JP4538200B2 - Coil component manufacturing method and coil device manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a rectifier circuit, a noise prevention circuit, a coil device equipped in a resonance circuit in various AC devices, a coil component used therefor, and a manufacturing method thereof.
[0002]
[Prior art]
Conventionally, this type of coil device is configured by winding a coil around an annular core, and a surface-mount type coil device has both ends of a coil connected to a land provided on the surface of a printed wiring board. It is mounted on a printed wiring board (see, for example, Patent Document 1).
[0003]
Further, a coil device is proposed in which the coil component (90) shown in FIGS. 21 and 22 is surface-mounted on a printed wiring board (8) shown in FIG. As shown in the figure, the coil component (90) includes a ring-shaped core (1) whose surface is covered with an insulating layer, and a plurality of coil pieces (91) disposed on the core (1) at intervals. Each coil piece (91) is U-shaped and is installed on the core (1) across the inner and outer peripheral surfaces of the core (1). Each coil piece (91) has a pair of legs, and the tips of both legs are bent at about 90 degrees to form joints (92) and (93).
[0004]
On the other hand, on the surface of the printed wiring board (8), as shown in FIG. 23, a pair of lands (82) (83) to which a pair of joints (92) (93) of the coil piece (91) should be connected. Are arranged in a circle, and the plurality of lands (82) arranged on the inner circumferential side and the plurality of lands (83) arranged on the outer circumferential side are connected to each other by the connecting portion (84) in a phase shifted relationship with each other. Yes.
[0005]
24 and 25, a pair of joint portions (92) and (93) of each coil piece (91) of the coil component (90) are joined to the lands (82) and (83) on the printed wiring board (8). Thus, the plurality of coil pieces (91) are connected in series with each other to form a spiral coil.
[0006]
In the manufacturing process of the coil component (90), as shown in FIG. 22, the core (1) is first prepared by covering the ring-shaped core piece with resin, and the belt-shaped lead member is pressed. A plurality of U-shaped coil pieces (91) having a pair of joint portions (92) and (93) are produced.
Next, each coil piece (91) is installed in the core (1) so that each coil piece (91) straddles the inner peripheral surface and the outer peripheral surface of the core (1), and these coil pieces (91) are connected to the core. The coil component (90) shown in FIG. 21 is obtained by fixing to (1).
[0007]
[Patent Document 1]
JP 2002-289423 A
[Problems to be solved by the invention]
However, in the method of manufacturing the coil component (90) as described above, since a plurality of coil pieces (91) must be individually installed on the core (1), the operation is extremely complicated and automation is difficult. There was a problem.
Further, when the plurality of coil pieces (91) are fixed to the core (1), the position of each coil piece (91) is unstable, and there is a possibility that the position and posture of the coil piece (91) may be shifted. It was.
SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to manufacture a coil component that can be manufactured by a simpler operation than before and each coil piece can be fixed to the core at an accurate position, a coil device using the coil component, and a coil component. It is to provide a manufacturing method.
[0009]
[Means for solving the problems]
The coil component which is the object of the present invention includes a ring-shaped core (1) whose surface is covered with an insulating layer (12), and a plurality of coil pieces (31) installed on the core (1) at intervals. Each coil piece (31) is U-shaped and straddles the inner and outer peripheral surfaces of the core (1), and both end portions of each coil piece (31) are the surface of the printed wiring board. Are connected to each other in series to form a helical coil, and the method of manufacturing the coil component includes:
A first step of producing a comb-shaped lead plate (3) formed by projecting a plurality of lead portions (34) in the same direction on a strip-shaped connecting portion (30);
Each of the plurality of lead portions (34) of the lead plate (3) is defined as a first fold line b at a position separated from the connecting portion (30) by a distance larger than the height H of the core (1). A position away from the position by a distance w slightly larger than the radial width W of the core (1) is defined as a second fold line a, and the first portion of the lead portion (34) from the connecting portion (30). Without forming a fold line up to the fold line b, it is bent into a U shape and formed so that the U shapes of a plurality of lead portions (34) are arranged in a line, and then the connecting portion (30) is cylindrical. A second step of arranging the plurality of lead portions (34) on the outside of the connecting portion (30) around the cylindrical connecting portion (30),
The connecting portion (30) of the lead plate (3) protrudes from the central hole (10) of the core (1) and the plurality of lead portions (34) straddle the inner peripheral surface and outer peripheral surface of the core (1). A third step of installing the lead plate (3) on the core (1);
A fourth step of cutting the lead plate (3) at the base end position of each lead portion (34) or a position near the lead end portion to separate the plurality of lead portions (34) from each other.
[0010]
In a specific configuration, in the second step, the tip of each lead portion (34) of the lead plate (3) is bent to form a joint portion (33) to be joined to the surface of the printed wiring board. Thereafter, in the fourth step, the plurality of lead parts (34) separated by cutting are bent in the vicinity of the cutting position to form a joint part (32) to be joined to the surface of the printed wiring board. Alternatively, in the fourth step, both ends of the plurality of lead portions (34) separated by cutting are bent to form joint portions (32) and (33) to be joined to the surface of the printed wiring board.
[0011]
In the coil component manufacturing method according to the present invention, in the first step, the lead plate (3) in which the plurality of lead portions (34) to form the coil pieces (31) are connected to each other by the connecting portion (30) in the first step. Is obtained. Next, in a second step, the lead plate (3) is formed into a shape in which each lead portion (34) is placed on the core (1). In the third step, all the lead portions (34) of the lead plate (3) are simultaneously installed on the core (1), and then in the fourth step, the lead plate (3) is the base end of the lead portion (34). Cut in the vicinity of the position, the lead portions (34) are separated from each other while being installed on the core (1).
[0012]
According to the manufacturing method, the lead portions (34) of the lead plate (3) are kept connected to each other by the connecting portion (30) until the fourth step is completed. As a result, the step of forming the lead portion (34) into a U-shape and the step of installing the lead portion (34) on the core (1) need not be performed for each lead portion (34), and the lead plate (3). By carrying out plastic working on the lead plate (3) on the core (1), all of the plurality of lead portions (34) are carried out simultaneously.
Therefore, the work of installing a plurality of coil pieces (31) on the core (1) is performed more efficiently than the conventional work of installing the coil pieces formed to a predetermined standard one by one on the core (1). It is.
[0017]
The coil component manufacturing method according to the present invention is a method of manufacturing the above-described coil component,
A first step of producing a comb-shaped lead plate (3) formed by projecting a plurality of lead portions (34) in the same direction on a strip-shaped connecting portion (30);
Each of the plurality of lead portions (34) of the lead plate (3) is defined as a first fold line b at a position separated from the connecting portion (30) by a distance larger than the height H of the core (1). A position away from the position by a distance w slightly larger than the radial width W of the core (1) is defined as a second fold line a, and the first portion of the lead portion (34) from the connecting portion (30). Without forming a fold line up to the fold line b, it is bent into a U shape and formed so that the U shapes of a plurality of lead portions (34) are arranged in a line, and then the connecting portion (30) is cylindrical. A second step of arranging the plurality of lead portions (34) on the outside of the connecting portion (30) around the cylindrical connecting portion (30),
The connecting portion (30) of the lead plate (3) protrudes from the central hole (10) of the core piece (11) and the plurality of lead portions (34) do not contact the inner peripheral surface and the outer peripheral surface of the core piece (11). The lead plate (3) is placed on the core piece (11) so as to cross over, and the core piece (11) and a plurality of lead portions (34) of the lead plate (3) are surrounded by a mold. A third step of filling the inside of the mold with resin to form the insulating layer (12);
Cutting the lead plate (3) protruding from the insulating layer (12) at the base end position of each lead portion (34) or a position near it, and separating the plurality of lead portions (34) from each other; Have.
[0018]
In the coil component manufacturing method according to the present invention, in the first step, the lead plate (3) in which the plurality of lead portions (34) to form the coil pieces (31) are connected to each other by the connecting portion (30) in the first step. Is obtained. Next, in the second step, the lead plate (3) is formed into a shape in which each lead portion (34) is placed on the core piece (11).
In the third step, all the lead portions (34) of the lead plate (3) are simultaneously installed in a non-contact manner on the inner peripheral surface and outer peripheral surface of the core piece (11), and in this state the lead plate ( The lead part (34) and the core piece (11) of 3) are accommodated in the mold. At this time, the lead plate (3) is accommodated in the mold in a state in which only a part thereof, for example, the connecting portion (30) of the lead plate (3) is supported. Further, the leading end and the base end of the lead portion (34) of the lead plate (3) are projected from the mold. Thereafter, by filling the mold with resin, the surfaces of the core piece (11) and the lead plate (3) are covered with resin, and the gap between the core piece (11) and the lead portion (34) is made of resin. Buried. Finally, in the fourth step, the lead plate (3) is cut in the vicinity of the base end position of the lead portion (34), and each lead portion (34) is separated from each other while being installed on the core piece (11). Will be.
[0019]
According to the manufacturing method, the lead portions (34) of the lead plate (3) are kept connected to each other by the connecting portion (30) until the fourth step is completed. Thus, the step of forming the lead portion (34) into a U-shape and the step of installing the lead portion (34) on the core piece (11) do not have to be performed for each lead portion (34), and the lead plate (3 ) Is subjected to plastic working, and then the lead plate (3) is placed on the core piece (11), so that all of the plurality of lead portions (34) are carried out simultaneously. Also, in the process of accommodating the lead portion (34) and the core piece (11) of the lead plate (3) in the mold, if a part of the lead plate (3) is supported as described above, the core piece (11). On the other hand, it is possible to keep all the lead portions (34) non-contact at the same time. As a result, the work of embedding the plurality of coil pieces (31) in the insulating layer (12) covering the core (1) is facilitated.
[0022]
【The invention's effect】
According to the present invention, coil parts can be manufactured with simpler work than before, and each coil piece can be fixed to the core at an accurate position.
[0023]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be specifically described below with reference to the drawings.
First embodiment of coil component Fig. 1 shows a coil component (9) produced by the method of manufacturing a coil component according to the present invention. The coil component (9) includes a ring-shaped core (1), and a plurality (eight in this embodiment) of the core (1) installed on the core (1) across the inner peripheral surface and the outer peripheral surface. It is composed of a U-shaped coil piece (31).
As shown in FIG. 2, a pair of flat joint portions (32) and (33) formed by bending the tip portions are formed at the tip portions of the pair of leg portions of each coil piece (31). The parts (32) and (33) are located on a plane including the bottom surface of the core (1). Further, the joint portion (32) which is located inside the core (1) is formed in a trapezoidal shape and protrudes in a direction away from the inner peripheral surface of the core (1). The joint part (33) which will be located outside protrudes in a direction away from the outer peripheral surface of the core (1).
[0024]
As shown in FIG. 3, the core (1) is composed of a ring-shaped core piece (11) and an insulating layer (12) covering the surface of the core piece (11). In FIG. 3, the radial width of the core (1) is represented by W, and the height of the core (1) is represented by H.
[0025]
In the manufacturing process of the coil component according to the present invention, first, the core piece (11) is covered with an insulating layer (12) made of resin to produce the core (1) shown in FIG. The comb-shaped lead plate (3) shown in FIG. 4 is produced by processing. The lead plate (3) is formed by projecting a plurality (eight in this embodiment) of lead portions (34) in the same direction on a strip-shaped connecting portion (30), and adjacent lead portions (34). ) Is evenly spaced. Further, the base end portion of each lead portion (34) is formed in a shape in which the width is gradually reduced toward the connecting portion (30) by notching both side surfaces into the same shape.
[0026]
Next, by pressing the lead plate (3), a plurality of lead portions (34) are bent into a U-shape arranged in a row as shown in FIG. 5, and the leading end portion of each lead portion (34) is connected to a connecting portion ( The joint (33) is formed by bending 90 degrees away from 30). Since the plurality of lead portions (34) are connected to each other by the connecting portion (30), all the lead portions (34) can be simultaneously plastically deformed by pressing the entire lead plate (3). Is possible.
At this time, two fold lines a and b are formed on each lead portion (34) of the lead plate (3) when the lead portion (34) is bent into a U-shape. A bending line c for forming the joint portion (32) is formed at the tip portion. The interval w between the fold line a and the fold line b is set to a length slightly larger than the radial width W of the core (1), and the length h from the fold line a to the fold line c. Is equal to the length from the bend line b to the notch line d connecting the edge of the notch at the base end of the lead part (34), and substantially the same as the height H of the core (1). Set to
[0027]
Then, as shown in FIG. 6, the connecting portion (30) is bent so that the lead portion (34) of the lead plate (3) is arranged on the outside, and the lead plate (3) is formed into an annular shape. At this time, the connecting portion (30) of the lead plate (3) is formed in a circular shape slightly smaller than the central hole (10) of the core (1).
[0028]
Then, as indicated by an arrow in FIG. 6, the connecting portion (30) of the lead plate (3) is inserted into the central hole (10) of the core (1). At this time, the lead plate (3) is pushed into the core (1) until the connecting portion (30) of the lead plate (3) protrudes from the bottom surface of the core (1), and a plurality of lead portions ( 34) is installed on the core (1) so as to straddle the inner and outer peripheral surfaces of the core (1). Thus, as shown in FIG. 7, the region between the two fold lines of the lead portion (34) is in contact with the upper surface of the core (1) and is formed at the tip of the lead portion (34). The bottom surface of the part (33) is located on the same plane as the bottom surface of the core (1). At this time, since the plurality of lead portions (34) of the lead plate (3) are connected to each other by the connecting portion (30), all the leads can be obtained by installing the lead plate (3) on the core (1). The part (34) is installed on the core (1) at the same time.
[0029]
Thereafter, by disconnecting the connecting portion (30) of the lead plate (3) at the position indicated by the broken line AA in FIG. 7, the plurality of lead portions (34) of the lead plate (3) are separated from each other. become.
Finally, as indicated by arrows in FIG. 8, the base end portion of each lead portion (34) protruding from the bottom surface of the core (1) is bent 90 degrees in a direction away from the inner peripheral surface of the core (1). As a result, a joint portion (32) located inside the core (1) is formed, whereby a plurality of coil pieces (31) straddling the inner peripheral surface and the outer peripheral surface of the core (1) are obtained. Here, since the portion to be the joint portion (32) of each lead portion (34) is formed in a trapezoidal shape whose cross-sectional area decreases toward the tip portion, the joint portion (32 ), The joint portions (32) of the adjacent coil pieces (31) do not contact each other.
As shown in FIGS. 1 and 2, the coil component (9) having a plurality of U-shaped coil pieces (31) installed across the inner peripheral surface and outer peripheral surface of the core (1) by the above-described manufacturing process. ) Is obtained.
[0030]
According to the method for manufacturing a coil component according to the present invention, the plurality of lead portions (34) of the lead plate (3) are separated from each other by separating the connecting portion (30) of the lead plate (3) in the final step. Until it is in a state, it is maintained as a single lead plate (3), so the process of forming the lead part (34) into a U-shape and the lead part (34) are installed in the core (1). It is not necessary to perform the process for each lead portion (34). After the lead plate (3) is pressed, the lead plate (3) is placed on the core (1), whereby a plurality of lead portions ( All 34) will be implemented at the same time.
Therefore, the work of installing a plurality of coil pieces (31) on the core (1) is performed more efficiently than the conventional work of installing the coil pieces formed to a predetermined standard one by one on the core (1). It is.
[0031]
As shown in FIGS. 9 and 10, the coil component (9) formed through the manufacturing process described above is mounted on the surface of the printed wiring board (2) so that the coil pieces (31) are connected in series. The completed coil device is completed.
On the surface of the printed circuit board (2), as shown in FIG. 9, a pair of lands (22) and (23) to which a pair of joints (32) and (33) of the coil piece (31) are to be connected are circular. The lands (82) arranged on the inner peripheral side and the lands (83) arranged on the outer peripheral side are connected to each other by the connecting portion (24) in a phase-shifted relationship. Then, as shown in FIG. 10, the pair of joint portions (32) and (33) of each coil piece (31) of the coil component (9) are joined to the lands (22) and (23) on the printed wiring board (2). Thus, the plurality of coil pieces (31) are connected in series with each other to form a spiral coil.
[0032]
Another configuration example of the above-described coil component (9) is shown in FIG. The coil component (9) includes a joint portion (32) positioned inside the core (1) among the pair of joint portions (32) and (33) formed at the tip of each coil piece (31). It is configured to be in close contact with the bottom of (1). Here, the bottom surfaces of the joint portions (32) and (33) of each coil piece (31) are located on the same plane.
In the coil component (9), there is no possibility that the joint portions (32) of the adjacent coil pieces (31) come into contact with each other, and therefore it is not necessary to cut out the joint portion (32) into a trapezoidal shape. As a result, the cross-sectional area of the coil piece (31) through which the current should flow is kept constant, and the internal resistance of the coil can be reduced. Further, the lead plate (3) on which the coil piece (31) is to be formed has a simple comb shape in which the width of each lead portion (34) is constant from the distal end portion to the proximal end portion as shown in FIG. Since it can be formed, its design is easy.
[0033]
Still another configuration example of the coil component (9) is shown in FIGS. In the coil component (9), a coil piece receiving groove (13) for receiving the lead portion (34) of the lead plate (3) is recessed in the insulating layer (12) of the core (1).
According to the coil component (9), when the lead plate (3) is installed on the core (1), the plurality of lead portions (34) of the lead plate (3) are connected to the core (1) as shown in FIG. Positioned by the coil piece receiving groove (13) of the insulating layer (12). As a result, each lead part (34) is accurately fixed to a predetermined position of the core (1) in a predetermined posture. However, even after the plurality of lead portions (34) are separated from each other by separating the connecting portion (30) of the lead plate (3), thereby forming the plurality of coil pieces (31), FIG. Thus, since each coil piece (31) is held by the core (1) in a state of being accommodated in the coil piece accommodation groove (13), its installation posture is kept constant.
[0034]
Second embodiment of coil component Fig. 15 shows a configuration example of a coil component (94) manufactured by another method of manufacturing a coil component according to the present invention. Here, the coil piece (31) straddles the inner peripheral surface and the outer peripheral surface of the ring-shaped core piece (11) in a non-contact manner and is embedded in the insulating layer (12).
[0035]
In the manufacturing process of the coil component (94) according to the present invention shown in FIG. 15, the process until the lead plate (3) is formed into an annular shape is the same as the manufacturing process of the first embodiment of the coil component (9) described above. Advance in the process.
However, the interval w between the fold line a and the fold line b shown in FIG. 5 is set to a length slightly larger than the radial width of the core piece (11), and the fold line a to the fold line c. Is equal to the length from the bend line b to the notch line d connecting the edge of the notch at the base end of the lead part (34), and is substantially equal to the height of the core piece (11). Set to the same length.
[0036]
Then, the connecting portion (30) of the lead plate (3) is inserted into the central hole (10) of the core piece (11). At this time, the lead plate (3) is pushed into the core piece (11) until the connecting portion (30) of the lead plate (3) protrudes from the bottom surface of the core piece (11), and a plurality of leads of the lead plate (3) are thus pushed. The part (34) is installed on the core piece (11) so as to straddle the inner peripheral surface and the outer peripheral surface of the core piece (11). At this time, the position of the lead plate (34) with respect to the core piece (11) is adjusted so that each lead part (34) straddles the core piece (11) in a non-contact manner. Since the plurality of lead portions (34) are connected to each other by the connecting portion (30), by installing the lead plate (3) on the core piece (11), all the lead portions (34) are simultaneously connected to the core piece. Installed in (11).
[0037]
From this state, the core piece (11) and the plurality of lead portions (34) of the lead plate (3) are accommodated in the mold. At this time, the lead portion (34) of the lead plate (3) is accommodated in the mold while the connecting portion (30) is supported, and the joint portion (33) at the tip of the lead portion (34). Project from the mold. Thereafter, an insulating layer (12) covering the core piece (11) and the lead portion (34) is formed by filling the mold with resin. As a result, the gap between the core piece (11) and the lead portion (34) is filled with resin, and the portion of each lead portion (34) of the lead plate (3) facing the core piece (11) is It will be embedded in the insulating layer (12).
[0038]
Thereafter, by disconnecting the connecting portion (30) of the lead plate (3) at the position indicated by the BB broken line in FIG. 16, the plurality of lead portions (34) of the lead plate (3) are separated from each other. become.
Finally, as shown by the arrows in FIG. 17, the base end portion of each lead portion (34) protruding from the bottom surface of the core piece (11) is 90 degrees away from the inner peripheral surface of the core piece (11). By bending, a joint portion located inside the core piece (11) is formed, thereby obtaining a plurality of coil pieces (31) straddling the inner and outer peripheral surfaces of the core piece (11) in a non-contact manner. . At this time, the portion of the lead portion (34) that becomes the joint portion is formed in a trapezoidal shape whose cross-sectional area decreases toward the tip portion, so that the joint portions of the adjacent coil pieces (31) contact each other. Never do.
By the above manufacturing process, as shown in FIG. 15, a plurality of U-shaped coil pieces (31) installed across the inner peripheral surface and outer peripheral surface of the core piece (11) are embedded in the insulating layer (12). Coil part (94) is obtained.
[0039]
According to the coil component manufacturing method of the present invention, the plurality of lead portions (34) of the lead plate (3) are separated from each other by cutting the connecting portion (30) of the lead plate (3) in the final step. Since the lead plate (3) is kept in an integrated state until the lead plate (3) is formed, the step of forming the lead portion (34) into a U-shape and the lead portion (34) into the core piece (11) It is not necessary to perform the process of installing the lead plate (3) for each lead portion (34). After the lead plate (3) is subjected to plastic working, the lead plate (3) is installed on the core piece (11). All of the lead portions (34) are performed simultaneously. Also, in the step of accommodating the lead portion (34) of the lead plate (3) and the core piece (11) in the mold, the connecting portion (30) of the lead plate (3) which is located outside the mold. If it is supported, it is possible to keep all the lead portions (34) in non-contact simultaneously with the core piece (11).
Accordingly, it is easy to cover the lead portion (34) of the lead plate (3) and the core piece (11) with resin in a state where each lead portion (34) is kept in non-contact with the core piece (11). In addition, the work of installing a plurality of coil pieces on the core piece (11) is efficiently performed.
[0040]
Further, in the coil component according to the present invention, as shown in FIG. 15, each coil piece (31) is fixed to the core (1) by being embedded in the insulating layer (12). The operation | work which fixes each coil piece (31) becomes unnecessary.
[0041]
Coil device (95)
FIG. 18 shows a coil device (95) manufactured by the method for manufacturing a coil device according to the present invention. Here, the U-shaped coil piece (31) has a pair of leg portions (35) and (36) straddling the inner peripheral surface and the outer peripheral surface of the core (1), and two coil pieces (31) adjacent to each other. The first leg portion (35) of one coil piece (31) and the second leg portion (36) of the other coil piece (31) are connected to each other, and each coil piece ( 31) are connected in series to each other to form a spiral coil.
[0042]
In the manufacturing method of the coil device (92) according to the present invention shown in FIG. 18, the lead plate (3) is installed on the core (1), and the connecting portion (30) of the lead plate (3) is separated to make a plurality of pieces. The process until the lead portions (34) are separated from each other is performed in the same process as the manufacturing process of the first embodiment of the coil component (9) described above. However, it is not necessary to cut out the base end portion of the lead portion (34) of the lead plate (3). Through this step, each coil piece (31) includes a pair of legs (35) and (36) straddling the inner and outer peripheral surfaces of the core (1).
Thereafter, as shown in FIG. 19, of the pair of legs (35) and (36) of each coil piece (31), the tip of the first leg (35) in contact with the inner peripheral surface of the core (1) is removed. Bend and adhere to the bottom of the core (1).
[0043]
Next, each coil piece (31) is twisted clockwise as indicated by an arrow in FIG. 19 with respect to the core (1), and each coil piece (31) that comes into contact with the outer peripheral surface of the core (1) as shown in FIG. ) Of the second leg portion (36) is opposed to the tip end portion of the first leg portion (35) of the adjacent coil piece (31).
Finally, the second leg (36) of the coil piece (31) is bent by bending the tip of the second leg (36) of each coil piece (31) so as to contact the bottom surface of the core (1). ) Is pressed against the tip of the first leg (35) of the adjacent coil piece (31). As a result, each coil piece (31) is connected in series with the adjacent coil piece (31), and the coil device (95) including the coil shown in FIG. 18 is obtained.
[0044]
In the coil device according to the present invention, adjacent coil pieces (31) are directly connected to each other to form a helical coil, and therefore, a plurality of coil pieces (31) are provided on the printed wiring board. There is no need to form conductor patterns for connecting to each other in series. As a result, the manufacturing process of the printed wiring board can be simplified.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a first embodiment of a coil component obtained by a method for manufacturing a coil component according to the present invention.
FIG. 2 is a perspective view showing the coil component upside down.
FIG. 3 is a partially broken perspective view of a core.
FIG. 4 is a plan view of a lead plate.
FIG. 5 is a perspective view showing a state in which the lead plate is pressed.
FIG. 6 is a perspective view showing a process of installing the lead plate on the core.
FIG. 7 is a front view showing a state in which the lead plate is installed on a core.
FIG. 8 is a front view showing a state in which a connecting portion of the lead plate is cut off.
FIG. 9 is a perspective view showing a process of mounting the first embodiment of the coil component obtained by the coil component manufacturing method according to the present invention on the printed wiring board;
FIG. 10 is a perspective view showing a state where the coil component is mounted on a printed wiring board.
FIG. 11 is a perspective view showing another coil component obtained by turning over the coil component obtained by the method of manufacturing a coil component according to the present invention.
FIG. 12 is a plan view of a lead plate forming a coil piece of the coil component.
FIG. 13 is a perspective view showing still another coil component obtained by the coil component manufacturing method according to the present invention.
FIG. 14 is a perspective view showing a process of installing the lead plate of the coil component on the core.
FIG. 15 is a perspective view showing a second embodiment of the coil component obtained by the method of manufacturing a coil component according to the present invention.
FIG. 16 is a front view showing a state in which a core piece and a lead plate are embedded in an insulating layer.
FIG. 17 is a front view showing a state in which the connecting portion of the lead plate is cut off.
FIG. 18 is a perspective view showing a coil device according to the present invention.
FIG. 19 is a perspective view showing a state where a coil piece is installed on a core.
FIG. 20 is a perspective view showing a state in which each coil piece is twisted.
FIG. 21 is a perspective view of a coil component obtained by a conventional coil component manufacturing method.
FIG. 22 is a perspective view showing a core and a coil piece of the coil component.
FIG. 23 is a plan view showing a printed wiring board on which the coil component is mounted.
FIG. 24 is a front view showing a process of mounting the coil component on a printed wiring board.
FIG. 25 is a front view showing a state where the coil component is mounted on a printed wiring board.
[Explanation of symbols]
(1) Core
(10) Central hole
(11) Core piece
(2) Printed circuit board
(22) Land
(23) Land
(3) Lead plate
(30) Connecting part
(31) Coil piece
(32) Joint
(33) Joint
(34) Lead
(35) Leg
(36) Leg
(9) Coil parts
(95) Coil device

Claims (5)

A ring-shaped core (1) whose surface is covered with an insulating layer (12) and a plurality of coil pieces (31) spaced from each other on the core (1), each coil piece (31 ) Is U-shaped and straddles the inner and outer peripheral surfaces of the core (1). Both ends of each coil piece (31) are joined to the surface of the printed circuit board, thereby forming a plurality of coils. In the method of manufacturing a coil component in which the pieces (31) are connected in series with each other to form a spiral coil,
A first step of producing a comb-shaped lead plate (3) formed by projecting a plurality of lead portions (34) in the same direction on a strip-shaped connecting portion (30);
Each of the plurality of lead portions (34) of the lead plate (3) is defined as a first fold line b at a position separated from the connecting portion (30) by a distance larger than the height H of the core (1). A position away from the position by a distance w slightly larger than the radial width W of the core (1) is defined as a second fold line a, and the first portion of the lead portion (34) from the connecting portion (30). Without forming a fold line up to the fold line b, it is bent into a U shape and formed so that the U shapes of a plurality of lead portions (34) are arranged in a line, and then the connecting portion (30) is cylindrical. A second step of arranging the plurality of lead portions (34) on the outside of the connecting portion (30) around the cylindrical connecting portion (30),
The connecting portion (30) of the lead plate (3) protrudes from the central hole (10) of the core (1) and the plurality of lead portions (34) straddle the inner peripheral surface and outer peripheral surface of the core (1). A third step of installing the lead plate (3) on the core (1);
A fourth step of cutting the lead plate (3) at the base end position of each lead portion (34) or a position near the lead portion (34) to separate the lead portions (34) from each other. Production method.   In the second step, the tip of each lead portion (34) of the lead plate (3) is bent to form a joint portion (33) to be joined to the surface of the printed wiring board, and then the fourth step. The coil according to claim 1, wherein a plurality of lead portions (34) separated by cutting are bent in the vicinity of the cutting position to form a joint portion (32) to be joined to the surface of the printed wiring board. Manufacturing method of parts.   2. The joint portion (32) (33) to be joined to the surface of the printed wiring board is formed by bending both ends of the plurality of lead portions (34) separated by cutting in the fourth step. The manufacturing method of the coil components as described in 2. A core (1) configured by covering the surface of a ring-shaped core piece (11) with an insulating layer (12), and a plurality of coil pieces (31) disposed on the core (1) at intervals. Each coil piece (31) is U-shaped and straddles the inner and outer peripheral surfaces of the core (1), and both ends of each coil piece (31) are joined to the surface of the printed circuit board. In the method of manufacturing a coil component in which a plurality of coil pieces (31) are connected in series with each other to form a helical coil,
A first step of producing a comb-shaped lead plate (3) formed by projecting a plurality of lead portions (34) in the same direction on a strip-shaped connecting portion (30);
Each of the plurality of lead portions (34) of the lead plate (3) is defined as a first fold line b at a position separated from the connecting portion (30) by a distance larger than the height H of the core (1). A position away from the position by a distance w slightly larger than the radial width W of the core (1) is defined as a second fold line a, and the first portion of the lead portion (34) from the connecting portion (30). Without forming a fold line up to the fold line b, it is bent into a U shape and formed so that the U shapes of a plurality of lead portions (34) are arranged in a line, and then the connecting portion (30) is cylindrical. A second step of arranging the plurality of lead portions (34) on the outside of the connecting portion (30) around the cylindrical connecting portion (30),
The connecting portion (30) of the lead plate (3) protrudes from the central hole (10) of the core piece (11) and the plurality of lead portions (34) do not contact the inner peripheral surface and the outer peripheral surface of the core piece (11). The lead plate (3) is placed on the core piece (11) so as to cross over, and the core piece (11) and a plurality of lead portions (34) of the lead plate (3) are surrounded by a mold. A third step of filling the interior of the mold with resin to form an insulating layer (12);
Cutting the lead plate (3) protruding from the insulating layer (12) at the base end position of each lead portion (34) or a position near it, and separating the plurality of lead portions (34) from each other; A method for manufacturing a coil component, comprising: A method of manufacturing a coil device comprising a coil component surface-mounted on a printed wiring board, the coil component comprising: a ring-shaped core (1) having a surface covered with an insulating layer (12); and the core (1) comprises a plurality of coil pieces (31) spaced apart from each other, and each coil piece (31) is U-shaped and straddles the inner and outer peripheral surfaces of the core (1). A coil in which a plurality of coil pieces (31) are connected in series to form a helical coil by joining both ends of each coil piece (31) to the surface of the printed wiring board. In the device manufacturing method,
A first step of producing a comb-shaped lead plate (3) formed by projecting a plurality of lead portions (34) in the same direction on a strip-shaped connecting portion (30);
Each of the plurality of lead portions (34) of the lead plate (3) is defined as a first fold line b at a position separated from the connecting portion (30) by a distance larger than the height H of the core (1). A position away from the position by a distance w slightly larger than the radial width W of the core (1) is defined as a second fold line a, and the first portion of the lead portion (34) from the connecting portion (30). Without forming a fold line up to the fold line b, it is bent into a U shape and formed so that the U shapes of a plurality of lead portions (34) are arranged in a line, and then the connecting portion (30) is cylindrical. A second step of arranging the plurality of lead portions (34) on the outside of the connecting portion (30) around the cylindrical connecting portion (30),
The connecting portion (30) of the lead plate (3) protrudes from the central hole (10) of the core (1) and the plurality of lead portions (34) straddle the inner peripheral surface and outer peripheral surface of the core (1). A third step of installing the lead plate (3) on the core (1);
A fourth step of cutting the lead plate (3) at the base end position of each lead portion (34) or in the vicinity thereof to separate the plurality of lead portions (34) from each other to obtain a coil component;
And a fifth step of surface-mounting the coil component on a printed wiring board.

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