JP6549779B2 - Coil component, method of manufacturing the same, electronic device - Google Patents

Description

  The present invention relates to a coil component, a method of manufacturing the same, and an electronic device, and more particularly to a lead-out structure of an air core coil.

  With the advancement of high performance of electronic devices including portable devices, high performance is also required for parts used in the electronic devices. However, with the advancement of the performance of electronic devices, the number of parts is also increased, and therefore, the movement toward miniaturization of the parts themselves is increasing. The same is true for coil components with high current characteristics using windings, and measures to reduce the size more than ever have been studied.

  In order to obtain high current characteristics, there have been many coil parts using a rectangular lead, which is also called a flat wire. However, although the formation of the winding portion of the air core coil is relatively easy, it is not easy to stably connect the lead portion to the terminal electrode, and a method of forming the lead portion in a direction in which the lead wire is easily drawn. Has been taken. For example, as shown in FIGS. 8 and 9 of Patent Document 1 below, a tablet formed in a shape having a columnar convex portion at the peripheral portion of a flat plate shape is a wire having a rectangular cross section. A structure is shown in which a wound coil is placed, and both ends of the coil are placed along the outer side surface of the columnar convex portion of the tablet, and a part of the coil is exposed from the sealing material to connect with an external electrode. .

Unexamined-Japanese-Patent No. 2010-245473 (FIG. 8, FIG. 9)

  In the technique described in Patent Document 1 described above, in order to stabilize the lead portion, molding is performed using a tablet as shown in FIG. 8 of the same document and positioning the lead portion using this surface. , It is possible to stabilize the withdrawal position. However, as shown in FIG. 9 of the same document, a large space (see “12a” in FIG. 9) is required outside the air core coil, and in the coil component of the type embedded in the magnetic body, It has been a limitation in promoting miniaturization. For this reason, securing the stability of the drawing-out position at the time of magnetic body formation had become a subject, making space-saving a drawing-out part.

  The present invention focuses on the above points, and in the air core coil, it reduces the space of the lead-out portion to achieve miniaturization, and a coil component having high stability of the lead-out position at the time of forming the magnetic body It aims at providing the manufacturing method. Another object is to provide an electronic device using the coil component.

  The coil component of the present invention is formed of metal magnetic particles and a resin, and a rectangular magnetic body having a long side and a short side on the side mounted on a substrate is in contact with one long side surface of the cross section of the flat wire. And a winding portion formed by repeatedly winding a flat wire so as to be superimposed on the wound flat wire, and being embedded in the magnetic body, and the winding portion on one long side of the magnetic body When the surface of the magnetic body formed from the leader drawn out from the outer peripheral surface and the end of the leader and mounted on the substrate is divided into four areas by two diagonal lines, the four areas A pair of lead-out portions which are respectively included in the two short side sides of the above and further drawn out to the outside of the magnetic body from a position closer to one long side of the magnetic body in the two areas Air core coil, and the lead-out portion and the electrical Viewed from the surface of the magnetic body mounted on the substrate, in other words, viewed through the surface of the magnetic body, the pair of terminal electrodes being connected to each other The lead-out portion is at a position in contact with the outer circumferential surface of the circumferential portion, and the circumferential portion with respect to the area S1 of the magnetic material outside the circumferential portion when seen through the surface of the magnetic body mounted on the substrate. The ratio S3 / S1 of the area S3 of the inner side magnetic body is set to 0.38 or more.

  One of the main modes is characterized in that the electrical connection portion between the pair of lead portions and the pair of terminal electrodes is formed only on the surface mounted on the substrate. Still another aspect is characterized in that the inner peripheral shape of the circumferential portion seen through the surface of the magnetic body mounted on the substrate is an oval or a rounded rectangle. Alternatively, the pair of terminal electrodes are formed on the surface of the magnetic body mounted on the substrate.

  An electronic device according to the present invention is characterized by including any one of the above coil components. The method of manufacturing a coil component according to the present invention comprises a rectangular magnetic body formed of metal magnetic particles and a resin and having long sides and short sides on the side mounted on a substrate, and one long side of a cross section of a rectangular wire. A flat wire is wound so that the surfaces are in contact, and a flat wire is repeatedly formed so as to be superimposed on the wound flat wire, and a winding portion to be embedded in the magnetic material and the long side of the magnetic material The lead wire drawn from the outer peripheral surface of the circumferential portion and the end of the lead wire, when the surface of the magnetic body mounted on the substrate is divided into four areas by two diagonal lines, A pair of the two areas which are respectively included in two areas on the short side of the four areas and further drawn out of the two areas from the position closer to one long side of the magnetic body in the two areas. An air core coil having a lead-out portion; And the pair of terminal electrodes electrically connected to each other, and viewed through the surface of the magnetic body mounted on the substrate, the pair of lead-out portions are the outer peripheral surface of the circumferential portion A method of manufacturing a coil part characterized in that the conductor parts drawn from both ends of the circumferential portion have crossing portions when viewed from the direction of the coil axis formed by the circumferential portion. However, a predetermined gap is formed between the outer circumferential surface of the winding portion and the outer circumferential surface of the winding portion toward the end of the conducting wire, and is directed in the opposite direction and parallel to each other. Forming a pair of lead wires and bending the end portions of the pair of lead wires to form a pair of lead portions extending in the same direction in parallel with the coil axis. The intersection of the two processes and the pair of leader lines is curved A third step of processing and extending along the outer peripheral surface of the peripheral portion, and bending the pair of lead portions into contact with the outer peripheral surface of the peripheral portion while maintaining parallel to the coil axis When setting the air core coil formed in the first to fourth steps in a mold while monitoring the process and the positions of the peripheral portion and the pair of lead portions, and embedding a magnetic material made of metal particles and resin The ratio S3 / S1 of the area S3 of the magnetic body inside the circumferential portion to the area S1 of the magnetic body outside the circumferential portion is seen through the surface of the magnetic body mounted on the substrate. And a fifth step of forming the magnetic body so as to be 0.38 or more.

  Another coil component manufacturing method of the present invention is a rectangular magnetic body formed of metal magnetic particles and a resin and having long sides and short sides on the side mounted on a substrate, and one long side of a cross section of a flat wire. The flat wire is wound so that the side faces are in contact, and a rectangular wire is repeatedly formed so as to be superimposed on the wound flat wire, and a circumferential portion embedded in the magnetic material, and one long side of the magnetic material When the surface of the magnetic body formed from the lead wire drawn from the outer peripheral surface of the circumferential portion in the above and the end of the lead wire and mounted on the substrate is divided into four areas by two diagonal lines And are respectively included in two areas on the short side of the four areas, and are drawn to the outside of the magnetic body from a position closer to one long side of the magnetic body in the two areas. An air core coil having a pair of lead portions; And a pair of terminal electrodes electrically connected to the projecting portion, and viewed through the surface of the magnetic body mounted on the substrate, the pair of lead-out portions is the circumferential portion A method of manufacturing a coil component characterized by being in contact with the outer peripheral surface of the coil, wherein the conductor is wound to form the circumferential portion, and viewed from the axial direction of the coil formed by the circumferential portion; Each conducting wire drawn out from both ends of the winding portion is pulled out in a direction away from the outer circumferential surface of the winding portion while having a crossing portion, and further toward the end of the conducting wire and between the outer circumferential surface of the winding portion A first step of forming a predetermined gap, bending in opposite directions and in parallel to form a pair of leader lines, and bending an end side of the pair of leader lines, the coil Forming a pair of lead-outs parallel to the axis and directed in the same direction And a third step of bending the pair of lead portions so as to be in contact with the outer peripheral surface of the circumferential portion while maintaining the pair of lead portions parallel to the coil axis, and bending a crossing portion of the pair of lead wires Setting the air core coil formed in the first to fourth steps in a mold while monitoring the fourth step extending along the outer circumferential surface of the circumferential portion and the positions of the circumferential portion and the pair of lead portions When embedding a magnetic material made of metal particles and a resin, the surface of the magnetic material mounted on the substrate is seen through the surface of the magnetic material relative to the area S1 of the magnetic material outside the magnetic material. And a fifth step of molding the magnetic body such that the ratio S3 / S1 of the area S3 of the inner magnetic body is 0.38 or more. The above and other objects, features and advantages of the present invention will be apparent from the following detailed description and the accompanying drawings.

  According to the present invention, a rectangular magnetic body formed of metal magnetic particles and resin and having a long side and a short side on the side mounted on the substrate is in contact with one of the long side surfaces of the cross section of the rectangular wire. And the winding portion is formed by winding a flat wire repeatedly so as to be superimposed on the wound flat wire, and a winding portion embedded in the magnetic body, and an outer periphery of the winding portion on one long side of the magnetic body When the surface of the magnetic body formed from the leader drawn out from the surface and the end of the leader and mounted on the substrate is divided into four areas by two diagonal lines, the four areas It has a pair of lead parts which are respectively included in two areas on the short side of the two, and further drawn to the outside of the magnetic body from a position closer to one long side of the magnetic body in the two areas. Electrically connected to the air core coil and the lead out part And the pair of lead-out portions are in contact with the outer peripheral surface of the circumferential portion when seen through the surface of the magnetic body mounted on the substrate. . For this reason, the pair of lead-out portions are disposed near the short side of the magnetic body, and space saving of the lead-out portions can be achieved. Thereby, the ratio of the magnetic material outside the air core coil can be reduced, and waste magnetic material can be reduced. As a result, current characteristics can be enhanced. In addition, the ratio S3 / S1 of the area S3 of the inner side of the circumferential part to the area S1 of the outer side of the circumferential part is 0.38 or more, the area S1 of the outer side of the circumferential part is 1.3 to 1.8 of the prior art. This can be doubled, and the inductance can be easily obtained by increasing the cross sectional area of the magnetic path. Moreover, the polishing process of the lead-out portion is easy, and the stability of the lead-out position can be enhanced. In addition, by stabilizing the position of the lead portion, connection stability with the terminal electrode can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows the coil components of Example 1 of this invention, (A) is a top view, (B) is a side view which looked at said (A) from arrow F1 direction, (C) is a flat wire which forms a coil. It is a figure which shows the cross-sectional shape of. It is a figure which shows the manufacturing procedure of the circumference | surroundings part of the air core coil of this invention. It is a figure which shows the manufacture procedure of the extraction part of the air core coil of this invention. It is a figure which shows the specific example of the air core coil of this invention, (A) and (B) is a figure which shows the planar shape of the air core coil manufactured by the manufacturing method of Example 1, (C)-(E) It is a figure which shows the planar shape of the air core coil manufactured by the manufacturing method of Example 2. FIG. It is a top view which shows the example of this invention. It is a table | surface which shows the area ratio of the magnetic body inner side of the circumference | surroundings part by the difference of the dimension of the specific example of this invention, and a comparative example, and the circumference | surroundings part outer side.

  Hereinafter, the best mode for carrying out the present invention will be described in detail based on examples.

  First, the basic structure of the coil component of the present invention will be described with reference to FIG. FIG. 1 is a view showing a coil component of Example 1, (A) is a plan view, (B) is a side view of (A) viewed from the direction of arrow F1, and (C) forms an air core coil. It is a figure which shows the cross-sectional shape of the rectangular wire to As shown in FIG. 1A, the coil component 10 of the present embodiment is called a chip type, and has a configuration in which an air core coil 20 is embedded in a rectangular solid magnetic body 12 having long sides and short sides. It has become. Specifically, it is a small coil component having a long side of 2.0 mm or less. The magnetic body 12 is formed of a resin and metal particles. The magnetic body 12 has terminal electrodes 14 and 16 on both sides of the surface (the surface shown in FIG. 1A) on the side mounted on the substrate (not shown). The portions 26A and 26B are connected to the terminal electrodes 14 and 16, respectively.

  In the present invention, the magnetic body 12 is in the form of a rectangular parallelepiped and has long sides 12A and 12B and short sides 12C and 12D, and the surface mounted on the substrate is represented by two diagonal lines DA and DB. It can be divided into four areas. That is, it is divided into areas EL1 and EL2 on the long side 12A and 12B side and areas ES1 and ES2 on the short side 12C and 12D side. The pair of lead portions 26A, 26B are included in the areas ES1, ES2 on the short side 12C, 12D. Here, "included" means that the drawers 26A and 26B are attached to the diagonal lines DA and DB and a part thereof is in the areas ES1 and ES2, and the areas ES1 and ES2 are completely contained. Both cases are included. An example completely contained will be described in a specific example described later.

  Next, a method of manufacturing the coil component of the first embodiment will be described with reference to FIGS. 2 and 3. FIG. 2 is a view showing the winding procedure of the air core coil, and FIG. 3 is a view showing the formation procedure of the lead-out portion of the air core coil. Note that FIG. 3 (C-2) to (E-2) will be described in the second embodiment. In this embodiment, as a wire for winding the air core coil 20, as shown in FIG. 1C, the cross section of the wire called a flat wire has long sides 30C and 30D and short sides 30A and 30B. The square was used with a coating for insulation on the surface of the wire. The air core coil 20 is formed of a winding portion 22 in which the flat wire 30 is overlapped and wound, and lead portions 26A and 26B connecting the winding portion 22 and the terminal electrodes 14 and 16. The formation of the circumferential portion 22 was performed by a method called alpha winding.

  Specifically, in order to make the air core coil 20, as shown in FIG. 2 (A), an iron core 40 called an oval (oval type) is prepared, and around the iron core 40, the above flat wire is prepared. The flat wire 30 is repeatedly wound so as to be in contact with one of the long side surfaces of the cross section of the cross section 30 and further to be superimposed on the wound flat wire 30. That is, the flat wire 30 overlaps from the inner side to the outer side to form the circular portion 22. At this time, the rectangular wire 30 has a length necessary to form the peripheral portion 22 and the lead portions 26A and 26B, and the respective lead portions 26A and 26B are formed from both ends of the flat wire 30. The middle point of the part where the necessary length is drawn is applied to the iron core 40 as shown in FIG. 2A, and both ends of each flat wire 30 are wound around the iron core 40 in the opposite direction. It is wound by moving it.

  By winding in the opposite direction around the iron core 40 as the winding direction, the winding portion 22 in which the winding portions 22A and 22B having the reverse winding direction are continuous is formed (FIG. 2 (B) And (C)). The inner circumferential shape of the orbiting portion 22 obtained as described above is formed by the orbiting portion 22 of the air core coil 20 using an iron core 40 of oval cross section (oval type) as a winding axis of the flat wire 30. The coil shaft 29 (see FIG. 1A) has an inner circumferential shape in the axial direction of the coil shaft 29 such that two semicircular arcs are at the end of the two linear long axes LA, and the short axis LB It has an oval shape.

  Next, the lead portions 26A and 26B are formed on both ends of the circumferential portion 22. First, both ends of the circumferential portion 22 are pulled out so as to intersect as seen from the axial direction of the coil shaft 29. That is, the end portions 28A and 28B of the lead wires 24A and 24B are drawn away from the coil axis 29 when viewed from the short axis LB side. Then, as shown in FIG. 3A, the end portions 28A and 28B of the pair of lead wires 24A and 24B are separated from the outer peripheral surface of the circumferential portion 22 by one or more conductive wires (space d) and parallel to each other The lead wires 24A and 24B are subjected to bending so as to be (1st forming). Specifically, as shown in FIG. 3A, bending is performed at the intersections 23A and 23B of the lead wires 24A and 24B and the positions PA and PB at the roots of the lead portions 26A and 26B.

  Next, as shown in FIG. 3B, the pair of lead wires 24A and 24B are bent in the same direction at positions PA and PB which become the roots of the lead portions 26A and 26B, and are parallel to the coil axis 29 A pair of lead portions 26A and 26B are formed (second forming). Then, as shown in FIG. 3 (C-1), the intersections 23A and 23B of the pair of lead wires 24A and 24B are bent and processed into a planar shape along the outer peripheral surface of the circumferential portion 22. (Third forming).

  Then, as shown in FIG. 3 (D-1), the pair of lead wires 24A, 24B are brought close to the circumferential portion 22 while keeping the pair of lead portions 26A, 26B parallel to the coil shaft 29. 24B is bent (fourth forming). The air core coil 20 in which the lead portions 26A and 26B are formed as described above is set in a mold while monitoring the positions of the circumferential portion 22 and the pair of lead portions 26A and 26B (FIG. 3 (E-1 ), Molding is performed using a magnetic material obtained by kneading metal particles and a resin (molding step).

  As described above, according to the first embodiment, the air core coil 20 having the winding portion 22 around the conducting wire and the pair of lead portions 26A and 26B drawn from both ends of the winding portion 22 is made of metal particles and resin In the coil component 10 having a pair of terminal electrodes 14 and 16 embedded in the magnetic body 12 and connected to the pair of lead portions 26A and 26B, the magnetic body 12 is a rectangular solid having a long side and a short side. When the surface of the magnetic body 12 mounted on the substrate is divided into four areas by two diagonal lines DA and DB, the pair of lead portions 26A and 26B are included in the four areas. The following two effects can be obtained since they are respectively included in the two areas ES1 and ES2 on the short side of.

(1) The pair of lead portions 26A, 26B is disposed near the short side of the magnetic body 12, and space saving of the lead portions 26A, 26B can be achieved. Thereby, the ratio of the magnetic material outside the air core coil 20 can be reduced to reduce the amount of waste magnetic material. This leads to the enlargement of the air core coil 20 within the product size, and the difference between the ratio of the magnetic material outside the air core coil 20 and the ratio of the magnetic material inside the air core coil 20 can be reduced, resulting in the current The characteristics can be enhanced. Specifically, the ratio “S3 / S1” of the inner circumference S3 of the circumferential portion to the area S1 outside the circumferential portion can be 0.38 or more. The ratio of S3 on the inner side of the orbiting portion can be made higher than before.
(2) By forming the lead portions 26A, 26B according to the above-described procedure, the lead portions 26A, 26B can be easily polished and processed, and the lead portion 26A can be accurately and surely by a relatively simple method. , 26B can be exposed on the surface of the magnetic body. Further, since positional accuracy of the lead portions 26A, 26B can be easily obtained, positioning in the embedding step can be performed in the magnetic body while monitoring the lead portions 26A, 26B, so that assembly accuracy is good, and terminal electrodes reliably. It can be connected with 14, 16. This is because, if the amount of polishing is insufficient in the lead-out portion of the above-mentioned prior art, the exposure of the lead-out portion becomes insufficient, and conversely, the lead-out position may change when it is over-sharpened. It is because such an inconvenience does not occur.
(3) Since the inner circumferential shape of the circumferential portion 22 is oval (oval), the ratio of the inner circumferential area can be further increased to contribute to the improvement of the current characteristics.

  Next, a second embodiment of the present invention will be described. In addition, suppose that the same code | symbol is used for the component the same as Example 1 mentioned above thru / or respond | correspond (the same may be said of the following specific examples). In the first embodiment described above, after forming the pair of lead portions 26A and 26B, the intersections 23A and 23B are bent so as to be flat along the outer peripheral surface of the circumferential portion 22 (Example 1) And forming the lead wires 24A and 24B so that the lead portions 26A and 26B approach the winding portion 22 (fourth forming in Example 1). This embodiment is an example in which the bending accuracy is improved by reversing the procedure of the third forming and the fourth forming, and it is difficult to form a gap between the outer peripheral surface of the circumferential portion 22 and the lead portions 26A and 26B. is there.

  An example of the manufacturing procedure of the coil component of a present Example is shown by FIG. 3 (C-2)-(E-2). The procedure for forming the circumferential portion 22 of the air core coil 20 is the same as that of the first embodiment described above, and the steps of FIGS. 3A and 3B are the same as those of the first embodiment, so the description thereof will be omitted. In the process up to FIG. 3B, when the lead portions 24A and 24B are bent to form the lead portions 26A and 26B in the process shown in FIG. 3C-2 in this embodiment. Then, while keeping the pair of lead portions 26A, 26B parallel to the coil shaft 29, the pair of lead wires 24A, 24B are bent so as to approach the circumferential portion 22. The bending angle α at this time is, for example, 20 ° to 80 °. Thereafter, as shown in FIG. 3 (D-2), the intersections 23A and 23B of the pair of lead wires 24A and 24B are bent and planarized along the outer peripheral surface of the circumferential portion 22. Process to The air core coil 20 in which the lead portions 26A and 26B are formed as described above is set in a mold while monitoring the positions of the circumferential portion 22 and the pair of lead portions 26A and 26B (FIG. 3 (E-2 ), Molding is performed using a magnetic material obtained by kneading metal particles and a resin (molding step).

  In the present embodiment, since the gap between the outer peripheral surface of the circumferential portion 22 and the lead portions 26A and 26B can be further reduced than in the first embodiment described above, the stability of the lead portions 26A and 26B can be further enhanced. . For example, if the lead wires 24A and 24B and the outer peripheral surface of the circumferential portion 22 are fixed using a conductive wire having a fusion layer, the stability of the position of the lead portions 26A and 26B can be further enhanced. Thereby, while the area of the magnetic body 12 of the outer side of the circumference | surroundings part 22 can be made small, a thin conducting wire can be used. For example, in the case where the length (L) × width (W) of the magnetic body 12 is a dimension ratio such as 2.0 × 1.6 (mm) size (see the example of FIG. 4C), the lead portion 26A, 26B is located on the diagonal lines DA and DB, and in the case of L × W = 2.0 × 1.2 size (see FIG. 4D), the lead portions 26A and 26B are shorter than the diagonal lines DA and DB. It will fit in the area ES1, ES2 on the side.

  As a result, the positions of the lead portions 26A and 26B can be made farthest from the side surface of the magnetic body (see the interval IB in FIG. 4C), which is a preferable position for securing the thickness of the magnetic body 12. The thickness of the magnetic body can be reduced by preventing the occurrence of cracks or the like triggered by the periphery of the lead portions 26A, 26B. The positions of the lead portions 26A and 26B based on the L × W dimensional ratio also apply to the first embodiment. In addition, the present embodiment has an advantage that the area on the inner peripheral side of the circumferential portion 22 can be further increased as compared with the above-described first embodiment. The other basic effects are the same as those of the first embodiment described above.

  <Specific example> Next, using the specific example and the comparative example of the present invention, the arrangement of the lead portions 26A, 26B and the coil axis 29 having a shape having the major axis LA and the minor axis LB. The area balance of the magnetic body 12 will be described below. FIG. 5 shows an example coil component 10. The length of the mounting surface of the product (coil component 10) is L, the width is W, the length of the minor axis of the outer periphery of the orbiting portion 20 is X1, the length of the major axis is Y1, and the inner periphery of the orbiting portion 22 is The length of the minor axis is X2, and the length of the major axis is Y2. Moreover, the area of the outer side of the winding part 22 is S1, the area of the winding part 22 is S2, the area of the inner side of the winding part 22 is S3, and the coils of Comparative Examples 1 to 4 and Specific Examples 1 to 8 under the conditions shown in FIG. I made parts.

  In FIG. 6, "side out" of the "lead out" means that the leads 26A and 26B are pulled out from the side adjacent to the short side of the surface mounted on the substrate of the magnetic body 12, "Example 1" and "Example 2" indicate that the air core coil was formed by the manufacturing method of Example 1 and Example 2 described above. Further, the first specific example corresponds to an elliptical shape of the inner circumferential shape of the air core coil 50A of FIG. 4A, and the fifth specific example is an inner circumferential of the air core coil 50B of FIG. 4B. It corresponds to an elliptical shape. Further, the third specific example corresponds to the oval shape of the inner circumferential shape of the air core coil 50C of FIG. 4C, and the seventh specific example corresponds to the inner circumferential shape of the air core coil 50D of FIG. It corresponds to what was made into the oval shape, and the specific examples 4 and 8 correspond to what made the rectangle (cornered rectangle) of the air core coil 50E of FIG.4 (E). In Examples 4 and 8, the cross section of the iron core 40 is prepared in a rectangular shape, and after rounding of R 0.1 mm at four corners, the air core coil 50E is formed. For this reason, it is a rounded rectangle with the same rounded corner. Thus, the air core coil 50E is obtained without damaging the coating of the conducting wire.

  The product size was two types of 2.0 × 1.6 × 1.0 mm and 2.0 × 1.25 × 1.0 mm, and the height of the magnetic body 12 was 0.9 mm in each case. Each corner of the magnetic body 12 was rounded by R 0.1 mm. The composite magnetic material used was a mixture of 95 w% of FeSiCrB as metal particles and 5 wt% of epoxy resin as a resin. Also, for the air core coil 20, a flat wire with a cross-sectional size of 0.25 × 0.05 mm and 0.25 × 0.035 mm (with a fusion layer) is used, and the number of turns of the winding portion 22 is It was 11 turns. In addition, as the terminal electrodes 14 and 16, after a Ti / Ag layer is formed by sputtering, a conductive paste is overlapped, hardened at a temperature of 200 ° C., and finally plated with Ni / Sn to obtain a combined thickness It was made to connect with end parts 28A and 28B of drawer parts 26A and 26B, respectively so as to be 0.02 mm.

  The evaluations of Comparative Examples 1 to 4 and Specific Examples 1 to 8 formed as described above were performed in view of the mounted side. Specifically, on the surface of the magnetic body 12 from which the terminal electrodes 14 and 16 have been removed, the lead-out portions 26A and 26B are two of the magnetic body 12 at a magnification of 50 with a scanning electron microscope (SEM). The diagonals were connected by straight lines each having a width of 10 μm, and the straight lines (diagonals DA, DB) were divided into four areas, and the locations of the lead portions 26A, 26B were evaluated. When the straight lines (diagonals DA and DB) are drawn as described above, when rounding to each corner of the magnetic body 12, the long side and the short side of the magnetic body are extended, and the intersecting points are determined. This point was reconsidered with the corner of the magnetic body, and the corner of the opposing position was connected. In addition, polishing was performed to the half of the height of the magnetic body 12 in the same direction as described above, and the respective areas of the polished surfaces were determined by image conversion. Here, “S3 / S1”, which is the ratio of the area S3 inside the circumferential portion to the area S1 outside the circumferential portion, can be 0.38 or more. As a result, the area S1 on the outer side of the winding portion can be made 1.3 to 1.8 times that of the conventional one, and the magnetic path cross-sectional area can be made large to easily take an inductance. In this case, it is possible to design the current characteristic to be 1.5 to 2.2 times. In addition, about said magnification, magnification may be changed so that the sample to evaluate may be settled in one image, and the same evaluation becomes possible by setting it as the range of 35-100 times.

The following can be confirmed from the results of FIG.
a. From the results of Comparative Example 1 and Comparative Example 2, no improvement effect of the area ratio S3 / S1 can be seen even when the circumferential portion 22 is rectangular (rounded rectangle) in the case of side drawing.
b. From the results of Comparative Example 3 and Comparative Example 4, even in the case of side drawing, although the area ratio S3 / S1 is increased by making the orbiting portion 22 rectangular, it did not reach the area balance. .
c. In the example 1 and the example 5, the effect of making it elliptical is seen, and compared with the comparison example 1 and the comparison example 3, the area ratio S3 / S1 is 0.21, 0.13 to 0.38, 0.43. We were able to.
d. The effects of bringing the lead portions 26A and 26B closer to the orbiting portion 22 as compared to the specific examples 1 and 5 in which the manufacturing procedures are different, respectively, can be seen in specific example 2 and specific example 6, and the area ratio S3 / S1 could be set to 0.41, 0.46.
e. Although specific examples 3, 4, 7 and 8 are examples in which the orbiting portion 22 is formed into an oval (oval shape) and a rounded rectangle, both are effective, and the area ratio can be further increased.
f. When the major axis / minor axis (Y2 / X2) is larger than the long side / short side (L / W), the thickness of the magnetic material on the outer side of the circumferential portion 22 is taken to be the long side by utilizing the size of the magnetic body 12 It is possible to make the thickness substantially the same on the short side and to reduce the place where the magnetic flux is concentrated, which leads to the improvement of the electrical performance such as the inductance and the saturation current and the reduction of the magnetic flux leakage.

The present invention is not limited to the embodiments described above, and various modifications can be made without departing from the scope of the present invention. For example, the following are also included.
(1) The shapes, dimensions, and materials described in the above embodiments are merely examples, and may be changed as appropriate.
(2) In the embodiment described above, the terminal electrodes 14 and 16 are provided on the side of the surface on which the coil component 10 is mounted. However, this is also an example and can be appropriately changed as necessary.
(3) The dimensions shown in the specific example are also an example, and design changes can be made as appropriate within the range where the same effects can be obtained. Further, the number of turns of the winding portion of the air core coil is also an example, and may be appropriately increased or decreased as needed.
(4) In the above embodiment, the inner peripheral shape of the air core coil 20 is an oval (oval type) or a rounded rectangular shape, but this is also an example, and design changes can be made as appropriate within the range of achieving similar effects. is there.
(5) In the above embodiment, although the case where a flat wire is used as the conducting wire is described as an example, the conducting wire used in the present invention may be a round wire. If the cross-sectional area of the conductive wire is 0.01 mm ² or more, the forming shape of the present invention can be stably formed, which is advantageous.

  As described above, according to the present invention, a rectangular magnetic body formed of metal magnetic particles and resin and having a long side and a short side on the side mounted on the substrate, and one long side of the cross section of the rectangular wire The flat wire is repeatedly wound on the flat wire so as to be in contact with each other, and a flat wire is repeatedly formed so as to overlap on the wound flat wire, and a winding portion embedded in the magnetic body and one long side of the magnetic body When the surface of the magnetic body formed from the leader drawn out from the outer peripheral surface of the circumferential portion and the end of the leader and mounted on the substrate is divided into four areas by two diagonal lines, A pair which are respectively included in two areas on the short side of the four areas and further drawn out to the outside of the magnetic body from a position closer to one long side of the magnetic body in the two areas. An air core coil having a lead-out portion of , Look through the surface of the magnetic material on the side mounted on the substrate, the pair of lead-out portion is characterized in that in a position in contact with the outer peripheral surface of the rounding part. For this reason, the lead wire and the lead portion are disposed on one long side of the magnetic body, and the space for drawing the conducting wire can be reduced to miniaturize. Thereby, the ratio of the magnetic material outside the air core coil can be reduced, and waste magnetic material can be reduced. As a result, current characteristics can be enhanced. In addition, the ratio S3 / S1 of the area S3 of the inner side of the circumferential part to the area S1 of the outer side of the circumferential part is 0.38 or more, the area S1 of the outer side of the circumferential part is 1.3 to 1.8 of the prior art. This can be doubled, and the inductance can be easily obtained by increasing the cross sectional area of the magnetic path. Moreover, the polishing process of the lead-out portion is easy, and the stability of the lead-out position can be enhanced. For this reason, it can apply to the use of coil parts. In particular, since the connection stability with the terminal electrode can be obtained by stabilizing the position of the lead portion, it is suitable for the application of a small-sized and high-performance coil component.

10, 10A to 10E: coil component 12: magnetic body 12A, 12B: long side 12C, 12D: short side 14, 16: terminal electrode 20, 20A, 20B: air core coil 22, 22A, 22B: circulating portion 23A, 23B : Crossing part 24A, 24B: Lead wire 26A, 26B: Leading part 28A, 28B: End 29: Coil shaft 30: Flat wire 30A, 30B: Short side 30C, 30D: Long side 40: Iron core 50A to 50E: Empty Core coil ES1, ES2, EL1, EL2: area DA, DB: diagonal LA: long axis LB: short axis

Claims (7)

A rectangular magnetic body formed of metal magnetic particles and a resin and having long sides and short sides on the side mounted on a substrate,
A winding portion which is wound such that the surface on one long side of the cross section of the flat wire is in contact, and the flat wire is repeatedly wound so as to overlap on the wound flat wire and embedded in the magnetic material; A lead wire drawn from the outer peripheral surface of the circumferential portion at one long side of the magnetic body, and an end of the lead wire, formed with diagonals of the magnetic body on the side mounted on the substrate are two diagonal lines Divided into four areas, which are respectively included in the two areas on the short side of the four areas, and further from the position closer to one long side of the magnetic body in the two areas An air core coil having a pair of lead-out portions drawn out of the magnetic body;
A pair of terminal electrodes electrically connected to the lead-out portion;
And have
When seen through the surface of the magnetic body mounted on the substrate, the pair of lead-out portions are in contact with the outer peripheral surface of the circumferential portion,
The ratio S3 / S1 of the area S3 of the magnetic material on the inner side of the circumferential portion to the area S1 of the magnetic material on the outer side of the circumferential portion is 0 when seen through the surface of the magnetic body mounted on the substrate. A coil component characterized by .38 or more.   The coil component according to claim 1, wherein an electrical connection portion between the pair of lead-out portions and the pair of terminal electrodes is formed on a surface to be mounted on the substrate.   The coil component according to claim 1 or 2, wherein an inner peripheral shape of the circumferential portion is an oval or a rounded rectangle when seen through the surface of the magnetic body mounted on the substrate. .   The coil component according to any one of claims 1 to 3, wherein the pair of terminal electrodes are formed on the surface of the magnetic body mounted on the substrate.   An electronic device comprising the coil component according to any one of claims 1 to 4. A rectangular magnetic body formed of metal magnetic particles and a resin and having long sides and short sides on the side mounted on a substrate,
A winding portion which is wound such that the surface on one long side of the cross section of the flat wire is in contact, and the flat wire is repeatedly wound so as to overlap on the wound flat wire and embedded in the magnetic material; A lead wire drawn from the outer peripheral surface of the circumferential portion at one long side of the magnetic body, and an end of the lead wire, formed with diagonals of the magnetic body on the side mounted on the substrate are two diagonal lines Divided into four areas, which are respectively included in the two areas on the short side of the four areas, and further from the position closer to one long side of the magnetic body in the two areas An air core coil having a pair of lead-out portions drawn out of the magnetic body;
And a pair of terminal electrodes electrically connected to the lead-out portion,
In a method of manufacturing a coil component, the pair of lead-out portions are in contact with the outer peripheral surface of the circumferential portion when seen through the surface of the magnetic body mounted on the substrate. ,
When viewed from the coil axis direction formed by the winding portion, the respective lead wires drawn from both ends of the winding portion are drawn in a direction away from the outer peripheral surface of the winding portion while having crossing portions, and further ends of the wires A first step of forming a pair of lead wires by forming predetermined gaps respectively with the outer circumferential surface of the circumferential portion, bending in opposite directions and in parallel to each other, and
A second step of bending an end portion side of the pair of lead wires to form a pair of lead portions parallel to the coil axis and directed in the same direction;
A third step of bending an intersection portion of the pair of leader lines to extend along an outer peripheral surface of the circumferential portion;
A fourth step of bending the pair of lead portions so as to be in contact with the outer peripheral surface of the circumferential portion while maintaining the pair of lead portions parallel to the coil axis;
The air core coil formed in the first to fourth steps is set in a mold while monitoring the positions of the peripheral portion and the pair of lead portions, and the magnetic material made of metal particles and resin is embedded in the mold. The ratio S3 / S1 of the area S3 of the magnetic material on the inner side of the circumferential portion to the area S1 of the magnetic material on the outer side of the circumferential portion is 0.38 when seen through the surface of the magnetic body mounted on the substrate. A fifth step of forming the magnetic body so as to become the above;
A method of manufacturing a coil component comprising: A rectangular magnetic body formed of metal magnetic particles and a resin and having long sides and short sides on the side mounted on a substrate,
A winding portion which is wound such that the surface on one long side of the cross section of the flat wire is in contact, and the flat wire is repeatedly wound so as to overlap on the wound flat wire and embedded in the magnetic material; A lead wire drawn from the outer peripheral surface of the circumferential portion at one long side of the magnetic body, and an end of the lead wire, formed with diagonals of the magnetic body on the side mounted on the substrate are two diagonal lines Divided into four areas, which are respectively included in the two areas on the short side of the four areas, and further from the position closer to one long side of the magnetic body in the two areas An air core coil having a pair of lead-out portions drawn out of the magnetic body;
And a pair of terminal electrodes electrically connected to the lead-out portion,
In a method of manufacturing a coil component, the pair of lead-out portions are in contact with the outer peripheral surface of the circumferential portion when seen through the surface of the magnetic body mounted on the substrate. ,
The conducting wire is wound to form the winding portion, and when viewed from the coil axis direction formed by the winding portion, the respective lead wires drawn from both ends of the winding portion have crossing portions and the outer periphery of the winding portion It is drawn out in the direction away from the surface, and is further processed so as to form predetermined gaps respectively with the outer peripheral surface of the circumferential portion toward the end of the conducting wire, and so as to be opposite to each other and parallel. A first step of forming a pair of leader lines;
A second step of bending an end portion side of the pair of lead wires to form a pair of lead portions parallel to the coil axis and directed in the same direction;
A third step of bending the pair of lead portions so as to be in contact with the outer peripheral surface of the circumferential portion while maintaining the pair of lead portions parallel to the coil axis;
A fourth step of bending an intersection portion of the pair of lead wires to extend along an outer peripheral surface of the circumferential portion;
The air core coil formed in the first to fourth steps is set in a mold while monitoring the positions of the peripheral portion and the pair of lead portions, and the magnetic material made of metal particles and resin is embedded in the mold. The ratio S3 / S1 of the area S3 of the magnetic material on the inner side of the circumferential portion to the area S1 of the magnetic material on the outer side of the circumferential portion is 0.38 when seen through the surface of the magnetic body mounted on the substrate. A fifth step of forming the magnetic body so as to become the above;
A method of manufacturing a coil component comprising:

Images