portion 22 that covers the side surface of the coil insertion portion 19 of the lower core 13, and an outer portion 20 of the lower core 13. And a wall portion 23 covering the inner side surface. The exterior body 21 has an extending portion 24 that extends upward so as to cover the outer periphery and the back surface of the lower core 13 and to surround the outer periphery of the upper core 12. The cylindrical portion 22 covers the side surface of the coil insertion portion 19 of the lower core 13 and ensures insulation between the side surface of the coil insertion portion 19 and the coil 14. The cylindrical portion 22 has an extending portion 25 that extends between the coil insertion portion 19 and the coil 14 of the upper core 12. The extending portion 25 ensures insulation between the coil insertion portion 19 of the upper core 12 and the coil 14. The wall portion 23 covers the inner side surface of the outer portion 20 of the lower core 13, and ensures insulation between the outer portion 20 of the lower core 13 and the outer surface of the coil 14. The wall portion 23 has an extending portion 26 that extends between the inner side surface of the outer portion 20 of the upper core 12 and the outer surface of the coil 14 to ensure insulation between them.

  Next, as shown in FIGS. 4A and 4B, the coil 14 is inserted into the lower core molded body 16. A coil insertion portion 19 of the lower core 13 is inserted into the lower half inside the coil 14. The terminal portions 18 connected to both ends of the coil 14 come out of the exterior body 21. The portion of resin that insulates the inner side surface of the coil 14 from the coil insertion portion 19 is a cylindrical portion 22. A wall portion 23 is a resin portion that insulates the outer side surface of the coil 14 from the outer portion 20 of the lower core 13.

  Next, as shown in FIGS. 5A and 5B, the upper core 12 is inserted into the extending portion 24 of the exterior body 21 of the lower core molded body 16. A coil insertion portion 19 of the upper core 12 is inserted into the upper half of the coil 14. An extending portion 25 of the cylindrical portion 22 is positioned between the side surface of the coil insertion portion 19 of the upper core 12 and the inner side surface of the coil 14 to ensure insulation between them. An extending portion 26 of the wall portion 23 is positioned between the inner side surface of the outer portion 20 of the upper core 12 and the outer side surface of the coil 14 to ensure insulation between them.

  Next, a filler 17 is filled between the lower core molded body 16, the coil 14, and the upper core 12, and the filler 17 is cured to form the filler 17. FIGS. The coil component 11 shown in FIG.

  The coil component 11 of the present invention manufactured as described above has the conventional coil component shown in FIGS. 6 and 7 by forming the exterior body 21 and the cylindrical portion 22 simultaneously by integral molding with the lower core 13. Unlike 1, since the cylindrical insulator 5 (bobbin) and the case 7 are not required, the number of parts can be reduced and the manufacturing cost can be reduced.

  Further, the coil component 11 of the present invention is less in number than the conventional coil component 1 shown in FIGS. 6 and 7 because the exterior body 21 and the cylindrical portion 22 are simultaneously formed by integral molding with the lower core 13. Manufacture can be performed with manufacturing man-hours, and manufacturing can be facilitated.

  Further, the coil component 11 of the present invention is different from the conventional coil component 1 shown in FIGS. 6 and 7 in that the casing 7 and the cylindrical portion 22 are formed by integral molding with the lower core 13. Since the assembly tolerance between the lower core 2 and the assembly tolerance between the lower core 2 and the cylindrical insulator 5 is not required, the manufacturing is easy.

  Further, the coil component 11 of the present invention is formed by integrally molding with the lower core 13, and thus the case 7 is not required unlike the conventional coil component 1 shown in FIGS. The dimensions of the coil component 11 can be reduced and the weight can be reduced.

  Moreover, the coil component 11 of the present invention can improve the direct current superposition characteristics by providing the insulating gap plate 15 between the upper core 12 and the lower core 13. Further, since the side surface of the gap plate 15 is covered with the exterior body 21 by integral molding, the coil component 11 can be reduced in size.

  Moreover, in the exterior body 21, the extending | stretching part 24 which surrounds the outer periphery of the upper core 12 and is extended upwards can improve the insertion position precision of the upper core 12, and the lower core molded object 16 and the upper core can be improved. 12 can be easily assembled.

  Moreover, in the cylindrical part 22, by providing the extending | stretching part 25 extended between the coil insertion part 19 and the coil 14 of the upper core 12, the coil insertion part 19 and the coil 14 are used without using separate components. Insulation between the upper core 12 and the upper core 12 can be easily improved, and the assembly of the lower core molded body 16 and the upper core 12 can be facilitated.

  In addition, by providing the wall portion 23 with the extending portion 26 extending between the outer portion 20 of the upper core 12 and the coil 14, there is no need to use a separate part between the outer portion 20 and the coil 14. While ensuring insulation, the insertion position accuracy of the upper core 12 can be improved, and the assembly of the lower core molded body 16 and the upper core 12 can be facilitated.

  In addition, the coil component 11 of this invention is applicable also to coil components other than a reactor like the inductor element used for various electronic devices.

  In the embodiments, terms indicating directions such as “upper” and “lower” indicate relative directions that depend only on the relative positional relationship of the components, and indicate absolute directions such as the vertical direction. is not.

  The coil component and the manufacturing method thereof according to the present invention include an inductor element for various electronic devices and a manufacturing method thereof, and a reactor for operating an electric motor such as a power motor for electric vehicles and various machine tools and a manufacturing method thereof. Useful.

DESCRIPTION OF SYMBOLS 11 Coil components 12 Upper core 13 Lower core 14 Coil 15 Gap board 16 Lower core molding 17 Filler 18 Terminal part 19 Coil insertion part 20 Outer part 21 Exterior body 22 Cylindrical part 23 Wall part 24, 25, 26 Extension Part

Claims (5)

A first core having a first coil insertion portion and made of a magnetic material;
An insulating exterior body formed by integral molding with the first core and covering an outer periphery of the first core;
An insulating cylindrical portion formed by the integral molding and covering a side surface of the first coil insertion portion;
A coil made of a conductor inserted into the first coil insertion part via the cylindrical part;
A second core having a second coil insertion portion inserted into the coil from the opposite side to the first coil insertion portion, and made of a magnetic material;
A filler that fills a space between the exterior body and the second core;
A coil component having terminal portions connected to both ends of the coil and led out of the exterior body. The coil component according to claim 1, wherein an insulating gap plate is provided between the first core and the second core, and the side surface of the gap plate is covered by the integral molding. The coil component according to claim 1, wherein the exterior body has a portion that covers the periphery of the second core, and the cylindrical portion has a portion that extends between the second coil insertion portion and the coil. . The first core and the second core have outer portions that are opposed to each other on the outside of the coil, and are disposed between the outer portion and the coil, and have a wall portion that is provided by the integral molding. Item 1. The coil component according to Item 1. Preparing a first core made of a magnetic material having a first coil insertion portion;
Forming an insulating outer body covering the outer periphery of the first core and an insulating cylindrical part covering a side surface of the first coil insertion part by integral molding; and
Inserting a coil made of a conductor into the first coil insertion portion via the cylindrical portion;
Inserting a second core made of a magnetic material into the coil from the side opposite to the first coil insertion part, the second coil insertion part having a second coil insertion part;
Filling the space between the exterior body and the second core with an insulating filler;
The manufacturing method of the coil components which have this.

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