JP4209397B2 - Coil component, common mode choke coil, and method of manufacturing coil component - Google Patents

Description

The present invention relates to a coil component , a common mode choke coil , and a method of manufacturing a coil component, and more particularly, a coil component including a core, a conductive wire, and a metal terminal, and the conductive wire is wound around the core, insulated, and connected to the metal terminal. , A common mode choke coil , and a method of manufacturing a coil component .

  As a coil component, a common mode choke coil having a configuration including a toroidal coil in which a plurality of conductive wires are wound around a toroidal core, a case, and a plurality of metal terminals is known.

  The conducting wire wound around the toroidal core is covered with insulation. The case has a substantially rectangular parallelepiped shape, and is provided with a coil body housing portion in which a recess for housing the toroidal core is formed at a substantially central position on the upper surface. A toroidal coil is accommodated in the recess of the coil main body accommodating portion.

One end of a plurality of metal terminals protrudes from the top surface around the concave portion of the coil body housing portion on the upper surface of the case to form a connecting portion, and each connecting portion is wound around a toroidal core. One end and the other end of each conducting wire are connected to one connecting portion. The other ends of the plurality of metal terminals form so-called user terminals that protrude from positions near the bottom surface of the case. Examples of the coil component having such a configuration include a noise filter described in Japanese Utility Model Laid-Open No. 5-20416 (Patent Document 1).
Japanese Utility Model Publication No. 5-20416

  In the conventional coil parts, as described above, the coated conductors are configured so that the periphery of the conductors is covered with insulation. In recent years, the coated conductors such as coil parts used as automobile parts have high heat resistance and strong insulation. A coating is used. When connecting the coated conductor to the connecting portion of the metal terminal in the conventional coil component manufacturing process, the insulating coating of the coated conductor is peeled off to provide a conductor exposed portion, and the conductor exposed portion is connected to the metal terminal. It is necessary to connect to the part. As a method for removing the insulating coating of the coated conductor and providing the conductor exposed portion, for example, a method of peeling the insulating coating by irradiating the coated conductor with a laser is considered.

  When laser irradiation is to be performed in the above-described conventional coil component manufacturing process, the toroidal coil is housed in the recess of the coil body housing portion, and the coated conductor is positioned near the connecting portion of the metal terminal on the upper surface of the case. It is conceivable to irradiate the coated conductor with a laser after being placed in the position. If the toroidal coil is housed in the recess of the coil body housing portion after the conductor wire is irradiated with laser in advance and the conductor exposed portion is provided, the conductor exposed portion can be placed at an optimal position for connecting to the metal terminal. This is because there is a possibility that inconvenience such as inability to occur.

  In this way, when the coated conductor is irradiated on the coated conductor after the coated conductor is arranged at a position near the joint portion of the metal terminal on the upper surface of the case, the laser can be irradiated on the coated conductor from above the upper surface of the case. Conceivable. In this case, since the laser can be directly irradiated on the upper side of the coated conductor, the insulating coating of the coated conductor can be peeled off, but the lower portion of the coated conductor, that is, the portion of the coated conductor facing the upper surface of the case However, it is difficult to irradiate the laser, and the generation of the exposed portion of the conductive wire becomes uncertain, and the reliability of the coil component, which is a product, may be reduced.

Accordingly, an object of the present invention is to provide a coil component , a common mode choke coil , and a method of manufacturing the coil component in which the conductor exposed portion is reliably generated.

In order to achieve the above object, the present invention provides a coil body having a core, a coated conductor wire that is insulated and coated with a heat-resistant material , and is opposed to the one surface and the one surface. A case having another surface and a coil main body accommodating portion for accommodating the coil main body, one end portion forming a connecting portion connected to the coated conductor, and the other end forming a user terminal, the connecting portion The part provides a coil component including a metal terminal disposed on the one surface side.

In the case, a through hole or a notch penetrating from the one surface to the other surface is formed in the vicinity of the connecting portion, and the covered conducting wire is formed on the side of the one surface of the case on the side of the one side. At least part of the portion of the covered conductor that crosses the through-hole or the notch is a conductor exposed portion in which the insulating coating is peeled around the entire circumference by a laser ; The conductor exposed portion is connected to the connecting portion, and only the through hole faces the conductor exposed portion in the direction from the one surface toward the other surface.

  The case has a through hole or notch penetrating from one surface to the other surface in the vicinity of the connecting portion, so it is arranged so as to cross the through hole or notch on the one surface side of the case It is possible to irradiate a laser beam from one surface side and the other surface side through the through-hole or notch to the coated conductor. For this reason, it can be set as the coil component by which the production | generation of the conducting wire exposure part was performed reliably.

  Here, the connecting portion has a bendable first claw portion and a bendable second claw portion, and the first claw portion is bent so that the first claw portion of the case is bent. The coated lead wire is pressed on the surface to form a temporary fixing portion for temporarily fixing the movement of the coated lead wire, and the second claw portion is bent and comes into contact with the lead wire exposed portion. It is preferable that it is connected.

  The connecting portion has a bendable first claw portion and a bendable second claw portion, and the first claw portion is bent to press the coated conductor on one surface of the case. In addition, since the temporary fixing portion that temporarily fixes the movement of the coated conductor is regulated, the coated conductor can be stably held on one surface. For this reason, the production | generation of the conducting wire exposure part by laser irradiation can be performed reliably.

The present invention also provides a coil body having a core, a coated conductor wire that is insulated and coated with a heat resistant material around the core, one surface, another surface facing the one surface, and the A case having a coil body housing portion for housing the coil body, one end portion forming a connecting portion connected to the coated conductor, the other end portion forming a user terminal, and the connecting portion being the one There is provided a common mode choke coil comprising a metal terminal disposed on the surface side.

In the case, a through hole or a notch penetrating from the one surface to the other surface is formed in the vicinity of the connecting portion, and the covered conducting wire is formed on the side of the one surface of the case on the side of the one side. At least part of the portion of the covered conductor that crosses the through-hole or the notch is a conductor exposed portion in which the insulating coating is peeled around the entire circumference by a laser ; The conductor exposed portion is connected to the connecting portion, and only the through hole faces the conductor exposed portion in the direction from the one surface toward the other surface .

  The case has a through hole or notch penetrating from one surface to the other surface in the vicinity of the connecting portion, so it is arranged so as to cross the through hole or notch on the one surface side of the case It is possible to irradiate a laser beam from one surface side and the other surface side through the through-hole or notch to the coated conductor. For this reason, it can be set as the common mode choke coil by which the production | generation of the conducting wire exposed part was performed reliably.

The present invention also provides a coil body having a core and a coated conductor wire that is insulated and coated with a heat-resistant material around the core, one surface, the other surface facing the one surface, and the coil. The coil main body accommodating portion for accommodating the main body and one end portion are connected to the coated conductor, the other end portion is a user terminal, and the connecting portion is disposed on the one surface side. A through hole or a notch that has a metal terminal and penetrates from the one surface to the other surface and is housed in the coil body housing portion of the case formed in the vicinity of the connecting portion; and the coated conductor From the one surface with respect to a portion of the coated conductor crossing the through-hole or notch, Laser irradiation in the direction toward the other surface and the direction from the other surface toward the one surface Irradiating laser through the through-hole or the notch, thereby forming at least a part of the covered conductor crossing the through-hole or the notch as a conductor exposed part from which the insulating coating has been peeled over the entire circumference; And a step of connecting the connecting portion by making the connecting portion face the exposed portion of the conductive wire and electrically connecting the exposed portion of the conductive wire to the exposed portion of the conductive wire.

As described above, it is possible to provide a coil component , a common mode choke coil , and a method of manufacturing the coil component in which the conductor exposed portion is reliably generated.

  A coil component according to an embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 1, the coil component 1 is specifically a common mode choke coil, and includes a coil body 10, a resin case 20, and four metal terminals 30, 30, 30, 30.

  The coil body 10 includes an annular toroidal core 11 and two coated conductors 12 and 12 that are insulated around the periphery. The covered conducting wire 12 is made of, for example, a polyamideimide wire, and the entire circumference of the conducting wire is covered with a heat-resistant insulating coating. The toroidal core 11 is wound around the coated conductors 12 and 12 so that the two coated conductors 12 and 12 pass alternately on the inner peripheral side and the outer peripheral side of the annular toroidal core 11. The two covered conducting wires 12 and 12 are staggered in the circumferential direction of the toroidal core 11.

  The case 20 has a substantially rectangular parallelepiped shape, and the dimension is about 9 × 6 × 7 mm. As shown in FIG. 1, a coil body housing portion 20 </ b> C having a substantially cylindrical recess 20 a for housing the coil body 10 is provided at a substantially central position of the upper surface 20 </ b> A of the case 20. The coil main body 10 is accommodated in 20a in a substantially coaxial positional relationship with the recess 20a. A pair of locking portions 21 are provided at a position in the diameter direction of the recess 20a and in the left-right direction in FIG. The locking portion 21 can be engaged with a pair of engagement portions (not shown) of a lid member (not shown), and the upper surface 20A of the case 20 shown in FIG. It is comprised so that it may be covered with. The upper surface 20A of the case 20 corresponds to one surface.

  As shown in FIGS. 1 and 2, the case 20 has four through holes 20b, 20b, 20b, and 20b penetrating from the top surface 20A to the bottom surface 20B. Each of the through holes 20b has a substantially quadrangular prism shape whose axes coincide with each other in the direction connecting the top surface 20A and the bottom surface 20B, and is formed around the recess 20a of the coil body housing portion 20C and on the top surface 20A of the substantially rectangular parallelepiped case 20. It is formed in the vicinity of four corners. The bottom surface 20B corresponds to another surface.

  The metal terminal 30 is supported by the case 20. More specifically, when the case 20 is molded, a part of the metal terminal 30 is disposed in the molten resin that becomes the case 20. The case 20 and the metal terminal 30 are integrally formed so that the metal terminal 30 is fixed to and supported by the case 20. A portion 30A (FIG. 2, etc.) near one end of the metal terminal 30 enters the through hole 20b from the inside of the case 20 at a substantially central position between the upper surface 20A and the bottom surface 20B of the case 20, and is in the through hole 20b. It extends in the direction of the upper surface 20A of the case 20 along the one side surface of the through-hole 20b having a substantially quadrangular prism shape, and extends upward in FIG. 2 from the upper surface 20A.

  The portion of the metal terminal 30 located in the through hole 20b has a plate shape. In this way, the portion 30A near the one end of the metal terminal 30 is disposed in the through hole 20b, but the portion 30A near the one end of the metal terminal 30 has a plate shape and is thin, and is not in the through hole 20b. A space penetrating from the top surface 20A to the bottom surface 20B is secured.

  In the opening that opens to the upper surface 20A of the through hole 20b, as shown in FIG. 1, the covered conducting wire 12 is arranged so as to cross the opening of the through hole 20b, and the opening of the through hole 20b of the covered conducting wire 12 is opened. A part of the portion crossing the portion forms a conductor exposed portion 12A in which the insulating coating is peeled over the entire circumference. It should be noted that one end and the other end of the coated conductive wire 12 are actually disposed on the opening of the through hole 20b as shown in FIG. 1, and are in a state of crossing the through hole 20b halfway.

  One end of the metal terminal 30 ahead of the portion 30 </ b> A near the one end, which is the portion disposed in the through hole 20 b of the case 20, forms a connecting portion 31 that is connected to the coated conductor 12. As shown in FIGS. 1 to 3, the connecting portion 31 is a portion of the metal terminal 30 that protrudes upward from the upper surface 20 </ b> A of the case 20, and can be bent with a first claw portion 31 </ b> A that can be bent. 2 claw portions 31B. As will be described later, the first claw portion 31A and the second claw portion 31B are formed by bending the first claw portion 31A so that a part of the covered conductive wire 12 is replaced with the upper surface 20A of the case 20 in the manufacturing process of the coil component 1. At the time before performing the step of pressing and temporarily fixing, the case 20 protrudes upward from the upper surface 20A of the case 20, but is bent after the step and is in the state shown in FIG. .

  As shown in FIG. 1, the first claw portion 31 </ b> A is bent so as to be parallel to the upper surface 20 </ b> A of the case 20 and to be parallel to the rectangular short side forming the upper surface 20 </ b> A of the substantially rectangular parallelepiped case 20. The covered conductor 12 is pressed against the upper surface 20A of the case 20 by pressing a part of the covered conductor 12 crossing the opening of the through hole 20b, and the movement of the covered conductor 12 is restricted and temporarily fixed. The first claw portion 31A forms a temporary fixing portion.

  The second claw portion 31B is bent in the same direction as the bent direction of the first claw portion 31A. The second claw portion 31B is brought into contact with the conductor exposed portion 12A of the coated conductor 12 by being bent, and in this state, is connected by laser welding or the like using a YAG laser in the manufacturing process of the coil component 1 described later. Is done.

  The portion of the metal terminal 30 closer to the other end than the portion 30A closer to the one end disposed in the through hole 20b of the case 20 is bent at a substantially right angle with respect to the portion 30A closer to the one end, and from the through hole 20b. The case 20 enters the inside of the case 20 and extends in the direction of the side surface of the case 20 corresponding to the short side of the upper surface 20A of the substantially rectangular shape of the substantially rectangular parallelepiped case 20, that is, the left direction and the right direction in FIG. It protrudes from the side surface to the outside of the case 20 and away from the case 20.

  As shown in FIG. 2, the portion protruding to the outside of the case 20 bends substantially vertically in the middle, and extends parallel to the direction from the upper surface 20 </ b> A to the bottom surface 20 </ b> B of the case 20. Then, in FIG. 2, it bends substantially perpendicularly at a position below the bottom surface 20 </ b> B, extends again in a direction away from the case 20, and reaches the other end. The other end of the metal terminal 30 serves as a user electrode when the user places the coil component 1 on a substrate (not shown) or the like and is electrically connected to the pattern.

In the manufacturing process of the coil component 1 in the manufacturing method of the coil component, when connecting the conductor exposed portion 12A of the coated conductor 12 to the connecting portion 31, first, as shown in FIG. 20 is integrally formed. The metal member 3 has a portion 30 ′ that becomes the metal terminal 30, and is integrally formed so that a part of the portion 30 ′ that becomes the metal terminal 30 is located inside the case 20. The portion of the metal member 3 other than the portion that becomes the metal terminal 30 is tie-bar cut at a position indicated by a two-dot chain line A as an unnecessary portion after connecting a conductor exposed portion 12A and a connecting portion 31 described later. Discarded. The metal member 3 has a substantially planar shape, and has four projecting portions 3A, 3A, 3A, and 3A and four portions disposed at the through-hole 20b of the case 20 having a portion that becomes the connecting portion 31 at the tip. Only the portions 3B, 3B, 3B, 3B (FIG. 5) protrude substantially vertically from the substantially planar metal member 3.

  In addition, the coil body 10 formed of the toroidal core 11 around which the coated conducting wire 12 is wound is in a state of being housed in the recess 20a of the coil body housing portion 20C of the case 20. Next, one end portion and the other end portion of the two covered conducting wires 12 and 12 are wound around the four projecting portions 3A, 3A, 3A, and 3A of the metal member 3, respectively, as shown in FIGS. Turn to temporarily fix the covered conductor 12 to the protrusions 3A, 3A, 3A, 3A. Thus, the covered conducting wire 12 is stably arranged so as to cross the opening of the through hole 20b. Next, as shown in FIG. 4, the first claw portion 31 </ b> A is bent substantially vertically to press a part of the covered conductor 12 against the upper surface 20 </ b> A of the case 20, thereby restricting the movement of the covered conductor 12. And temporarily fix.

  Next, by irradiating the YAG laser from above the case 20 in FIGS. 5 and 6 in the direction from the upper surface 20A to the bottom surface 20B of the case 20 through the through hole 20b, it is positioned above the conducting wire in FIGS. Remove the insulation coating from the conductor. Further, by irradiating the YAG laser through the through hole 20b from the lower side of the case 20 in FIGS. 5 and 6 in the direction from the bottom surface 20B of the case 20 to the upper surface 20A through the through hole 20b from the lower side of the case 20, FIG. In FIG. 6, the insulation coating located on the lower side of the conducting wire is removed from the conducting wire to provide a conducting wire exposed portion 12A (FIG. 1).

  Next, the second claw portion 31B is brought into contact with the conductor exposed portion 12A by bending the second claw portion 31B in the same direction as the bent first claw portion 31A shown in FIG. Then, the coated conductor 12 is cut at a position indicated by a two-dot chain line B. Then, the conductor exposed portion 12A is connected to the connecting portion 31 of the metal terminal 30 by irradiating both the second claw portion 31B and the conductor exposed portion 12A with a YAG laser at a position where the YAG laser can be irradiated simultaneously. To do.

  Since the through hole 20b penetrating from the upper surface 20A to the bottom surface 20B is formed in the case 20 in the vicinity of the connecting portion 31, the covered conductor 12 arranged so as to cross the through hole 20b on the upper surface 20A side of the case 20 On the other hand, laser irradiation can be performed from the upper surface 20A side and the bottom surface 20B side through the through hole 20b. For this reason, production | generation of 12 A of conducting wire exposed parts can be performed reliably. Further, since the coated conducting wire 12 can be supported by the portion around the through hole 20b, the coated conducting wire 12 can be prevented from moving during the laser irradiation, and the laser irradiation can be performed stably.

  The connecting portion 31 has a bendable first claw portion 31A and a bendable second claw portion 31B, and the first claw portion 31A is bent so that the upper surface 20A of the case 20 is bent. Since the covered conducting wire 12 is pressed and the movement of the covered conducting wire 12 is regulated and temporarily fixed, the covered conducting wire 12 can be stably held on the upper surface 20A. For this reason, generation | occurrence | production of 12 A of conducting wire exposed parts by laser irradiation can be performed reliably.

  Further, since the connection is performed by the YAG laser, when the user reflows the coil component 1 so as to be soldered to a substrate or the like, the connected portion is prevented from being disconnected and disconnected due to high temperature. Can do.

The coil component , the common mode choke coil , and the method of manufacturing the coil component according to 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, in the present embodiment, the through hole 20b is formed in the case 20, but instead of the through hole 20b, as shown in FIGS. 7 and 8, from the top surface to the bottom surface of the case 20 ′, 20 ″. A notch 20b'20b "penetrating therethrough may be formed.

  Even in this case, the coated conductor not shown is arranged so as to cross the notch 20b'20b "on the upper surface side of the case 20 ', 20", and the notched conductor notch 20b'20b "not shown. At least a part of the crossing portion forms a conductor exposed portion in which the insulating coating is peeled off over the entire circumference, and the conductor exposed portion is connected to the connecting portion. Laser irradiation can be performed in the direction from the top surface to the bottom surface and the direction from the bottom surface to the top surface of the case 20 ′, 20 ″ through '20b ″, and the insulating coating can be peeled off.

  Moreover, the upper surface and the bottom surface of the case may be reversed, and the conductor exposed portion may be connected to the connecting portion on the bottom surface side.

  The case 20 is made of resin, but is not limited to this, and may be made of, for example, a resin containing a magnetic substance (ferrite) powder or the magnetic substance itself.

Further, although the YAG laser is used as the laser, the present invention is not limited to this. For example, a YVO laser, a CO ₂ laser, a SHG that is half the wavelength of the YAG laser, that is, a laser using a second harmonic, an LD (semiconductor) A laser, an excimer laser, or the like may be used.

  Moreover, although the coil component 1 by this Embodiment was a common mode choke coil, it is not limited to this. Moreover, although the covered conducting wire 12 was comprised from the polyamide imide wire, it is not limited to this. For example, a polyester wire or a polyurethane wire may be used.

  In addition, the metal terminal 30 is integrally formed with the case 20, but the present invention is not limited to this. For example, the metal terminal is supported by the case by pressing a portion near one end of the metal terminal into the through hole of the case. Also good. For example, a portion near one end of the metal terminal is inserted from the opening of the through hole that opens to the bottom surface, and press-fitted in the direction from the bottom surface side to the top surface side of the case. Even in this case, the metal terminal needs to have a space through the case in the through hole so as not to block the through hole in the through hole.

The coil component , common mode choke coil , and method for manufacturing the coil component of the present invention are particularly useful in the field of coil components used at high temperatures.

The top view which shows the common mode choke coil by embodiment of this invention. The front view which shows the common mode choke coil by embodiment of this invention. The right view which shows the common mode choke coil by embodiment of this invention. The top view which shows the state by which the metal member and the case were integrally molded in the process of manufacturing the common mode choke coil by embodiment of this invention, and the covering conducting wire was wound around the protrusion part of the metal member. The front view which shows the state by which the metal member and the case were integrally molded and the covering conducting wire was wound around the protrusion part of the metal member in the process of manufacturing the common mode choke coil by embodiment of this invention. The right view which shows the state by which the metal member and the case were integrally molded and the covering conducting wire was wound around the protrusion part of the metal member in the process of manufacturing the common mode choke coil by embodiment of this invention. The schematic plan view which shows the outline shape of the modification of the case of the common mode choke coil by embodiment of this invention. The schematic plan view which shows the outline shape of the modification of the case of the common mode choke coil by embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coil component 10 Coil main body 11 Toroidal core 12 Coated conducting wire 12A Conductive wire exposed part 20, 20 ', 20 "Case 20A Upper surface 20B Bottom surface 20C Coil main body accommodating part 20a Recess 20b Through-hole 20b', 20b" Notch 30 Metal terminal 31 Joint Line part 31A 1st claw part 31B 2nd claw part

Claims (4)

A coil body having a core and a coated conductor wire that is insulated and coated with a heat-resistant material and wound around the core;
A case having one surface, another surface opposite to the one surface, and a coil body housing portion for housing the coil body;
One end portion forms a connecting portion that is connected to the coated conductor, the other end portion forms a user terminal, and the connecting portion includes a metal terminal disposed on the one surface side,
In the case, a through hole or a notch penetrating from the one surface to the other surface is formed in the vicinity of the connecting portion, and the covered conducting wire is formed on the side of the one surface of the case on the side of the one side. At least part of the portion of the coated conductor that crosses the through hole or the notch is a conductor exposed portion in which the insulating coating is peeled around the entire circumference by a laser ; The conductor exposed portion is connected to the connecting portion,
A coil component , wherein only a through hole faces the conductor exposed portion in a direction from the one surface to the other surface . The connecting portion has a bendable first claw portion and a bendable second claw portion,
The first claw portion is bent to press the coated conducting wire against the one surface of the case to form a temporary fixing portion that regulates and temporarily fixes the movement of the coated conducting wire,
The coil component according to claim 1, wherein the second claw portion is bent and is in contact with and connected to the conductor exposed portion. A coil body having a core and a coated conductor wire that is insulated and coated with a heat-resistant material and wound around the core;
A case having one surface, another surface opposite to the one surface, and a coil body housing portion for housing the coil body;
One end portion forms a connecting portion that is connected to the coated conductor, the other end portion forms a user terminal, and the connecting portion includes a metal terminal disposed on the one surface side,
In the case, a through hole or a notch penetrating from the one surface to the other surface is formed in the vicinity of the connecting portion, and the covered conducting wire is formed on the side of the one surface of the case on the side of the one side. At least part of the portion of the coated conductor that crosses the through hole or the notch is a conductor exposed portion in which the insulating coating is peeled around the entire circumference by a laser ; The conductor exposed portion is connected to the connecting portion,
A common mode choke coil , wherein only a through hole is opposed to the conductor exposed portion in a direction from the one surface to the other surface . A coil body having a core and a coated conductor wire that is insulated and coated with a heat-resistant material and wound around the core, one surface, another surface opposite to the one surface, and the coil body The coil body housing portion and one end portion are connected to the coated conductor, the other end portion is a user terminal, and the connecting portion has a metal terminal disposed on the one surface side. A through hole or notch penetrating from the one surface to the other surface is housed in the coil body housing portion of the case formed in the vicinity of the connecting portion; and
  Disposing the coated conducting wire across the through hole or notch on the one surface side of the case;
  The portion of the coated conductor crossing the through hole or the notch is irradiated with laser in a direction from the one surface toward the other surface, and the through hole in a direction from the other surface toward the one surface. Or by irradiating with laser through the notch, at least part of the portion of the covered conductor crossing the through hole or the notch to be a conductor exposed portion from which the insulating coating is peeled over the entire circumference;
  A method of manufacturing a coil component, comprising the step of connecting the connecting portion to the exposed portion of the conductive wire so that the connecting portion is electrically connected to the exposed portion of the conductive wire.

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