JP5071365B2 - Coil parts - Google Patents

Description

  The present invention particularly relates to a coil component used in various electronic devices as a power choke coil.

  In recent years, as a power choke coil used for a power supply circuit of a computer or the like, an operation frequency region of the power supply circuit is about 10 μA while ensuring an inductance value of about 1 μH and a DC resistance value of about several mΩ in a high frequency region of about 300 kHz to 1 MHz. The thing corresponding to the large electric current of a grade is calculated | required. In addition, there is an increasing demand for a small-sized DC resistance value corresponding to a large current.

  A conventional coil component will be described below with reference to the drawings.

  7 is a perspective view of a conventional coil component, FIG. 8 is a cross-sectional view taken along line AA of FIG. 7, FIG. 9 is a plan view of a coil portion in which a plurality of ring portions of the coil component are arranged in a plane, and FIG. It is a perspective view of the coil part which piled up the some ring part of the coil component up and down.

  7 to 10, the conventional coil component is formed by bending a plurality of ring portions 2 made of metal flat plates connected to each other at the connecting portion 1 and arranged in a plane and overlapping each other at the connecting portion 1. A coil part 3, a magnetic body part 4 containing a coil part 3 mixed with an insulating resin and magnetic powder and press-molded, and a drawer formed integrally with the coil part 3 at both ends of the coil part 3 And a terminal portion 6 formed integrally with the lead portion 5 and protruding from the magnetic body portion 4.

  The plurality of ring portions 2 are coated with insulating resin on the surface to form an insulating film 7 (the hatched portion in FIG. 9), and when the plurality of ring portions 2 are folded, the adjacent ring portions 2 Was trying not to short.

For example, Patent Document 1 is known as prior art document information related to the invention of this application.
JP 2004-111456 A

  However, if the coil component is made smaller, the distance between the ring portion 2 and the terminal portion 6 is shortened. In this state, when the magnetic body portion 4 is pressure-molded by stacking the plurality of ring portions 2, the ring adjacent to the drawer portion 5. In order to prevent this, the outer peripheral side edge of the part 2 may bite into the lead-out part 5 and damage the insulating coating 7 to cause a short circuit. The relief part 8 was provided by notching. This can prevent a short circuit, but has led to an increase in DC resistance.

  The present invention solves these problems, and provides a coil component that does not cause a short circuit between a lead portion and a ring portion, is small, and has a small DC resistance value.

  In order to achieve the above object, the present invention has the following configuration.

  The invention according to claim 1 of the present invention includes a coil part having a through hole, a lead part connected to the coil part, a terminal part connected to the lead part, and the terminal part covering the coil part. The coil part is made of a flat metal plate, has a notch part and a plurality of ring parts having an insulating coating layer formed on the surface, and a plurality of ring parts formed at the end of the ring part. A ring connecting portion connected to the ring portion, a lead portion connected to an end portion of the ring portion not connected to the ring portion and having an insulating coating layer formed on a surface thereof, and a terminal portion connected to the lead portion Is formed by bending the ring connecting portion so that a plurality of the ring portions overlap in the vertical direction, and is separated from the outer peripheral side edge of the ring portion adjacent to the drawer portion. A configuration in which a recess which is tortuous in that direction. According to this configuration, since the recessed portion that is curved in the direction away from the outer peripheral edge of the ring portion adjacent to the drawer portion is formed in the drawer portion, the drawer portion and the ring adjacent to the drawer portion are formed. The outer peripheral side edge of the part is not brought into contact, the insulating coating layer is not damaged, and the short-circuit between the lead-out part and the ring part can be eliminated. Thereby, the pressurization force at the time of pressure-molding an exterior part can be made high, and a magnetic characteristic can be stabilized. Further, it is not necessary to form a relief portion at the outer peripheral side edge of the ring portion at the portion facing the lead-out portion, and the direct current resistance of the coil portion can be reduced by increasing the width of the ring portion. It has an effect.

  The invention described in claim 2 of the present invention has a configuration in which the inside of the recess formed in the lead-out portion is closed with an insulating coating layer. According to this configuration, since the inside of the concave portion formed in the lead-out portion is closed with the insulating coating layer, the outer peripheral side edge of the ring portion adjacent to the concave portion does not enter, and the lead-out portion, the ring portion, It is possible to prevent the contact between the lead portion and the ring portion more precisely and to eliminate the short circuit between the contact portion and the ring portion.

  As described above, in the coil component according to the present invention, the coil portion is formed of a metal flat plate, formed with a plurality of ring portions each having a notch portion and an insulating coating layer formed on the surface thereof, and an end portion of the ring portion. A ring connecting portion that connects a plurality of the ring portions, a lead portion that is connected to an end portion of the ring portion that is not connected to the ring portion and has an insulating coating layer formed on the surface thereof, and a terminal connected to the lead portion Is formed by bending the ring connecting portion so that the plurality of ring portions overlap each other vertically, and from the outer peripheral side edge of the adjacent ring portion to the drawer portion Since the concave portion that is curved in the direction of leaving is formed, it is possible to provide a coil component that is small and has a low direct current resistance value without causing a short circuit between the lead portion and the ring portion. Cormorant is intended to achieve the excellent effect.

  Hereinafter, a coil component according to an embodiment of the present invention will be described with reference to the drawings.

  1 is a perspective view of a coil component according to an embodiment of the present invention, FIG. 2 is a cross-sectional view taken along line BB of FIG. 1, and FIG. 3 is a metal in which the coil component according to an embodiment of the present invention is arranged in a planar shape. FIG. 4 is a perspective view of a coil portion in which a plurality of ring portions of the coil component are vertically stacked.

  1 to 4, the coil component according to the embodiment of the present invention includes a coil part 12 having a through hole 11, a lead part 13 connected to the coil part 12, and a terminal part connected to the lead part 13. 14 and an exterior portion 15 that covers the coil portion 12 and protrudes the terminal portion 14.

  The coil portion 12 is arranged in a planar shape by punching a metal flat plate such as a copper plate, and the like. A ring connecting portion 18 formed at an end portion and connected to a plurality of the ring portions 17, a lead-out portion 13 formed at an end portion of the ring portion 17 not connected to the ring portion 17, and a connection to the lead-out portion 13 The terminal portion 14 is formed by bending the ring connecting portion 18 so that the plurality of ring portions 17 overlap each other.

  Further, the drawer portion 13 is formed with a concave portion 19 that is curved in a direction away from the outer peripheral side edge portion 21 of the adjacent ring portion 17.

  Further, an insulating coating layer 20 is formed on at least the surfaces of the ring portion 17 and the lead portion 13 (the hatched portion in FIG. 3). The insulating coating layer 20 may be appropriately selected from insulating resins such as acrylic, urethane, enamel, and epoxy resins. A liquid insulating resin may be used for the ring portion 17 and the drawing portion 13. It is formed by applying and curing on the surface. In this case, the insulating coating layer 20 is formed thick until the inside of the recess 19 formed in the lead-out portion 13 is closed with the insulating coating layer 20.

  Furthermore, the exterior portion 15 is formed by mixing iron metal magnetic powder, a thermosetting resin, and an electrically insulating material, covering the coil portion 12, press-molding, and thermosetting the thermosetting resin. ing.

  And the terminal part 14 which protruded from the exterior part 15 is bent so that it may go along the side surface of the said exterior part 15, and may be turned to the lower surface side of the said exterior part 15, and a coil component is comprised.

  The manufacturing method of the coil component according to the embodiment of the present invention configured as described above will be described with reference to the manufacturing process diagrams showing the manufacturing process of the coil component according to the embodiment of the present invention shown in FIGS. To do.

  First, as shown in FIG. 5A, a copper flat plate is punched using a mold (not shown) to form a ring portion 17 for forming a coil portion 12 having a through hole 11 (ring portion formation). Process).

  Next, as shown in FIG. 5B, the recessed portion 19 is formed by pressing the drawer portion 13 using a mold (not shown) (a recessed portion forming step). Here, the concave portion 19 formed in the lead-out portion 13 is adjacent to the adjacent ring portion 17 when the ring connecting portion 18 is bent and the plurality of ring portions 17 are stacked one above the other. It forms by detouring the said drawer | drawing-out part 13 in the direction away from the outer peripheral side edge part 21 of the said ring part 17. FIG.

  Next, as shown in FIG. 5C, the insulating coating layer 20 (the hatched portion in FIG. 5C) is formed at least on the surfaces of the ring portion 17 and the lead-out portion 13 (insulating coating layer forming step). . In this step, after the acrylic liquid insulating resin is transferred to the ring portion 17 and the drawing portion 13 by a pad printing method, the liquid insulating resin is cured to form the insulating coating layer 20. In this case, the inside of the recess 19 formed in the lead-out portion 13 becomes a resin pool when a liquid insulating resin is applied, and the insulating coating layer 20 having a size larger than the thickness of the lead-out portion 13 and the ring portion 17. Is formed. And it is set as the process of repeating application | coating and hardening of insulating resin until the inside of the said recessed part 19 is block | closed with the said insulating film layer 20. FIG.

  Next, as shown in FIG. 6A, the coil portion 12 is formed by bending the ring connecting portion 18 so that the plurality of ring portions 17 are vertically stacked (coil portion forming step).

  Next, as shown in FIG. 6B, the coil portion 12 is covered with the exterior portion 15 (exterior portion formation step). In this step, a mixture of iron-based metal magnetic powder, a thermosetting resin, and an electrical insulating material is inserted into the molding die 22 so as to sandwich the coil portion 12, and the upper and lower punches 23 are used for FIG. After pressure molding in the direction of the arrow b), the thermosetting resin is thermoset.

  Finally, as shown in FIG. 6C, the terminal portion 14 protruding from the exterior portion 15 is bent along the side surface of the exterior portion 15 and wraps around the lower surface side of the exterior portion 15 (terminal portion processing step). ) To produce a coil component.

  The coil component according to the embodiment of the present invention configured and manufactured as described above is bent in the pulling portion 13 in a direction away from the outer peripheral side edge portion 21 of the ring portion 17 adjacent to the pulling portion 13. Since the recessed portion 19 is formed, the drawing portion 13 and the outer peripheral side edge portion 21 of the ring portion 17 adjacent to the drawing portion 13 are not in contact with each other, and the insulating coating layer 20 is not damaged. A short circuit between the lead portion 13 and the ring portion 17 can be eliminated. Thereby, the pressurizing force at the time of pressure forming the exterior portion 15 can be increased to stabilize the magnetic characteristics.

  Further, it is no longer necessary to form the relief portion 8 as in the conventional coil component at the outer peripheral side edge portion 21 of the ring portion 17 at the portion facing the drawer portion 13, and the width of the ring portion 17 is increased. Thus, the DC resistance of the coil portion 12 can be reduced.

  And since the inside of the recessed part 19 formed in the drawer | drawing-out part 13 was block | closed with the insulating coating layer 20, the outer peripheral side edge part 21 of the ring part 17 adjacent to this recessed part 19 does not enter, and pressurizes the exterior part 15 By preventing deformation of the lead-out portion 13 in the direction of approaching the outer peripheral side edge portion 21 of the adjacent ring portion 17 when molding, the contact between the lead-out portion 13 and the ring portion 17 is more accurately prevented, A short circuit between the drawing portion 13 and the ring portion 17 can be eliminated.

  The coil component of the present invention does not cause a short circuit between the lead portion and the adjacent ring portion, is small, and has an excellent effect of reducing the DC resistance value. It is useful to apply.

The perspective view of the coil components in one embodiment of this invention BB sectional view of FIG. The top view of the some ring part which consists of a metal flat plate which has arrange | positioned the coil components in one embodiment of this invention in planar shape The perspective view of the coil part which piled up the plurality of ring parts of the same coil parts up and down Manufacturing process diagram showing the manufacturing process of the coil component Manufacturing process diagram showing the manufacturing process of the coil component Perspective view of conventional coil parts AA line sectional view of FIG. A plan view of a coil part in which a plurality of ring parts of the coil component are arranged in a planar shape. The perspective view of the coil part which piled up the plurality of ring parts of the same coil parts up and down

Explanation of symbols

DESCRIPTION OF SYMBOLS 11 Through-hole 12 Coil part 13 Pull-out part 14 Terminal part 15 Exterior part 16 Notch part 17 Ring part 18 Ring connection part 19 Recessed part 20 Insulating coating layer 21 Outer peripheral side edge 22 Molding die 23 Punch

Claims (2)

A coil part having a through hole; a lead part connected to the coil part; a terminal part connected to the lead part; and an exterior part covering the coil part and projecting the terminal part. The portion is made of a metal flat plate, and a plurality of ring portions in which a cutout portion is formed and an insulating coating layer is formed on the surface, and a ring connecting portion formed at an end portion of the ring portion and connecting the plurality of ring portions, A plurality of ring parts having a lead part connected to an end part of the ring part not connected to the ring part and having an insulating coating layer formed on the surface and a terminal part connected to the lead part. Is formed by bending at the ring connecting portion so as to overlap vertically, and a concave portion is formed in the lead-out portion so as to bend away from the outer peripheral side edge of the adjacent ring portion. Yl components. The coil component according to claim 1, wherein the inside of the recess formed in the lead-out portion is closed with an insulating coating layer.

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