JP4316548B2 - Coil parts - Google Patents

Description

  The present invention relates to a coil component used for an electronic device or the like.

Conventionally, there is a coil component using a core whose outer frame shape is a square shape. A winding core is disposed in the B-shaped core, and a winding is wound around the winding core, whereby a magnetic path is formed inside the B-shaped core. The coil component having the above configuration includes an insulating spacer for insulating the core and the core, and an insulating base for insulating the core and the substrate. (For example, refer to Patent Document 1 and Patent Document 2).
JP-A-9-35965 Japanese Patent Laid-Open No. 11-144973

  By the way, the coil components described in Patent Document 1 and Patent Document 2 require both the insulating spacer and the insulating base to be attached to the square-shaped core, which takes time to assemble.

  Accordingly, an object of the present invention is to provide a coil component that can be easily assembled.

In order to achieve the above object, the present invention provides a box-shaped frame core whose cross section of the opening defined by the four wall portions is a square shape, and is disposed inside the frame core, and is separate from the frame core. A core of the body, a winding wound around the circumference of the winding core, electrodes formed at both ends of the conducting wire forming the winding, one surface of one wall portion of the frame core, and the winding core An insulating portion having a facing portion disposed between one end surface in the axial direction and a step portion disposed between one surface portion of one wall portion of the frame core and one end portion in the axial direction of the winding. A spacer, an insulating base that abuts against the other surface of one wall portion of the frame core, and a connecting portion that connects the insulating spacer and the insulating base, the insulating spacer, the insulating base, and the connecting portion. A coil part that constitutes a clamping body that clamps the one wall part, and a magnetic gap is formed between the frame core and both end faces in the axial direction of the core. The one end surface and other end surface of the winding core is protruded from each of the one end and the other end of the winding, the insulating spacer is a flat plate shape, the plate-shaped insulating spacers, opposing two of the Each extending portion has two opposing sides extending from the base end toward the free end when the connecting portion is the base end, and the interval between the two opposing sides is as follows: The coil component is characterized in that it gradually decreases from the base end side toward the free end side at least on the free end side.

According to such a configuration, the holding body integrally forms the insulating base for insulating between the frame core and the substrate and the insulating spacer for insulating between the frame core and the core. Therefore, the coil component can be easily assembled only by inserting the holding body into the frame core. Also, since one end surface in the axial direction of the winding does not protrude beyond one end surface in the axial direction of the winding core, leakage magnetic flux may pass through the protruding portion of the winding and cause eddy current loss. There is no. For example, if the height of the stepped portion is set in advance in consideration of the relationship with other members, by mounting the winding on the stepped portion, one end surface in the axial direction of the winding is Since it does not protrude beyond one end face in the axial direction, the distance between the magnetic gap formed between one end face of the winding and the frame core and the other end face of the winding and the frame core are formed. The distance of the magnetic gap can be easily made substantially the same. In particular, the distance of the magnetic gap formed between one end face of the winding and the frame core is made substantially the same as the distance of the magnetic gap formed between the other end face of the winding and the frame core. The direct current superimposition characteristics can be improved. In addition, after fixing the winding core around which the winding is wound on the insulating spacer, the winding and winding core are attached to the frame core by sandwiching one wall portion of the frame core between the insulating spacer and the insulating base. The coil parts can be easily manufactured. Furthermore, the distance between the two opposing sides of the extending portion gradually decreases from the base end side toward the free end side, that is, has a tapered shape, an R shape, a C shape, or the like. It becomes easier to insert the holding body into the frame core.

  Moreover, it is preferable that the most free end of the insulating spacer and the most free end of the insulating base are respectively provided with protrusions that engage with the frame core.

  According to such a configuration, since the projecting portion engages and is fixed to the frame core, it is not necessary to use an adhesive, and the coil component can be easily assembled.

Two of the sandwiching bodies are provided, the one end surface of the winding core faces the insulating spacer of one sandwiching body, and the other end surface of the winding core is in contact with the insulating spacer of the other sandwiching body. The one sandwiching body sandwiches the one wall portion from the first direction, and the other sandwiching body sandwiches the second wall portion facing the one wall portion opposite to the first direction. It is preferable to sandwich from the second direction.

According to such a configuration, the core is fixed in the axial direction of the core by being sandwiched between the two sandwiching bodies, and is fixed in the direction orthogonal to the axial direction of the core by the stepped portion and the protruding portion . When manufacturing coil parts, it is not necessary to use any adhesive. Thereby, even if it is a case where the apparatus in which a coil component is integrated is exposed to high temperature, fear of peeling of the adhesive agent by heat, etc. can be eliminated.

Moreover, it is preferable that this level | step-difference part has a semicircular shape .

According to such a configuration, since the step portion has a semicircular shape , the core can be reliably fixed in a direction orthogonal to the axial direction of the core. Thereby, normal operation of the coil component can be ensured even when the coil component 1 is disposed with its vertical and horizontal directions reversed. Further, according to another aspect of the present invention, a box-shaped frame core whose cross section of the opening defined by the four wall portions is a square shape, and a winding that is disposed inside the frame core and is separate from the frame core. A core, a winding wound around the circumferential surface of the winding core, electrodes formed at both ends of the conducting wire forming the winding, one surface of one wall portion of the frame core, and an axial direction of the winding core An insulating spacer having a facing portion disposed between one end surface of the first and second wall portions, a step portion disposed between one surface of one wall portion of the frame core and one end portion in the axial direction of the winding; and An insulating base that contacts the other surface of one wall portion of the frame core, and a connecting portion that connects the insulating spacer and the insulating base, and the insulating spacer, the insulating base, and the connecting portion A method of manufacturing a coil component that constitutes a sandwiching body that sandwiches a wall portion of the coil, comprising: a first placement step of placing one end face of the core on the facing portion; and the wound winding The winding core and the winding are mounted so that one wall portion is sandwiched between the insulating spacer and the insulating base in a second arrangement step of arranging on the step portion through the winding core. And a step of inserting the holding body into the opening of the frame core.

  According to the coil component of the present invention, easy assembly is possible.

  A coil component according to a first embodiment of the present invention will be described with reference to FIGS. 1 and 2 are schematic perspective views of the coil component 1. As shown in FIGS. 1 and 2, the coil component 1 includes a frame core 2, a winding core 3, a winding 4, and a sandwiching body 5.

  FIG. 3 is a perspective view of the frame core 2. The frame core 2 is a frame-shaped box-shaped core made of ferrite mainly composed of manganese (Mn) and zinc (Zn), and includes a first side surface 21, a second side surface 22, and a third A side surface 23 and a fourth side surface 24 are provided. The first side surface 21 and the second side surface 22, and the third side surface 23 and the fourth side surface 24 are opposed to each other, and the first side surface 21, the second side surface 22, the third side surface 23, and the fourth side surface. The side surface 24 forms a square-shaped opening 25 and an opening 26 (FIG. 2) as two opposing side surfaces.

  FIG. 4 is a perspective view of the core 3. The winding core 3 has a cylindrical shape and is made of ferrite mainly composed of manganese (Mn) and zinc (Zn).

  FIG. 5 is a perspective view of the winding 4 in a wound state. The winding 4 has a configuration in which a single rectangular wire having a substantially rectangular cross section is wound a predetermined number of times. The flat wire is covered with a polyamideimide resin or the like. Both ends of the flat wire forming the winding 4 are not wound, but are bent in a U shape, and electrodes 41 and 42 are formed at the ends. The electrodes 41 and 42 are obtained by peeling off the coating on the surface of the end of the winding 4 and covering it with solder. When forming the coil component 1, the winding 4 is wound around the winding core 3, but the axial length of the winding 4 when wound is larger than the axial length of the winding core 3. short.

  FIG. 6 is a perspective view of the holding body 5. The holding body 5 is made of a resin body that can insulate the frame core 2 and the core 3, and includes a bottom plate portion 51 that is an insulating base, a fitting portion 52 that is an insulating spacer, and a connecting portion 53. ing. The bottom plate portion 51 and the fitting portion 52 have a substantially planar shape, and protrude from the connection portion 53 in parallel with each other. A gap portion 54 is formed between the bottom plate portion 51 and the fitting portion 52. The free end side of the fitting portion 52 is tapered. The fitting portion 52 includes a substantially semicircular convex portion 521, and as a result, a concave portion 522 is formed in a substantially central portion of the planar shape. A pair of terminal fitting portions 55 are formed on the surface of the connection portion 53 opposite to the surface from which the bottom plate portion 51 and the fitting portion 52 protrude.

  As shown in FIGS. 1 and 2, the second side surface 22 of the frame core 2 is inserted and bonded to the gap portion 54 of the holding body 5 from the opening 25 side. One end surface of the core 3 in the axial direction is mounted on the concave portion 522 of the fitting portion 52 of the holding body 5 and is bonded with an epoxy resin or the like. A magnetic gap 11 is formed between one axial end surface of the core 3 and the second side surface 22, that is, in a space corresponding to the thickness of the recess 522 (FIG. 7). The other end surface in the axial direction of the core 3 is not in contact with the first side surface 21 of the frame core 2, and a magnetic gap 12 is formed between the core 3 and the first side surface 21. (FIG. 7).

  The winding 4 is mounted on the convex portion 521 of the holding body 5 while being wound around the core 3. A predetermined portion of the core 3 and the winding 4 is bonded with an epoxy resin or the like. The electrodes 41 and 42 of the winding 4 are respectively fitted to the pair of terminal fitting portions 55 of the holding body 5. In addition, a substantially U-shaped portion of the free end of the bottom plate portion 51 of the holding body 5 has a U-shape in order to increase mounting stability and fixing strength of the coil component 1 when the coil component 1 is mounted on the substrate. The dummy terminals 6 are fitted. The dummy terminal 6 is made of, for example, tin (Sn), copper (Cu), or the like.

  7 is a cross-sectional view of the coil component 1 when cut along the cutting line shown in FIG. By mounting the winding 4 on the convex portion 521 of the fitting portion 52 of the holding body 5, the intermediate portion in the axial direction of the winding core 3 and the intermediate portion in the axial direction of the winding 4 are substantially aligned. Yes. The height of the convex portion 521 and the concave portion 522 is set so that the intermediate portion in the axial direction of the core 3 and the intermediate portion in the axial direction of the winding 4 are substantially coincident with each other, that is, the distance between the magnetic gap 11 and the magnetic gap 12. The distance is set in advance so as to be substantially the same.

  Next, the manufacturing method of the coil component 1 by this Embodiment is demonstrated. First, one end surface of the winding core 3 is mounted in the concave portion 522 of the fitting portion 52 of the holding body 5 and bonded with an epoxy resin or the like. Subsequently, the winding 4 wound in advance is passed through the core 3 and mounted on the convex portion 521 of the fitting portion 52 of the holding body 5. At this time, both ends of the rectangular wire forming the winding 4 are bent at a right angle, but are not bent into a U-shape. In this state, the winding 4 and the core 3 are bonded with an epoxy resin or the like. Subsequently, the holding body 5 on which the winding 4 and the winding core 3 are mounted is slid into the second side surface 22 of the frame core 2 from the opening 25, and the holding body 5 and the frame core 2 are bonded with an epoxy resin or the like. Glue with. Finally, both ends of the winding 4 are bent in a U shape so as to be fitted to the pair of terminal fitting portions 55 of the holding body 5 to form the electrodes 41 and 42.

  As described above, by mounting the winding 4 on the convex portion 521 of the holding body 5, one end surface in the axial direction of the winding 4 protrudes from one end surface in the axial direction of the core 3. Therefore, the eddy current loss caused by the leakage magnetic flux passing through the winding is smaller than that in the case where one end surface in the axial direction of the winding protrudes from one end surface in the axial direction of the core. In particular, the DC superposition characteristics can be improved by making the distance of the magnetic gap 11 and the distance of the magnetic gap 12 substantially the same. Furthermore, the distance of the magnetic gap 11 and the distance of the magnetic gap 12 become substantially the same only by setting the height of the convex portion 521 in advance in consideration of the relationship with other members. Manufacturing is easy.

  Further, the holding body 5 is integrally formed with a bottom plate portion 51 for insulating between the frame core 2 and the substrate and a fitting portion 52 for insulating between the frame core 2 and the core 3. Since it is formed, the coil component 1 can be easily assembled simply by inserting the holding body 5 into the frame core 2. In addition, since the fitting portion 52 is tapered on the free end side, it becomes easier to insert the holding body 5 into the frame core 2.

  Next, a coil component 100 according to a second embodiment of the present invention will be described with reference to FIG. In the second embodiment, the same parts as those in the first embodiment described above are denoted by the same reference numerals, and the description thereof is omitted.

  The coil component 100 includes a bottom plate portion 151 and a fitting portion 152 corresponding to the bottom plate portion 51 and the fitting portion 52 in the first embodiment, but at the free ends of the bottom plate portion 151 and the fitting portion 152, The protrusion 151a and the protrusion 151b protrude so as to face each other. Two protrusions 151 a are provided at symmetrical positions with respect to the dummy terminal 6 in order to prevent a collision with the dummy terminal 6 fitted to a substantially middle portion of the free end of the bottom plate portion 151. In the present embodiment, the holding body 5 is inserted into the second side surface 22 of the frame core 2 from the opening 25, and further, the holding body 5 is also inserted into the first side surface 21 from the opening 26. Is inserted.

  FIG. 8 is a cross-sectional view of the coil component 100 when cut along a line corresponding to the cutting line of FIG. The protrusion 151a and the protrusion 151b are engaged with and fixed to the edges of the first side surface 21 and the second side surface 22. The size of each member is fixed by the sandwich body 5 inserted into the first side surface 21 and the sandwich body 5 inserted into the second side surface 22 in the axial direction of the core 3. Is set in advance. Further, the convex portion 521 of the fitting portion 152 of the holding body 5 has a semicircular shape, and the two holding bodies 5 are inserted from the opening 25 and the opening 26, respectively. The core 3 is also fixed in a direction orthogonal to the axial direction of the core 3.

  As described above, the protrusion 151a and the protrusion 151b are engaged with and fixed to the edges of the first side surface 21 and the second side surface 22, so that it is not necessary to use an adhesive, and the coil component 100 is used. Can be assembled easily. In addition, since one holding member 5 is inserted from the opening 25 into the second side surface 22 and the other holding member 5 is inserted from the opening 26 into the first side surface 21, the winding core 3 has the winding core. 3 is fixed from both the axial direction of 3 and the direction orthogonal to the axial direction of the core.

  Thus, since the core 3 and the coil | winding 4 are fixed mechanically, when manufacturing the coil component 100, it is not necessary to use an adhesive agent at all. Thereby, for example, even when a device in which the coil component 100 is incorporated is exposed to a high temperature, the risk of peeling of the adhesive due to heat can be eliminated. Furthermore, since the convex part 521 of the fitting part 152 of the holding body 5 has a semicircular shape, the core 3 is securely fixed in a direction orthogonal to the axial direction of the core 3. be able to. Thereby, normal operation of the coil component 1 can be ensured even when the vertical and horizontal positions of the coil component 1 are reversed.

  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, in the present embodiment, a square-shaped core is used as the frame core 2. However, the frame core 2 is not limited to a square shape, and may be an E-shaped core. In this case, the winding core and the E-shaped core are integrated. Further, the core may be a separate body instead of an integral type. Moreover, although the frame core 2 was comprised with the ferrite which has manganese (Mn) and zinc (Zn) which can hold big magnetic energy as a main component, you may use another ferrite.

  The shape of the core 3 is not limited to a cylindrical shape, and may be an elliptical cross section, a substantially rectangular column shape with curved corners, or the like. Moreover, the conducting wire which makes the winding core 3 is not limited to a flat wire, A round wire etc. may be used. However, since a cross-sectional area can be made larger than a wire having a circular cross section, and copper loss can be reduced, a rectangular wire is preferable. Further, the convex portion 521 is not limited to a tapered shape, and an easily insertable shape such as an R shape or a C shape can be used. Further, the electrode 41 and the electrode 42 may be provided not as a part of the winding 4 but as a part of the holding body 5, and in that case, an end portion of a conducting wire that forms the winding 4 on the electrode. Should just be connected.

1 is a perspective view of a coil component 1 according to a first embodiment of the present invention. 1 is a perspective view of a coil component 1 according to a first embodiment of the present invention. It is sectional drawing of the frame core 2 by the 1st Embodiment of this invention. It is a perspective view of the core 3 by the 1st Embodiment of this invention. It is a perspective view of the coil | winding 4 by the 1st Embodiment of this invention. It is a perspective view of the holding body 5 by the 1st Embodiment of this invention. It is a sectional view perspective view of coil component 1 by a 1st embodiment of the present invention. It is sectional drawing of the coil component 100 by the 2nd Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coil components 2 Frame core 3 Winding core 4 Winding 5 Holding body 5 Winding core 25, 26 Opening part 51 Bottom plate part 52 Fitting part 53 Connection part 54 Gap part 521 Protrusion part 522 Recess

Claims (5)

A box-shaped frame core whose cross section of the opening defined by the four wall portions is a square shape;
Arranged inside the frame core, and a winding core separate from the frame core;
A winding wound around the circumferential surface of the winding core;
Electrodes formed at both ends of the conducting wire forming the winding;
A facing portion disposed between one surface of one wall portion of the frame core and one end surface in the axial direction of the core, one surface of one wall portion of the frame core, and one end in the axial direction of the winding An insulating spacer having a step portion disposed between the two portions,
An insulating base in contact with the other surface of the one wall portion of the frame core;
A coil part comprising a connecting part for connecting the insulating spacer and the insulating base, and constituting a sandwiching body for sandwiching the one wall part by the insulating spacer, the insulating base and the connecting part,
A magnetic gap is formed between the frame core and both end surfaces in the axial direction of the core, and the one end surface and the other end surface of the core are respectively connected to the one end and the other end of the winding. projects, the insulating spacer is a flat plate shape, the plate-shaped insulating spacer has two extending portions that face, each of the extension portions, the base when the base end of the connecting portion Two opposing sides extending from the end toward the free end, and the distance between the two opposing sides gradually decreases from the base end side toward the free end side at least on the free end side Coil parts characterized by that.   The coil component according to claim 1, wherein a protrusion that engages with the frame core is provided at a free end of the insulating spacer and a free end of the insulating base. Two of the sandwiching bodies are provided, the one end surface of the winding core faces the insulating spacer of one sandwiching body, and the other end surface of the winding core is in contact with the insulating spacer of the other sandwiching body. Opposite,
The one sandwiching body sandwiches the one wall portion from the first direction, and the other sandwiching body has a second wall portion facing the one wall portion as a second opposite to the first direction. The coil component according to claim 2, wherein the coil component is clamped from a direction.   The coil part according to claim 3, wherein the step portion has a semicircular shape. A box-shaped frame core whose cross-section of the opening defined by the four wall portions is a square shape, a core that is arranged inside the frame core and is separate from the frame core, and a peripheral surface of the core The winding wound, the electrodes formed at both ends of the conducting wire forming the winding, and one surface of the wall portion of the frame core and one axial end surface of the winding core are disposed. An insulating spacer having a step, a step portion disposed between an opposing portion, one surface of one wall portion of the frame core, and one axial end portion of the winding; and the other surface of the wall portion of the frame core And an insulating base that contacts the insulating base, and a connecting portion that connects the insulating spacer and the insulating base, and the insulating spacer, the insulating base, and the connecting portion constitute a sandwich body that sandwiches the one wall portion. A method of manufacturing a coil component,
A first disposing step of disposing one end surface of the core on the facing portion;
A second arrangement step of arranging the wound winding on the step portion through the winding core;
An insertion step of inserting the clamping body on which the winding core and the winding are mounted into the opening of the frame core so that the one wall portion is sandwiched between the insulating spacer and the insulating base. The manufacturing method of the coil components characterized by the above-mentioned.

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