JP5242462B2 - Inductor and manufacturing method thereof - Google Patents

Description

  The present invention relates to an inductor including a core having flanges at upper and lower ends and wound with a conductive wire, and a sleeve having a rectangular outer shape surrounding the core, and a method of manufacturing the inductor.

  Conventionally, an inductor composed of the above-described components is known, for example, from Japanese Utility Model Laid-Open No. 5-50706. As shown in FIG. 20, the inductor 50 includes a drum-shaped core 52 around which a conductive wire 51 is wound, and a sleeve 53 having a circular outer shape surrounding the core 52. It is integrally joined on a resin substrate 54 having a specific shape and structure. A conductive surface 55 extending in the two outward directions from the center of the upper surface of the substrate 54 extends to the back surface through the end surface 56 of the substrate 54 to constitute an electrode (not shown). .

  According to this known technique, the inductor 50 having the above structure has a structure in which the two ends of the conductive wire 51 wound around the core 52 are soldered to the conductive surface 55. In addition to being easily connected to the conductive surface 55, when the inductor 50 is mounted on an electronic circuit board (not shown), the effect of being able to easily install the inductor 50 with respect to the electronic circuit board at a predetermined position is exhibited. ing.

Japanese Utility Model Publication No. 5-50706

  However, in recent years, along with the downsizing and high performance of electronic components, it has become necessary to make the inductor as low as 1.5 mm in height and compact, and when mounting on an electronic circuit board, It has been required to improve positioning accuracy with respect to the land, positioning workability, and stationary stability with respect to the electronic circuit board, and there is a problem that the above-mentioned known inductors cannot sufficiently meet this requirement.

  Therefore, the present inventors diligently studied the practical application of an inductor that can meet the above requirements. First, the shape and size of the sleeve surrounding the core around which the conductive wire is wound and the relative position between the core and the sleeve. The present invention has been completed by specifying the relationship and finding the fact that the tip of the electrode-formed conductive wire may be welded to a specific position of the sleeve.

  Accordingly, a first object of the present invention is to provide an inductor having a low profile and a compact shape / structure, and a second object is to form an electrode when mounting the inductor on an electronic circuit board. Another object of the present invention is to provide a wound inductor having a structure in which the position of the tip of a conductive wire can be easily recognized.

  In order to solve the above-mentioned problems, the present invention provides an inductor comprising a core around which a conductive wire is wound having upper and lower flanges at upper and lower ends and a sleeve surrounding the core. And using a sleeve having a rectangular shape, and two outer ends of the conductive wires led out from the core are printed on the lower surfaces of the two opposite corners of the sleeve. Adopting means to weld each electrode to a wide conductive surface.

  By adopting this means, the substrate for forming the tip of the conductive wire in the known technique is not necessary, and considering the printed surface of the inductor surface described later, the tip of the conductive wire converted into an electrode is used. The presence position can be easily recognized without looking at the lower surface of the inductor.

  In order to more specifically embody the above-described embodiment, the tip of the conductive wire wound around the core is directed downward from above between the outer peripheral surface of the lower flange and the inner peripheral surface of the sleeve. And a means of bending the middle of the tip part outward at a substantially right angle and then extending the tip part of the tip part toward two opposite corners of the sleeve. In particular, by making the position on the horizontal plane where the middle of the tip of the conductive wire bends coincide with the position on or near the virtual line that virtually connects the two corners, the conductive wire can be connected to the inductor with the shortest distance. The inductor according to the present invention can be made very compact, and as a result, a reduction in height can be promoted.

  In the present invention, a flange having an outer shape arbitrarily corresponding to the inner shape of the sleeve can be used as the upper and lower flanges, but from the viewpoint of improving manufacturing efficiency, a core having a flange having a circular outer shape is used. In addition, by making the outer diameter of the upper flange larger than the outer diameter of the lower flange, both ends of the conductive wire wound around the core are oriented in the same direction between the outer peripheral surface of the lower flange and the inner peripheral surface of the core. It makes it easy to pull out both ends of the conductive wire.

  In the present invention, means is adopted in which the upper surface of the upper flange and the upper surface of the sleeve are substantially flush with each other, and the adhesive layer is substantially flush with the upper surface of the upper flange. Further, in this aspect, means for allowing a part of the adhesive layer to enter the gap between the upper flange and the sleeve is adopted. Also in this embodiment, the outer shape of the sleeve and the inner shape of the core are circular, and the adhesive applied to the upper surface is allowed to enter the annular gap formed between the two without considering the relative rotational position of the two. Thus, a means of joining both members by an annular bonding portion is adopted.

  Further, in the present invention, the lower surface of the sleeve is positioned higher than the lower surface of the lower flange, and the outer diameter of the conductive wire is between 0.5 to 2.5 times, preferably 1.0 to 2 between them. A height difference of 0.0 times, more preferably 1.0 to 1.5 times is provided. Since the present invention employs the technical idea that the upper surface of the sleeve is flush with the upper surface of the upper flange as described above, by designing the lower surface of the lower flange to be changeable, the conductive wire Even if the outer diameter is changed, the change in the outer shape of the conductive wire is absorbed in the space on the lower surface of the lower flange, and as a result, the conductive wire does not protrude downward from the lower surface of the core and the conductive wire is not damaged.

  Further, in the inductor according to the present invention, even if a plurality of inductors or sleeves are arranged on a flat base plate in the production process or management process by chamfering the upper outer corner of the sleeve, the adjacent chamfered parts are arranged. Make them separable with fingers or using a jig.

  When the present invention is applied to a winding type inductor having a core height of 1.5 mm or less, the above-described functions and effects are more exhibited.

  In the present invention, the inductor having the above structure / shape has a first step of winding a conductive wire around a core having a lower core whose outer shape is smaller than the upper flange existing at the upper end, and the outer shape of the core wound with the conductive wire is square. A second step of relatively inserting the sleeve into the sleeve, a third step of spreading the two leading ends of the conductive wires exposed from the lower flange in a direction away from each other in the horizontal direction, and a tip of the tip portion. A fourth step in which the upper surface of the upper flange and the upper surface of the sleeve are substantially flush with each other, facing the opposite corners of the sleeve, and an adhesive is applied to the upper surface of the upper flange and the upper surface of the sleeve to apply the core A fifth step of integrating the flange and the flange, and welding the tip of the tip to a conductive surface wider than the outer diameter of the conductive wire provided at the bottom corner of the sleeve to form an electrode By a process involving a sixth step, it is prepared.

  In the second step of the manufacturing method, as a method of relatively inserting a core wound with a conductive wire into a sleeve having an outer shape of a square, a method of inserting the core into the sleeve first with the upper flange of the core And any method of inserting the lower flange first can be adopted. However, in order to make the upper surface of the upper flange of the core and the upper surface of the sleeve flush with each other and to apply the adhesive onto them, it is preferable to place the core in the sleeve with the upper flange first. Insert into.

  However, when this method is adopted, the lower flange protrudes from the lower surface of the sleeve, so that the horizontal base plate is provided with a recess for dropping the lower flange on the upper surface, and both ends of the conductive wire exposed on the lower flange side are provided. A base plate having a guide groove for positioning is used.

  The present invention makes it possible to form an inductor having a low profile and a compact shape and structure, and when the inductor is mounted on an electronic circuit board, the winding type has a structure capable of easily recognizing the tip position of the electroded conductive wire. The excellent effect of providing an inductor is exhibited.

It is a partial fracture perspective view of an inductor concerning the present invention. It is sectional drawing of the inductor. It is a reverse view of the inductor. It is principal part sectional drawing which shows the assembly process of the said inductor. It is another sectional view of the inductor. It is the elements on larger scale of the inductor. It is the other partial enlarged view of the inductor. It is the elements on larger scale of FIG. 5 which shows the state before welding a conductive wire. It is principal part sectional drawing which shows the other assembly process of the inductor which concerns on this invention. It is a fragmentary perspective view of the horizontal base board used in the same assembly process. It is principal part sectional drawing which shows the state immediately after assembling an inductor in the other assembly process of the inductor which concerns on this invention. It is principal part sectional drawing which shows the state which made the edge part of an electric conductor into an electrode. It is a perspective view which shows one use condition of the inductor which concerns on this invention. It is a perspective view which shows the other use condition. It is sectional drawing which shows the state in the middle of inserting the core in a sleeve in the other embodiment which concerns on this invention. It is sectional drawing which shows the state which inserted the core in the sleeve. It is sectional drawing which shows another aspect. It is a top view which shows the other aspect regarding the electroconductive surface formed in the back surface of a sleeve. It is a perspective view which shows the other aspect of an inductor. It is a partial fracture perspective view of a prior art.

  Next, the best mode for carrying out the present invention will be described in detail with reference to the drawings. In the following, the “tip” is a short region where a conductive wire is welded to a conductive surface as will be described later. The “tip portion” or “both ends” means a region of the conductive wire that extends outward without being wound around the core other than the conductive wire substantially wound around the core.

  As shown in FIGS. 1 and 2, the inductor 1 according to the present invention basically includes a core 3 around which a conductive wire 2 is wound and a sleeve 4 surrounding the core 3. However, in the inductor 1 according to the present invention, the height H1 of the core 3 is 1.5 mm or less, preferably 1.0 mm, and more preferably 0.85 mm or less. Further, the outer shape of the upper and lower flanges of the core 3 of the inductor 1 and the inner shape of the sleeve are preferably circular. In this aspect, the diameter D1 of the upper flange 5 existing at the upper end and the diameter D2 of the lower flange 6 existing at the lower end are different from each other, and the former is larger than the latter. It is different. Conventionally, as such a low-profile inductor, a so-called multilayer inductor in which conductive wires bent on the plane of a large number of ferrite substrates are printed has been mainstream. Since further improvement cannot be expected, in the present invention, the height H1 of the core 3 is made lower than 1.5 mm so as to further improve the inductor characteristics. Therefore, the feature of the present invention lies in its essence in that it is a winding type inductor, and a low-profile type, particularly, an inductor having a height of 1.5 mm or less is intended to be a compact inductor.

Further, the sleeve 4 of the inductor 1 according to the present invention preferably has a rectangular outer shape, its height H2 is smaller than the core height H1, and its upper surface 9 is substantially the core 3. It can be adjusted to be flush with the upper surface 7 of the upper flange 5. Therefore, it is significantly different from that of the prior art in that the lower surface 10 is arranged so as to be positioned higher than the lower surface 8 of the lower flange 6. In addition, since the sleeve 4 in this embodiment is rectangular, a large number of inductors or sleeves can be arranged and managed on the substrate in the inductor manufacturing process or product management process, so that the production efficiency is improved and the product is improved. It is convenient for management. However, on the other hand, if there is no gap between adjacent inductors or sleeves, it will be difficult to separate the inductors or sleeves one by one from their collection, so the upper outer corner will It is chamfered to form an inclined surface or an inclined curved surface 11 that bulges outward, so that adjacent inductors or sleeves are easily separated from each other.

In addition, as shown in FIG. 3, the outer diameter of the conductive wire 2 is formed by using a known conductive material for the horizontal surface portions of the two opposite corners 12a and 12b on the lower surface 10 of the sleeve 4 according to the present invention. Two conductive surfaces 13a and 13b wider than B are selectively printed and formed. Then, the two end portions 14a and 14b of the conductive wire 2 drawn downward and outward from the outside of the core 3 are welded to the conductive surfaces 13a and 13b printed and formed on the lower surface of the sleeve 4, Inductor electrodes 15a and 15b are formed. Therefore, the conductive wire 2 wound around the core 3 in the inductor 1 according to the present invention is between the outer peripheral surface 17 of the lower flange 6 and the inner peripheral surface 18 of the sleeve 4 and is opposite to the sleeve 4. After descending from above to below at a position substantially on the imaginary line L connecting the two corners 12a and 12b, it bends at a substantially right angle at the inner corner on the lower side of the sleeve 4 and then toward the two corners 12a and 12b. Extending radially outward.

  The gap G formed by the outer peripheral surface 17 of the lower flange 6 and the inner peripheral surface 18 of the sleeve 4 is specified as follows. That is, as shown in FIGS. 4 and 5, the sleeve 4 is placed on one horizontal base plate 22 by being inverted, and the core 3 around which the conductive wire 2 is wound is inserted into the sleeve 4. When the upper flange 5 of the core 3 is turned down and the inner peripheral surface 18 of the sleeve 4 is inscribed in the outer peripheral surface 19, a horizontal gap G is formed between the inner peripheral surface 18 and the outer peripheral surface 17. Can do. In the present invention, the gap K of the gap G is made slightly larger than the outer diameter B of the conductive wire 2. In this way, when carrying out the method of the present invention, which will be described later, the relative positional relationship between the core 3 and the sleeve 4 can be reliably determined, and the conductive wire 12 drawn out from the gap G can be reliably positioned. To do. That is, the position of the inner peripheral surface 18 of the sleeve 4 in which the tip of one conductive wire 2 is inscribed with respect to the outer peripheral surface 19 is m1, and the other tip is at a position m2 rotated 180 degrees from the position m1. If the portion is derived, the two tip portions are positioned on the diagonal L connecting the two corners 12a and 12b.

  Next, the height relationship between the core 3 and the sleeve 4 in the inductor 1 will be described. As shown in FIGS. 1, 2, and 6, the sleeve 4 is bonded to the core 3 through an adhesive layer 23. At the same time, since the upper surface 7 of the core 3 is substantially flush with the upper surface 9 of the upper flange 5, the lower surface 10 of the sleeve 4 having a height H 1 lower than the height H 2 of the core 3 is It is higher than the lower surface 8 of the lower flange 6 by at least a height difference C. Further, as shown in FIG. 7, the adhesive layer 23 includes a planar adhesive layer 23 a that is commonly bonded to the upper surface 7 of the upper flange 5 and the upper surface 9 of the sleeve 4, and an inner peripheral surface 18 of the sleeve 4. A part of the planar adhesive layer 23a flows into the annular gap I formed between the outer peripheral surface 19 of the upper flange 5 and the annular adhesive layer 23b formed. In addition, as shown in FIG. 7, by making the opening of the annular gap I into a funnel-shaped cross section, the annular adhesive layer 23b can be easily formed, and when the annular adhesive layer 23b is formed, The effect | action which spaces apart the outer peripheral surface 19 of the upper flange 5 inscribed in the surrounding surface 18 can be exhibited.

  The degree to which the lower surface 10 of the sleeve 4 according to the present invention is at least higher than the lower surface 8 of the lower flange 6 by the height difference C is, as shown in FIGS. 6 and 8, the thickness A of the conductive surfaces 13a and 13b of the lower surface 10. It is determined on the basis of the sum of the outer diameter B of the conductive wire 2. When the height difference C is abnormally smaller than the sum, when the core 3 is inserted into a sleeve 4 placed on a horizontal base plate, which will be described later, the top surfaces of the core 3 and the sleeve 4 cannot be made substantially the same level. As a result, when the electrode 2 is formed by welding the tip of the conductor 2 to be described later to the conductive surfaces 13a and 13b, a large space is formed between the electrode and the land on the electronic circuit board, and the two are joined together. Loss is likely to occur. On the contrary, if the height difference C is abnormally larger than the sum, the conductive wire 2 protrudes significantly from the lower surface 8 of the lower flange 6. In the present invention, since the thickness A of the conductive surfaces 13a and 13b is very small, ignoring the value and quantifying the degree of the height difference C is 0. 0 of the outer diameter B of the conductive wire 2. The range is 5 to 2.5 times, preferably 1.0 to 2.0 times, and more preferably 1.0 to 1.5 times.

Next, referring to a method for manufacturing an inductor having the above-described structure, that is, one assembling method, the method for manufacturing an inductor according to the present invention basically has a lower flange whose outer shape is smaller than that of the upper flange present at the upper end. A first step of winding a conductive wire around the core, a second step of relatively inserting the core around which the conductive wire is wound into a sleeve having a rectangular outer shape, and a conductive wire exposed from the lower flange. A third step of spreading the two tip portions in the horizontal direction away from each other, directing the tips of the tip portions to opposing corners of the sleeve, and making the upper surface of the upper flange and the upper surface of the sleeve substantially flush with each other A fourth step of aligning, a fifth step of integrating the core and the flange by applying an adhesive to the upper surface of the upper flange and the upper surface of the sleeve; Welded to the wide conductive surface than the outer diameter of the conductive wire disposed on the upper, lower corner of the sleeve, including a sixth step of electroded. Each of the steps will be described with reference to the drawings with respect to an aspect in which a core having an outer shape of the upper and lower flanges is inserted into a sleeve having a circular inner shape.
(First step)

As shown in FIG. 9 and FIG. 10, a core 3 having a lower flange 6 having an outer shape smaller than the upper flange 5 present at the upper end is prepared, and a conductive wire 2 is wound around the core 3 by a predetermined amount artificially or mechanically. Thus, measures are taken so that the unwinding of the portion where the conductive wire is not wound is not propagated to the region where the conductive wire 2 is wound, and at this time, preferably, the core 3 is exposed outward. The conductive wire 2 is cut so that the end portions 14a and 14b of the conductive wire 2 have a predetermined length.
(Second, third and fourth steps)

  Next, the sleeve 4 having conductive surfaces 13a and 13b printed on the two opposite corners 12a and 12b is prepared, and the lateral width is determined by the length of the diagonal line passing through the corners 12a and 12b on the lower surface 10 of the sleeve 4. A short strip-shaped horizontal base plate 22 is prepared. The base plate 22 has a recess 26 into which the lower flange 6 is dropped and two guide grooves 27 for positioning the conductive wires 2 extending in the width direction on the upper surface side. Then, the core 3 around which the conductive wire 2 is wound is placed on the horizontal base plate 22, and the leading end portions 14 a and 14 b of the conductive wire 2 are fitted into the guide groove 27 for positioning.

  Next, the sleeve 4 is extrapolated from the outside of the core 3, and at the same time, the two opposite corners 12 a and 12 b of the sleeve 4 are directed in the width direction of the horizontal base plate 22. In this case, the sleeve 4 is inserted first from the upper flange 5 of the core 3, and the one having the conductive surfaces 13a and 13b is selected as the corners 12a and 12b.

In this way, finally, as shown in FIG. 11, the top surface 7 of the upper flange 5 and the top surface 9 of the sleeve 4 are flush with each other, and the two tips of the conductive wire 2 exposed from the lower flange 6 14a and 14b are extended toward the corners 12a and 12b which are in the direction away from each other in the horizontal direction. In this embodiment, the second step, the third step and the fourth step described above proceed almost simultaneously. Therefore, in the present invention, the above-described steps are not interpreted in a limited order.
(Fifth process)

  After the fourth step, the tips of the leading ends 14a and 14b of the conductive wire 2 face the opposite corners 12a and 12b of the sleeve 4, and the upper surface 7 of the upper flange 5 and the upper surface 9 of the sleeve 4 are substantially flush with each other. Therefore, an adhesive is applied to the upper surfaces 7 and 9, and the upper flange 5 and the flange 4 of the core 3 are integrated as shown in FIGS. 1, 2, and 7.

Then, a plate-like adhesive layer 23 a is formed on the upper surfaces 7 and 9, and an annular adhesive in which a part of the adhesive enters the annular gap I formed between the upper flange 5 and the flange 4. Layer 23b is formed. In addition, although what has a thermosetting type or a thermoplastic resin as a main component can be used as an adhesive agent, the former is used suitably. On the plate-like adhesive layer 23a, the product symbol, the manufacturer name, etc. of the inductor according to the present invention are printed.
(Sixth process)

  In this way, when the inductor 1 in which the core 3 and the sleeve 4 are integrated is formed, the inductor 1 is inverted and the lower surface of the sleeve 4 shown in FIG. The tip of 14b comes to be located on the conductive surfaces 13a and 13b formed by printing on the opposite corners 12a and 12b of the sleeve 4. Therefore, using a known welding means, one core wire constituting the conductive wire 2 is melted together with the coating resin while pressing the tip of the conductive wire 2 against the conductive surfaces 13a and 13b. Since the width of the conductive surfaces 13a and 13b in the direction perpendicular to the conductive wire 12 is larger than the outer diameter B of the conductive wire 2, the tip is securely connected to the conductive surfaces 13a and 13b as shown in FIG. To be two external electrodes in the inductor 1 according to the present invention.

  In the inductor 1 thus obtained, the conductive surface, which is a component of the external electrode, is formed on the lower surface of the sleeve 4, so that a substrate for providing the conductive surface is not required unlike the known technique, and as a result, the inductor according to the present invention. Becomes a low profile that is limited only by the height of the core. Since the conductive wire in the inductor is extended from the core to the conductive surface at the shortest distance to simplify the fit, the inductor becomes very compact.

  Since the conductive surface that forms the external electrode in cooperation with the tip of the conductive wire is provided at the corner having the largest area on the lower surface of the sleeve, the welding range of the tip of the conductive wire with respect to the conductive surface is expanded. The degree of freedom for forming the external electrode is increased. In addition, the position of the external electrode formed at the corner can be recognized from above or obliquely above the inductor due to the presence of the corner. Printing can be performed on the planar adhesive layer formed on the top surface of the inductor,

  As shown in FIG. 13, when printing 28 is applied to the surface of the inductor 1, if the printed surface is read and the presence of the corner is read artificially or mechanically, the inductor 1 according to the present invention can be obtained. It becomes easy to mount the two corners 12a and 12b of the inductor 1 on the lands 21a and 21b by mounting on the electronic circuit board. In this embodiment, the prints 28 can be arranged in the direction in which the lands 21a and 21b are oriented. As shown in FIG. 14, markers having arbitrary shapes are formed at the two corners 12a and 12b where the external electrodes 15a and 15b exist. If 29a and 29b are provided, the inductor can be accurately placed at a predetermined position. As a result, the positions where the external electrodes 15a and 15b are present can also be indicated. By doing in this way, the external electrodes 15a and 15b of the inductor 1 according to the present invention can be made to coincide with the positions of the lands 21a and 21b of the electronic circuit board. As a result, both are securely soldered. In these embodiments, the markers 29a and 29b can be omitted by making the direction of the printing 28 coincide with the directions of the two corners 12a and 12b.

The present invention can be carried out as follows by changing a part of the embodiment as long as the fundamental technical idea is followed and the effect of the invention is not significantly impaired.
(1) As shown in FIG. 15, the sleeve 4 is inverted and placed on the horizontal base plate 22, and the core 3 around which the conductive wire 2 is wound is placed on the sleeve 4 with the upper flange 5 first. It is also possible to insert the core 3 into the sleeve 4 as shown in FIG. 16 and then form the external electrodes, and finally invert them again to bond them as shown in FIG. In this embodiment, when the core 3 is inserted into the sleeve 4, the inner peripheral surface 18 of the sleeve 4 is inscribed with respect to the outer peripheral surface 19 of the upper flange 5, and the inner peripheral surface 18 and the outer peripheral surface 17 are in between. A horizontal gap G is formed, and the outer diameter of the upper flange and the inner diameter of the sleeve are determined so that the gap K of the gap G is slightly larger than the outer diameter B of the conductive wire 2. When carrying out the method of the present invention, it is possible to reliably determine the relative positional relationship between the core 3 and the sleeve 4 and to ensure the positioning of the conductive wire 12 drawn out from the gap G. In this embodiment, as shown in FIG. 17, an adhesive 25 can be applied on the horizontal base plate 22 in advance.

(2) As shown in FIG. 18, conductive layers 13a, 13b, 13c, and 13d may be formed at the four corners 12a, 12b, 12c, and 12d on the lower surface of the sleeve 4.
(3) As shown in FIG. 19, the inner shape of the sleeve 4 and the outer shapes of the upper and lower flanges 5 and 6 of the core 3 are similar to the inner shape, as long as the outer shape of the sleeve 4 is maintained square. It can also be.

(4) Further, although not shown, a guide groove for guiding and positioning the tip portions 14a and 14b of the conductive wire 2 can be provided on the lower surface of the sleeve 4 instead of the horizontal base plate.
(5) Further, as a method of cutting the conductive wire 2 tip portions 14a and 14b to a predetermined length, when the middle of the tip portions 14a and 14b is fused to the conductive surfaces 13a and 13b, the molten state immediately after the fusion The conductive wire can also be cut by a method of tearing the underlying conductive wire, a so-called fusing method.

  INDUSTRIAL APPLICABILITY The present invention can be widely used in a method for manufacturing a so-called wound inductor that includes a core around which a conductive wire is wound and a sleeve surrounding the core.

1: Inductor 2: Conductive wire 3: Core 4: Sleeve 5: Upper flange,
6: Lower flange 7: Upper surface 8: Lower surface 9: Upper surface 10: Lower surface
11: Inclined surfaces 12a, 12b: Corners 13a, 13b: Conductive surfaces 14a, 14b: Tip portions 15a, 15b: Electrodes 17: Outer peripheral surface 18: Inner peripheral surface 19: Outer peripheral surface 20: Electronic circuit boards 21, 2, aa, 21b: Land 22: Horizontal base plate 23: Adhesive layer 23a: Flat adhesive layer 23b: Annular adhesive layer 24: Upper surface 25: Adhesive 26: Recess 27: Guide groove 28: Print 29: Marker 50: Inductor 51: Conductive wire ,
52: Core,
53: Sleeve,
54: substrate
55: Conductive surface,
56: End face A: Thickness B: Outer diameter C: Height difference D1, D2: Diameter E: Interval F: Interval G: Gap H1, H2: Height K: Interval G: Gap L: Virtual line m1: First part m2 : Second part.

Claims (8)

The core (3) around which the conductive wire (2) is wound , having upper and lower flanges (5, 6) each having a circular outer shape, and the outer shape form a square, while the inner shape is the core A sleeve (4) with a circular inner bore having a constant diameter larger than the diameter of the circular outer shape of the upper and lower flanges , and by receiving the core in the inner bore of the sleeve, the sleeve In the inductor (1) that surrounds the core at
The outer diameter (D2) of the lower flange (6) of the core (3) is made smaller than the outer diameter (D1) of the upper flange (5) so that the inner periphery of the inner flange of the lower flange of the core and the sleeve Through the gap (G) formed between the two surfaces, the two leading ends of the conductive wires (2) extending from the core are respectively taken out outward, and the leading ends of the two conductive wires are further connected to the sleeve. The electrodes are formed by welding to the conductive surfaces (13a, 13b) wider than the outer diameter (B) of the conductive wires, which are printed on the lower surfaces of the two opposite corners (12a, 12b) .
The upper surface (7) of the upper flange (5) of the core (3) and the upper surface (9) of the sleeve (4) are flush with each other, and an adhesive is applied over both the upper surfaces. Thus, in addition to the planar adhesive layer (23a) formed on the upper surface, a part of the adhesive is allowed to enter only the annular gap (I) between the upper flange and the sleeve, thereby the annular adhesive. Layer (23
The inductor according to claim 1, wherein the core and the sleeve are joined and integrated . One conductive surface (13a) of the two conductive surfaces (13a, 13b) straddles both lower surfaces of one opposite corner (12a) and one adjacent corner (12c) of the sleeve. And the other conductive surface (13b) extends across the lower surfaces of the other opposite corner (12b) of the sleeve and the remaining corner (12d) adjacent thereto. The inductor according to claim 1, wherein the two conductive surfaces (13a, 13b) are positioned symmetrically on the lower surface of the sleeve .   Between the outer peripheral surface (17) of the said lower flange (6) and the inner peripheral surface (18) of a sleeve (4), the front-end | tip part (14a, 14b) of the electrically conductive wire (2) wound around the said core (3) ) Is moved downward from above, and the middle of the tip is bent outward, and then the tip of the tip is extended toward the two opposite corners (12a, 12b) of the sleeve. The inductor according to claim 1 or 2, wherein the inductor is formed.   The position on the horizontal plane that bends the middle of the tip (14a, 14b) of the conductive wire (2) is on or near the virtual line (L) that virtually connects the two corners (12a, 12b). The inductor according to claim 3, wherein The annular gap (I) is located above the upper corner of the inner hole of the sleeve (4) and the core (3).
5. The funnel according to claim 1 , further comprising an opening having a funnel-shaped cross section that opens upward by an inclined surface formed at each of the upper corners of the flange portion (5) . Inductor. The inductor according to any one of claims 1 to 5 , wherein a height (H2) of the core (3) is 1.5 mm or less. Upper and lower flanges (5, 6) each having a circular outer shape are provided at the upper and lower ends, and the outer diameter (D2) of the lower flange (6) is smaller than the outer diameter (D1) of the upper flange (5). the core (3) made of Te, a first step of winding the conductive wire (2),
A core in which the conductive wire is wound, while the outer shape forming a square, sleeve inner shape with a hole inside a circle having the upper and lower larger constant diameter than the diameter of the circular contour of the flange of the core ( A second step of relatively inserting into the inner hole of 4),
A third step of spreading the two ends of the conductive wire exposed from the lower flange in a direction away from each other in the horizontal direction;
The upper surface (7) of the upper flange (5) of the core (3) and the upper surface (9) of the sleeve (4) are flush with each other, and an adhesive is applied to both of the upper surfaces. Accordingly, a part of the adhesive is allowed to enter only the annular gap (I) between the upper flange and the sleeve to form the annular adhesive layer (23b), and the core and the sleeve are joined and integrated. And a fourth step to
The tip of the front Symbol tip corner (12a, 12b) facing each of said sleeve with directing, wide conductive surface than the outer diameter (B) of conductive lines disposed on the upper, lower corner of the sleeve (13a, A fifth step of welding to 13b) to form an electrode ;
A method for manufacturing an inductor, comprising: Upper and lower flanges (5, 6) each having a circular outer shape are provided at the upper and lower ends, and the outer diameter (D2) of the lower flange (6) is smaller than the outer diameter (D1) of the upper flange (5). the core (3) made of Te, a first step of winding the conductive wire (2),
A core in which the conductive wire is wound, while the outer shape forming a square, sleeve inner shape with a hole inside a circle having the upper and lower larger constant diameter than the diameter of the circular contour of the flange of the core ( a process to insert into the inner bore of 4), with respect to the vertical inverted and placed on the inner hole of the sleeve on a horizontal base plate, said core, with its upper flange to the lower A second step to be inserted ;
A third step of spreading the two ends of the conductive wire exposed from the lower flange in a direction away from each other in the horizontal direction ;
The tip of the front Symbol tip corner (12a, 12b) facing each of said sleeve with directing, wide conductive surface than the outer diameter (B) of conductive lines disposed on the upper, lower corner of the sleeve (13a, A fourth step of welding to 13b) to form an electrode ;
A fifth step in which the sleeve into which the core is inserted is inverted again so that the upper flange of the core is positioned upward and the conductive surface of the sleeve is positioned downward;
The upper surface (7) of the upper flange (5) of the core (3) and the upper surface (9) of the sleeve (4) are flush with each other, and an adhesive is applied to both of the upper surfaces. Accordingly, a part of the adhesive is allowed to enter only the annular gap (I) between the upper flange and the sleeve to form the annular adhesive layer (23b), and the core and the sleeve are joined and integrated. A sixth step to
A method for manufacturing an inductor, comprising:

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