JP7245062B2 - COIL COMPONENT, ELECTRONIC DEVICE, AND COIL COMPONENT MANUFACTURING METHOD - Google Patents

Description

TECHNICAL FIELD The present invention relates to a coil component, an electronic device, and a method of manufacturing a coil component.

A coil component is known in which an end portion of a conductive wire and a portion of a metal plate are joined to electrically connect a conductive wire forming a winding portion and a terminal electrode made of a metal plate (for example, Patent Document 1 , 2). Patent Literature 1 discloses a terminal metal plate including a mounting portion, a holding portion extending from the mounting portion, and a molten piece extending from the holding portion. Patent Literature 2 discloses a terminal metal plate that includes a receiving portion, a welding portion extending from the receiving portion, and a holding portion that is separated from the welding portion and extends from the receiving portion.

JP 2009-158777 A JP 2018-41852 A

In the case of electrically connecting the lead wire and the terminal electrode by joining the end of the lead wire and the joining claw of the terminal metal plate, the lead wire and the terminal electrode are electrically connected at the locking portion consisting of the locking claw that locks the conductor wire. Then, an unintended electrical connection will occur. For example, when the conductive wire and the terminal metal plate are joined, the temperature of the locking claw rises, which may remove the insulating coating of the conductive wire from the locking claw and electrically connect the conductive wire and the terminal electrode. The temperature rise of the locking claw is disclosed in Patent Document 2 in the case where the locking claw and the joining claw extend integrally from the metal plate body like the terminal metal plate disclosed in Patent Document 1. It is larger than a terminal metal plate in which the engaging claws and the joint claws extend separately from the metal plate body. Since the electrical connection between the lead wire and the terminal electrode at the latching portion is not intended, the state of conduction is likely to change due to vibration or the like, resulting in reduced reliability.

SUMMARY OF THE INVENTION It is an object of the present invention to improve electrical insulation between a lead wire and a terminal electrode at a locking portion.

The present invention comprises: a base portion; a winding portion formed of a conductive wire wound around a portion of the base portion and having a core wire made of a conductor and an insulating coating covering a peripheral surface of the core wire; A base portion formed of a metal plate provided on the surface of the portion, a locking portion for locking the conducting wire pulled out from the winding portion, and a portion of the metal plate and the conducting wire are joined together to form a base portion. and a terminal electrode electrically connected to the lead drawn out from the encircling portion, wherein the locking portion is located between the encircling portion and the joining portion. and a portion of the conducting wire located between the engaging portion and the joint portion is composed of an exposed portion where the core wire is exposed and a non-exposed portion where the core wire is covered with the insulating coating wherein the exposed portion is positioned between the non-exposed portion and the joint portion, the non-exposed portion is positioned between the locking portion and the exposed portion, and the exposed portion is the The conductive wire is separated from the base portion in a floating state with respect to the base portion, and the core wire is held between the base portion and the locking portion with the insulating coating interposed therebetween. In the coil component, the thickness of at least a portion of the insulating coating in the engaging portion of the insulating coating is thicker than the thickness of the insulating coating in the winding portion of the insulating coating.

In the above configuration, the insulating coating covering the peripheral surface of the core wire may be made of an insulating material with a maximum allowable temperature of 120° C. or higher and 180° C. or lower.

In the above configuration, the core wire may contain copper, and the terminal electrode may contain phosphor bronze.

In the above configuration, the base portion is a core including a winding core portion and a flange portion provided at an axial end portion of the winding core portion, the terminal electrode is disposed on the flange portion, and the conducting wire is the winding wire. It may be configured such that it is wound around a core to form the winding portion, is pulled out from the winding core to the terminal electrode disposed on the collar, and the joint portion is formed on the collar. can.

The said structure WHEREIN: The said joining part can be set as the structure formed by welding the said conductor and a part of said metal plate. Further, in the above configuration, the conductive wire has a thickness of the insulating coating in contact with the locking portion and the base portion at a portion where the conductive wire is sandwiched and locked between the base portion and the locking portion. The thickness of the insulating coating may be the same as the thickness of the insulating coating and may be thicker than the thickness of the insulating coating in the winding portion except for the portions in contact with the locking portion and the base portion. Further, in the above configuration, the interval between the engaging portion and the joint portion may be 0.2 mm to 0.4 mm. Further, in the above configuration, the distance between the conducting wire and the base portion may be increased from the locking portion toward the joint portion. Further, in the above configuration, the insulating coating in the non-exposed portion may include the insulating coating that has shrunk due to heat when the joint is formed.

According to another aspect of the present invention, there is provided an electronic device comprising the coil component described above and a circuit board on which the coil component is mounted.

The present invention comprises a step of winding a conductive wire having a core wire made of a conductor and an insulating coating covering the peripheral surface of the core wire around a part of a base portion to form a winding portion, a metal plate body, and from the metal plate body a step of disposing a terminal metal plate having an extending joint claw and a locking claw extending from the metal plate main body with a space between the joint claw and the locking claw; a step of sandwiching the conductive wire via the insulating coating; and joining the joint claw and a portion of the conductive wire sandwiched between the metal plate main body and the joint claw to form the conductive wire and the terminal metal. and a step of electrically connecting the plates, wherein the insulating coating is applied to a portion of the conducting wire which is positioned between the locking claw and the joining claw due to heat generated when the joining claw and the conducting wire are joined. is contracted toward the locking claw to expose the core wire located on the joint claw side between the locking claw and the joint claw and to float with respect to the metal plate main body. An exposed portion away from the metal plate main body and a non-exposed portion in which the core wire located on the locking claw side is covered with the insulating film are formed, and the metal plate main body and the locking hook of the conductor wire are formed. A method for manufacturing a coil component, wherein the joint claw and the conductor wire are joined such that the insulating coating on at least a portion of the portion sandwiched between the claws is thicker than before the joint claw and the conductor wire are joined. be.

According to the present invention, it is possible to improve the electrical insulation between the lead wire and the terminal electrode at the engaging portion.

FIG. 1(a) is a diagram showing a coil component according to a first embodiment of the present invention, FIG. 1(b) is a cross-sectional view along AA in FIG. 1(a), and FIG. , and a cross-sectional view of the conductor at the winding portion. FIG. 2 is a perspective view showing a coil component according to a second embodiment of the invention. 3(a) is a view of the coil component in FIG. 2 viewed from the arrow F1 side, and FIG. 3(b) is a view of the coil component in FIG. 2 viewed from the arrow F2 side. 4(a) and 4(b) are cross-sectional views of the flange portion of the coil component of FIG. 2. FIG. FIG. 5(a) is an enlarged view of region A in FIG. 4(a), and FIG. 5(b) is a cross-sectional view of the conductor wire at the winding portion. 6 is a diagram for explaining a terminal metal plate of the coil component of FIG. 2. FIG. FIGS. 7A and 7B are diagrams (part 1) for explaining the method of manufacturing the coil component according to the second embodiment of the present invention. 8A and 8B are diagrams (part 2) for explaining the method of manufacturing the coil component according to the second embodiment of the present invention. FIG. 9 is a diagram showing an electronic device including a coil component according to a second embodiment of the invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings as appropriate. Components that are common in multiple drawings are given the same reference numerals throughout the multiple drawings. Please note that each drawing is not necessarily drawn to an exact scale for convenience of explanation.

A coil component 500 according to a first embodiment of the present invention will be described with reference to FIGS. 1(a) to 1(c). FIG. 1(a) is a diagram showing a coil component 500 according to a first embodiment of the present invention, FIG. 1(b) is a cross-sectional view along line AA in FIG. 1(a), and FIG. 1(c). 4] is a cross-sectional view of the conductor 104 at the winding portion 102. [FIG. As shown in FIGS. 1A to 1C, the coil component 500 includes a base portion 101, a winding portion 102, and terminal electrodes 103. As shown in FIGS. The winding portion 102 is formed by winding a conductive wire 104 around a portion of the base portion 101 . The conducting wire 104 is composed of a core wire 105 made of metal and an insulating coating 106 covering the peripheral surface of the core wire 105 .

The terminal electrode 103 is provided on a part of the surface of the base portion 101 . The terminal electrode 103 includes a base portion 108 made of a metal plate 107 provided on the surface of the base portion 101, a locking portion 109 for locking the conductive wire 104 drawn out from the winding portion 102 between the base portion 108 and the base portion 108. It has a joint portion 110 that is joined to the conducting wire 104 and electrically joins the conducting wire 104 and the terminal electrode 103 . The locking portion 109 is provided between the winding portion 102 and the joint portion 110 with a space from the joint portion 110 . Conducting wire 104 is locked with core wire 105 interposed between base portion 108 and locking portion 109 via insulating coating 106 . At least a portion of the insulating coating 106A on the conductor 104A in the engaging portion 109 of the conductor 104 is thicker than the insulating coating 106B on the conductor 104B in the winding portion 102 of the conductor 104 . In coil component 500 , insulating coating 106 A in engaging portion 109 is thicker than insulating coating 106 B in winding portion 102 over the entire peripheral surface of core wire 105 . By increasing the thickness of the insulating coating 106A in the locking portion 109, for example, when the end portion of the lead wire 104 and a portion of the metal plate 107 are melted to form the joint portion 110, locking is achieved by the melting temperature. It is obtained by contracting the insulating coating 106 located between the portion 109 and the joint portion 110 toward the locking portion 109 side. Note that the thickness of the insulating coating 106A in the locking portion 109 may be increased by other methods.

Here, depending on the positional relationship between the engaging portion 109 and the joint portion 110 and/or the material of the insulating coating 106, when the end portion of the lead wire 104 and part of the metal plate 107 are melted to form the joint portion 110, , the insulating coating 106 positioned on the locking portion 109 may be removed by burning or the like. In this case, the conductive wire 104 and the terminal electrode 103 may be electrically connected at the locking portion 109 . When the conducting wire 104 and the terminal electrode 103 are electrically connected to each other at the engaging portion 109, for example, a void (such as a blow hole) is generated in the joint portion 110, and the conducting wire 104 and the terminal electrode 103 at the joint portion 110 have a high DC resistance. Even when the terminal electrode 103 is electrically connected to the conducting wire 104 as a whole, the electrical connection may be made within the desired DC resistance range. In this case, the inspection process is passed. Further, after product shipment, the conductive wire 104 and the terminal electrode 103 may be rubbed against each other at the locking portion 109 due to vibration or the like, which may cause the insulating coating 106 to become thin, and the conductive wire 104 and the terminal electrode 103 may be electrically connected at the locking portion 109 . obtain. Since the electrical connection between the lead wire 104 and the terminal electrode 103 at the locking portion 109 is not an intended connection, the conduction state is likely to change due to vibration or the like, resulting in low reliability.

In the coil component 500 , the core wire 105 of the conductor wire 104 is interposed between the base portion 108 and the locking portion 109 via the insulating coating 106 and locked. The thickness of at least a part of 106A is thicker than the thickness of insulating coating 106B in winding portion 102 of insulating coating 106 . Therefore, electrical insulation between the lead wire 104 and the terminal electrode 103 at the locking portion 109 can be improved. For example, it is possible to suppress electrical connection between the lead wire 104 and the terminal electrode 103 at the locking portion 109 when the joint portion 110 is formed. Therefore, when a gap is generated in the joint portion 110 and the conductor 104 and the terminal electrode 103 are electrically connected with a high DC resistance, the gap can be removed because it is detected in the inspection process. In addition, even if vibrations are applied and rubbed after the product is shipped, electrical connection between the lead wire 104 and the terminal electrode 103 at the locking portion 109 can be suppressed. As a result, it is possible to suppress variations in the paths of the current between the conducting wires 104 and the terminal electrodes 103, thereby suppressing deterioration in reliability.

2, 3(a) and 3(b), 4(a) and 4(b), and 5(a) and 5(b), the second embodiment of the present invention A coil component 600 according to an embodiment will be described. FIG. 2 is a perspective view showing a coil component 600 according to a second embodiment of the present invention. In FIG. 2, the exposure of the core wire 36 of the conductor 32 located between the engaging portions 90 and 96 and the joint portions 70 and 76 is omitted for clarity of illustration. 3A is a view of coil component 600 viewed from the arrow F1 side of FIG. 2, and FIG. 3B is a view of coil component 600 viewed from the arrow F2 side of FIG. 3(a) and 3(b) omit illustration of part of the winding portion 30 in order to clearly show the winding core portion 12. As shown in FIG. 4(a) is a cross-sectional view of the coil component 600 at the flange portion 14, and FIG. 4(b) is a cross-sectional view of the flange portion 16. As shown in FIG. FIG. 5(a) is an enlarged view of area A in FIG. 4(a), and FIG. In FIG. 5A, since the cross-sectional shape of the conductors 32, 34 at the locking portions 92, 94, 96 is the same as the cross-sectional shape of the conductor 32 at the locking portion 90, only the locking portion 90 is shown. , and the description of the locking portions 92, 94, and 96 is omitted. Also, in FIG. 5B, since the conductor 34 has the same cross-sectional shape as that of the conductor 32 at the winding portion 30, only the conductor 32 will be described, and the description of the conductor 34 will be omitted. 2, FIGS. 3(a) and 3(b), FIGS. 4(a) and 4(b), and FIGS. 5(a) and 5(b), the coil component 600 includes the drum core 10 , a winding portion 30, and terminal electrodes 40, 42, 44, and 46.

The drum core 10 includes a core portion 12, a flange portion 14 provided at one axial end portion of the core portion 12, and a flange portion 16 provided at the other axial end portion of the core portion 12. And prepare. The core part 12 has, for example, a substantially rectangular cross-sectional shape, but it may have a polygonal shape such as a hexagon or an octagon, or may have a circular shape or an elliptical shape. The flanges 14 and 16 are, for example, rectangular parallelepipeds having recesses. The drum core 10 is made of Ni--Zn ferrite material, for example, but may be made of other materials. For example, the drum core 10 may be made of Mn--Zn ferrite material, Fe--Si--Cr, Fe--Si--Al or Fe--Si--Cr--Al or other soft magnetic alloy material, or magnetic material such as Fe or Ni. It may be made of a metallic material, an amorphous magnetic metallic material, or a nanocrystalline magnetic metallic material.

The dimensions of the coil component 600 are, for example, 3.2 mm in length, 2.5 mm in width, and 2.5 mm in height. Here, the length of the coil component 600 is the dimension in the axial direction (the X direction in FIG. 2) of the core portion 12 of the drum core 10, and the width is the direction perpendicular to the X direction and parallel to the mounting surface ( 2), and the height is a dimension in a direction orthogonal to the X and Y directions (Z direction in FIG. 2). The dimensions of the drum core 10 are, for example, 3.0 mm in length (dimension in the X direction in FIG. 2), 2.5 mm in width (dimension in the Y direction in FIG. 2), and 2.5 mm in height (dimension in the Z direction in FIG. 2). 1.6 mm. The core portion 12 of the drum core 10 has, for example, a width (the dimension in the Y direction in FIG. 2) of 1.6 mm and a height (the dimension in the Z direction in FIG. 2) of 0.8 mm.

The winding portion 30 comprises two conductors 32 and 34 . The conducting wire 32 is wound around the winding core portion 12 , one end of which is electrically connected to the terminal electrode 40 and the other end of which is electrically connected to the terminal electrode 46 . The conducting wire 34 is wound around the winding core portion 12 , one end of which is electrically connected to the terminal electrode 42 , and the other end of which is electrically connected to the terminal electrode 44 . The conducting wire 32 is wound around the winding core portion 12 on the conducting wire 34 . The conducting wires 32 and 34 have a structure in which a core wire 36 made of copper, for example, is covered with an insulating coating 38 made of polyurethane. The core wire 36 may be made of a metal other than copper, such as silver, palladium, or a silver-palladium alloy. The insulating coating 38 may be made of an insulating material other than polyurethane, and may be made of a resin material such as polyesterimide, polyester, or imide-modified polyurethane. It is preferable that it is made of a specified resin material. The diameter of the conductors 32 and 34 is, for example, 0.05 mm. The conductors 32 and 34 are wound around the winding core 12 the same number of turns.

The collar portion 14 has a lower surface 14A, an upper surface 14B, an end surface 14C, an end surface 14D, a side surface 14E, and a side surface 14F. The collar portion 16 has a lower surface 16A, an upper surface 16B, an end surface 16C, an end surface 16D, a side surface 16E and a side surface 16F. The lower surface 14A and the lower surface 16A are surfaces facing the circuit board when the coil component 600 is mounted on the circuit board. The side surface 14F and the side surface 16F are surfaces to which the winding core 12 is connected.

A concave portion 18 is formed in the end surface 14C of the collar portion 14, and a concave portion 20 is formed in the end surface 14D. The recesses 18 and 20 are formed at positions straddling the vertical centers of the end faces 14C and 14D. The concave portions 18 and 20 are formed, for example, so as to connect from the end surfaces 14C and 14D to the bottom portion via tapered surfaces. The tapered and bottom surfaces of recesses 18 and 20 are considered part of end surfaces 14C and 14D, respectively. The angles of the tapered surfaces of the end surfaces 14C and 14D are appropriately set according to the directions in which the conductors 32 and 34 are drawn out. Similar to the concave portions 18 and 20 formed in the flange portion 14, the flange portion 16 also has a concave portion 22 formed in the end surface 16C and a concave portion 24 formed in the end surface 16D. The thickness of the flanges 14 and 16 is, for example, 0.6 mm. The depth of the recesses 18, 20, 22, 24 is, for example, 0.5 mm, and the width of the bottom portion is, for example, 0.7 mm.

The terminal electrodes 40 and 42 are provided on the collar portion 14 . The terminal electrodes 44 and 46 are provided on the collar portion 16 . The terminal electrode 40 is composed of a terminal metal plate 50 , and the terminal electrode 42 is composed of a terminal metal plate 52 . The terminal electrode 44 is composed of a terminal metal plate 54 , and the terminal electrode 46 is composed of a terminal metal plate 56 . The terminal metal plates 50, 52, 54, 56 are Sn-plated phosphor bronze plates, but other metals such as brass plates or tough pitch copper plates may be used.

The terminal metal plate 50 extends from the bottom surface 14A of the collar portion 14 to the top surface 14B via the side surface 14E and is attached to the collar portion 14 by extending into the concave portion 18 provided in the end surface 14C. The terminal metal plate 52 extends from the bottom surface 14A of the collar portion 14 to the top surface 14B via the side surface 14E and is attached to the collar portion 14 by extending into the concave portion 20 provided in the end surface 14D. Similarly, the terminal metal plate 54 extends from the lower surface 16A of the collar portion 16 to the upper surface 16B via the side surface 16E and is attached to the collar portion 16 by extending into the concave portion 24 provided in the end surface 16D. . The terminal metal plate 56 extends from the bottom surface 16A of the collar portion 16 to the top surface 16B via the side surface 16E and is attached to the collar portion 16 by extending into the concave portion 22 provided in the end surface 16C.

The terminal metal plate 50 will be described with reference to FIG. FIG. 6 is a diagram for explaining the terminal metal plate 50 of the coil component 600. FIG. Since the terminal metal plates 52, 54, and 56 have the same structure as the terminal metal plate 50, only the terminal metal plate 50 will be described, and the description of the terminal metal plates 52, 54, and 56 will be omitted.

As shown in FIG. 6 , the terminal metal plate 50 includes a metal plate body 60 , a locking claw 62 extending from the metal plate body 60 , and a terminal metal plate 50 extending from the metal plate body 60 while being spaced apart from the locking claw 62 . and a joint claw 64 . The metal plate body 60 is attached to the surface of the flange 14 with one end pressed against the lower surface 14A of the flange 14 and the other end pressed against the upper surface 14B. The locking claw 62 and the joint claw 64 are arranged in the recess 18 provided in the end face 14C. The locking claws 62 are provided to sandwich and lock the conductive wire 32 with the metal plate main body 60 . The joining claw 64 is joined to the conducting wire 32 by, for example, welding, and is provided to electrically connect the conducting wire 32 and the terminal metal plate 50 .

2, 3(a) and 3(b), 4(a) and 4(b), and 5(a) and 5(b), one end of the conductor 32 and the joining claws 64 of the terminal metal plate 50 are joined by, for example, welding. Thereby, a ball-shaped joint portion 70 is formed, and the conducting wire 32 and the terminal electrode 40 are electrically connected by the joint portion 70 . The other end of the conducting wire 32 and the joining claw 64 of the terminal metal plate 56 are joined by, for example, welding. Thereby, a ball-shaped joint portion 76 is formed, and the conductive wire 32 and the terminal electrode 46 are electrically connected by the joint portion 76 . Similarly, one end of the conducting wire 34 and the joint claw 64 of the terminal metal plate 52 are joined to form a ball-shaped joining portion 72 , and the conducting wire 34 and the terminal electrode 42 are electrically connected by this joining portion 72 . It is The other end of the conductor wire 34 and the joint claw 64 of the terminal metal plate 54 are joined to form a ball-shaped joint portion 74 , and the conductor wire 34 and the terminal electrode 44 are electrically connected by this joint portion 74 . . Joints 70, 72, 74, 76 are welds when formed by welding such as laser welding or arc welding.

The conducting wire 32 has a base composed of a locking portion 90 formed by bending the locking claw 62 of the terminal metal plate 50 and the metal plate main body 60 of the terminal metal plate 50 at a portion located between the winding portion 30 and the joint portion 70 . It is sandwiched and locked with the portion 80 . The conducting wire 32 is locked by sandwiching the core wire 36 between the base portion 80 and the locking portion 90 with the insulating coating 38 interposed therebetween. In addition, the conducting wire 32 extends from the metal plate main body 60 of the terminal metal plate 56 and the locking portion 96 formed by bending the locking claw 62 of the terminal metal plate 56 at the portion located between the winding portion 30 and the joint portion 76 . It is sandwiched and locked with the base portion 86 . The conducting wire 32 is locked by sandwiching the core wire 36 between the base portion 86 and the locking portion 96 with the insulating coating 38 interposed therebetween.

Similarly, the conducting wire 34 has a portion positioned between the winding portion 30 and the joint portion 72, which is formed by bending the locking claw 62 of the terminal metal plate 52 into a locking portion 92 and the metal plate body 60 of the terminal metal plate 52. It is sandwiched between and locked with the base portion 82 made of. The conducting wire 34 is locked by sandwiching the core wire 36 between the base portion 82 and the locking portion 92 via the insulating coating 38 . In addition, the conducting wire 34 extends from the metal plate main body 60 of the terminal metal plate 54 and the locking portion 94 formed by bending the locking claw 62 of the terminal metal plate 54 at the portion located between the winding portion 30 and the joint portion 74 . It is sandwiched and locked between the base portion 84 and the base portion 84 . The conducting wire 34 is locked by sandwiching the core wire 36 between the base portion 84 and the locking portion 94 with the insulating coating 38 interposed therebetween.

At least a portion of the portion of the conductor 32 positioned between the joint portion 70 and the locking portion 90 and at least a portion of the portion positioned between the joint portion 76 and the locking portion 96 are coated with the insulating coating 38 . is peeled off and the core wire 36 is exposed. A portion of the conductor 32 between the joints 70 and 76 and the locking portions 90 and 96 and located on the side of the locking portions 90 and 96 remains without the insulating coating 38 being peeled off, for example.

Similarly, at least a portion of the portion of the conductor 34 located between the joint portion 72 and the locking portion 92 and at least a portion of the portion located between the joint portion 74 and the locking portion 94 are The insulating coating 38 is peeled off and the core wire 36 is exposed. For example, the insulating coating 38 remains without being peeled off from the portion of the conductor 34 that is located between the joining portions 72 and 74 and the locking portions 92 and 94 and located on the side of the locking portions 92 and 94 .

At least part of the insulating coating 38A on the conductor 32A, which is the portion of the conductor 32 that is locked by the locking portion 90, is thicker than the insulation coating 38B on the conductor 32B in the winding portion 30 of the conductor 32. It's becoming In at least a part of the conductor 32A locked by the locking part 90 of the conductor 32, the thickness of the insulating coating 38A at the part in contact with the locking part 90 and the base part 80 as shown in FIG. is equal to the thickness of the insulating coating 38B in the winding portion 30, and the thickness of the insulating coating 38A in other portions may be thicker than the thickness of the insulating coating 38B in the winding portion 30. 1(b), in at least a portion of the conductor 32A locked by the locking portion 90 of the conductor 32, the thickness of the insulating coating 38A is increased over the entire peripheral surface of the core wire 36. It may be thicker than the thickness of the insulating coating 38B in . Preferably, the thickness of the insulating coating 38A on the entire peripheral surface of the core wire 36 is thicker than the thickness of the insulating coating 38B on the winding portion 30 in all of the conductive wires 32A locked by the locking portion 90 among the conductive wires 32. . The same is true for the portion of the conductor 32 at the locking portion 92 and the portion of the conductor 34 at the locking portions 94 and 96 . That is, at least part of the insulating coating 38A on the conductor 32A, which is the portion of the conductor 32 that is locked by the locking portion 96, is greater than the insulation coating 38B on the conductor 32B in the winding portion 30 of the conductor 32. is also thicker. At least part of the insulating coating 38A on the conductor 34A, which is the portion of the conductor 34 that is locked by the locking portions 92 and 94, is thicker than the insulation coating on the conductor in the winding portion 30 of the conductor 34. It's becoming

Next, a method for manufacturing coil component 600 will be described. First, the drum core 10 is formed. For example, a Ni—Zn ferrite material is mixed with a binder, and the mixed material is compression-molded with a molding die to obtain a drum-shaped compact. If necessary, deburring may be performed on this compact. By sintering this compact at a predetermined firing temperature, the drum core 10 having the winding core 12 and the flanges 14 and 16 is obtained. Next, the terminal metal plates 50 and 52 are attached to the flange portion 14 of the drum core 10 by bending and caulking. The terminal metal plates 54 and 56 are attached to the flange portion 16 of the drum core 10 by bending and caulking. The conducting wire 34 is wound around the outer peripheral surface of the winding core portion 12 of the drum core 10 a required number of times, and the conducting wire 32 is wound around the winding core portion 12 outside the conducting wire 34 a required number of times to form the winding portion 30 . Wires 32 and 34 are wound the same number of times. The ends of the conductor wire 32 are pulled out onto the terminal metal plates 50 and 56, and the conductor wire 32 and the terminal metal plates 50 and 56 are joined for electrical connection. Similarly, the ends of the conductor wire 34 are pulled out onto the terminal metal plates 52 and 54, and the conductor wire 34 and the terminal metal plates 52 and 54 are joined for electrical connection.

A method of manufacturing the coil component 600 will be described in detail with reference to FIGS. 7(a) to 8(b). FIGS. 7A to 8B are diagrams for explaining the manufacturing method of the coil component 600. FIG. 7A to 8B illustrate the vicinity of one end of the conductor 32 joined to the terminal metal plate 50, but the vicinity of the other end of the conductor 32 and the vicinity of the conductor 34 are shown. Since the vicinity of both ends is the same, the description is omitted here.

As shown in FIG. 7(a), a terminal metal plate 50 having a metal plate body 60 and an engaging claw 62 and a joint claw 64 extending from the metal plate body 60 is arranged on the flange portion 14 of the drum core 10 by bending or the like. do. Conductive wires 32 and 34 are wound around the core portion 12 of the drum core 10 to form the winding portion 30 . One end of the lead wire 32 is pulled out onto the metal plate main body 60 of the terminal metal plate 50 using a jig 100 such as a clamp. Next, the insulating coating 38 of the portion of the conductor 32 sandwiched between the metal plate main body 60 and the joining claw 64 is removed to expose the core 36 . The insulating coating 38 can be removed by, for example, laser light irradiation.

As shown in FIG. 7(b), both the locking claw 62 and the joining claw 64 are bent at room temperature, and the lead wire 32 is sandwiched between the metal plate main body 60, the locking claw 62 and the joining claw 64 and fixed.

As shown in FIG. 8( a ), the wire 32 is cut so that the tip of the wire 32 is positioned outside the joining claws 64 . A commonly used method can be used for cutting the conducting wire 32 . The conducting wire 32 may be cut by press cutting using, for example, the terminal metal plate 50 and a jig used for bending the locking claws 62 and the joining claws 64 . In this case, the bending of the engaging claws 62 and the joining claws 64 and the cutting of the conductor wire 32 can be performed at once, so that the manufacturing process can be reduced. Moreover, it is preferable to perform the cutting on the metal plate main body 60 . By pressing and cutting on the metal plate main body 60, it is possible to suppress damage to the magnetic material or, conversely, breakage of the cutting blade. In addition, since the cutting blade for push-cutting can cut in only one direction, restrictions on the space for arranging it can be reduced. Therefore, the cutting position can be within the outer dimensions of the coil component 600, and it is possible to prevent the tip of the conductor wire 32 from deviating from the outer dimensions. For example, this also prevents the leading end of the conductor 32 from interfering with other components.

As shown in FIG. 8(b), the wire 32 and the joining claw 64 are joined together with the leading end of the conducting wire 32 positioned outside the joining claw 64. Then, as shown in FIG. Thereby, a joint portion 70 is formed, and the conductor wire 32 and the terminal metal plate 50 are electrically connected by the joint portion 70 . The connection between the conductor wire 32 and the connection claw 64 can be performed by welding such as laser welding or arc welding, but may be performed by other methods, such as thermocompression bonding, ultrasonic bonding, or solder bonding. A joining method in which heat is applied to 32 and joining claws 64 may be used. As an example, the conducting wire 32 and the joining claw 64 can be joined by irradiating the joining claw 64 with a laser beam to melt the joining claw 64 . When the joining claw 64 melts, the melted portion swells to form a joining portion 70 which is a welded portion with a roundness as a whole.

When the insulating coating 38 is made of polyurethane, the insulating coating 38 located between the engaging claw 62 and the joining claw 64 is moved toward the relatively low-temperature engaging claw 62 by the heat generated when the joint portion 70 is formed. The core wire 36 is exposed by shrinking. By setting the interval between the locking claw 62 and the joining claw 64 to an appropriate size (for example, about 0.2 mm to 0.4 mm), the portion of the lead wire 32 sandwiched between the metal plate main body 60 and the locking claw 62 can be reduced. At least part of the insulating coating 38 is thicker than before forming the joint 70 . For example, when the conductor 32 is firmly fixed to the metal plate main body 60 by the locking claws 62, as shown in FIG. , the thickness of the insulating coating 38 increases at that portion. Further, for example, when the locking force between the conductor 32 and the locking claw 62 is weakened due to springback when the locking claw 62 is bent, or when this locking force is weakened, the conductor 32 1(b), the thickness of the insulating coating 38 is increased over the entire peripheral surface of the core wire 36, as shown in FIG. 1(b). That is, the contraction force of the insulating coating 38 that has shrunk toward the locking claw 62 side becomes larger than the locking force of the locking claw 62, so that the gap between the metal plate main body 60 and the locking claw 62 is expanded, and the core wire The thickness of the insulating coating 38 increases over the entire peripheral surface of 36 . After the joint 70 is formed, all or part of the tip of the conductor 32 protruding from the joint 70 is cut.

In the manufacturing method of the present embodiment, the case of removing the insulating coating 38 of the portion of the conductor 32 corresponding to the joining claw 64 is shown as an example, but depending on the material of the insulating coating 38, the insulating coating 38 may be removed. No process is required.

In the coil component 600, as shown in FIGS. 4A to 5B, the core wire 36 of the conductor wire 32 is interposed between the base portion 80 and the locking portion 90 via the insulating coating 38, and locked. In addition, the thickness of at least a portion of the insulating coating 38A in the locking portion 90 of the insulating coating 38 is greater than the thickness of the insulating coating 38B in the winding portion 30 of the insulating coating 38 . Thereby, electrical insulation between the lead wire 32 and the terminal electrode 40 at the locking portion 90 can be improved. Therefore, it is possible to suppress variation in the current path between the conducting wire 32 and the terminal electrode 40, thereby suppressing a change in DC resistance. Moreover, since the thickness of the insulating coating 38</b>A in the locking portion 90 is increased, the conductor wire 32 can be locked firmly in the locking portion 90 . In addition, since the thickness of the insulating coating 38A in the locking portion 90 is increased, the effect of protecting the core wire 36 is improved. The same applies to the other end of the conductor 32 and the conductor 34 .

As described in FIG. 8B, the coil component 600 causes the insulating coating 38 located between the engaging claws 62 and the joining claws 64 to be removed by the heat generated when the joining claws 64 and the conducting wire 32 are joined. By contracting sideways, at least a portion of the insulating coating 38 sandwiched between the locking claws 62 is made thicker than before bonding. Thereby, electrical insulation between the lead wire 32 and the terminal electrode 40 at the locking portion 90 can be improved. The insulating coating 38 located between the locking claw 62 and the joint claw 64 thermally shrinks toward the locking claw 62, so that the locking portion 90 and the joint portion of the conductor 32 are separated as shown in FIG. 3(a). The core wire 36 is exposed at the portion located between 70 . Since the tip of the conducting wire 32 is fixed at the joint portion 70 and the insulating coating 38 thermally contracts, the core wire 36 exposed by the thermal contraction of the insulating coating 38 is in a floating state with respect to the terminal electrode 40 . contact is suppressed. In order to effectively prevent the exposed core wire 36 from coming into contact with the terminal electrode 40, the lead wire 32 shown in FIG. It is preferable to pull out the conductor 32 by

The insulating coating 38 is preferably made of an insulating material with a maximum allowable temperature of 120° C. or higher and 180° C. or lower. For example, it is preferably made of an insulating material belonging to heat resistance classes 120(E)°C, 130(B)°C, 155(F)°C, and 180(H)°C defined in JIS C4003 (2010). By way of example, the insulating coating 38 is preferably made of polyurethane, imide-modified polyurethane, polyesterimide, or polyester. By using the insulating coating 38 made of such an insulating material, the insulating coating 38 is shrunk by the heat generated when the joint portion 70 is formed, and the thickness of the insulating coating 38A at the locking portion 90 is at least partly covered. It can be made thicker than the thickness of the insulating coating 38B in the portion 30 . If the insulating coating 38 is formed of an insulating material having a maximum allowable temperature of less than 120° C., the insulating coating 38 will burn without shrinking due to the heat generated when forming the joint 70, or it will decompose and become useless. I'm going to stop doing it. Conversely, if the insulating coating 38 is made of an insulating material whose maximum allowable temperature is higher than 180° C., it can withstand the heat when forming the joint 70 and does not shrink.

The insulating coating 38A may be made of the same insulating material as the insulating coating 38B, or may be made of a combination of similar or completely different insulating materials. For example, the insulating coating 38A may be formed by using an insulating adhesive or the like around the same insulating material as the insulating coating 38B. The insulating coating 38A preferably has both flexibility and strength as a whole coating. good too. Insulating coating 38A may also be made generally harder than insulating coating 38B. As a result, the fixation at the locking portion 90 is made stronger, and the disconnection of the core wire 36 can be suppressed by making it stronger against vibrations from the outside.

In coil component 600, core wires 36 of conducting wires 32, 34 are formed containing copper, and terminal electrodes 40, 42, 44, 46 are formed containing phosphor bronze. As a result, the terminal metal plates 50, 52, 54, 56 can be easily bent, and the locking claws 62 and joining claws 64 extending separately from the metal plate main body 60 can be accommodated in a small volume. Therefore, coil component 600 can be miniaturized. Further, the force applied when bending the locking claw 62 and the joining claw 64 can be reduced, and the force applied to the conductors 32 and 34 can be reduced.

FIG. 9 is a diagram showing an electronic device 700 including a coil component 600 according to the second embodiment of the present invention. As shown in FIG. 9 , electronic device 700 includes circuit board 120 and coil component 600 mounted on circuit board 120 . The coil component 600 is mounted on the circuit board 120 by connecting the terminal electrodes 40 , 42 , 44 , 46 (only the terminal electrodes 40 and 46 are shown in FIG. 9 ) to the electrodes 122 of the circuit board 120 with solder 124 . ing.

Electronic device 700 has coil component 600 mounted on circuit board 120 . As a result, the electrical insulation between the lead wire 32 and the terminal electrodes 40 and 46 at the locking portions 90 and 96 and the electrical insulation between the lead wire 34 and the terminal electrodes 42 and 44 at the locking portions 92 and 94 are excellent. Electronic device 700 having coil component 600 can be obtained.

In the second embodiment, the case where the coil component is a common mode filter is shown as an example, but it is not limited to this case. The coil component may be another coil component such as a single-line coil component. Although the case of the drum core 10 having the flanges 14 and 16 provided at both ends of the core 12 as the base portion is shown as an example, the present invention is not limited to this case, and for example, the flanges may be provided only at one end of the core. It may be a core (T core) provided with , or may be a case other than a core.

Although the embodiments of the present invention have been described in detail above, the present invention is not limited to such specific embodiments, and various modifications and variations can be made within the scope of the gist of the present invention described in the scope of claims. Change is possible.

REFERENCE SIGNS LIST 10 drum core 12 winding core 14, 16 flange 18, 20, 22, 24 recess 30 winding 32, 32A, 32B, 34, 34A conducting wire 36 core 38, 38A, 38B insulating coating 40, 42, 44, 46 terminal electrode 50, 52, 54, 56 terminal metal plate 60 metal plate main body 62 locking claw 64 joint claw 70, 72, 74, 76 joint portion 80, 82, 84, 86 base portion 90, 92, 94, 96 locking portion 101 Base portion 102 Winding portion 103 Terminal electrode 104, 104A, 104B Lead wire 105 Core wire 106, 106A, 106B Insulating coating 107 Metal plate 108 Base portion 109 Locking portion 110 Joining portion 120 Circuit board 122 Electrode 124 Solder 500, 600 Coil component 700 Electron device

Claims (11)

a base portion;
a winding portion formed of a conductive wire wound around a portion of the base portion and having a core wire made of a conductor and an insulating coating covering a peripheral surface of the core wire;
A base portion provided on a surface of a portion of the base portion and formed of a metal plate, a locking portion for locking the conductor drawn out from the winding portion, and a portion of the metal plate and the conductor are joined together. and a terminal electrode electrically connected to the conducting wire drawn out from the winding portion,
The locking portion is provided between the winding portion and the joint portion with a space from the joint portion,
a portion of the conducting wire positioned between the engaging portion and the joint portion has an exposed portion where the core wire is exposed and an unexposed portion where the core wire is covered with the insulating coating;
The exposed portion is positioned between the non-exposed portion and the joint portion, the non-exposed portion is positioned between the locking portion and the exposed portion,
The exposed portion is separated from the base portion in a floating state with respect to the base portion,
The conductive wire is locked by sandwiching the core wire between the base portion and the locking portion via the insulating coating, and the thickness of at least a part of the insulating coating in the locking portion of the insulating coating is A coil component that is thicker than the insulating coating in the winding portion of the insulating coating. 2. The coil component according to claim 1 , wherein said insulating coating covering the peripheral surface of said core wire is made of an insulating material with a maximum allowable temperature of 120[deg.] C. or more and 180[deg.] C. or less. The core wire is formed containing copper,
3. The coil component according to claim 2 , wherein said terminal electrodes are formed containing phosphor bronze. The base portion is a core including a winding core portion and a flange portion provided at an end portion in the axial direction of the winding core portion,
The terminal electrode is arranged on the collar,
the conducting wire is wound around the winding core to form the winding portion and is pulled out from the winding core to the terminal electrode disposed on the flange;
4. The coil component according to claim 1, wherein said joint portion is formed on said flange portion. 5. The coil component according to claim 1, wherein said joining portion is formed by welding said conducting wire and a portion of said metal plate. In the conductive wire, at a portion held between and locked by the base portion and the locking portion, the thickness of the insulating coating in contact with the locking portion and the base portion is equal to the thickness of the insulating coating at the winding portion. 6. The coil component according to any one of claims 1 to 5, wherein a thickness of said insulating coating other than portions that are the same and are in contact with said locking portion and said base portion is thicker than a thickness of said insulating coating in said winding portion. The coil component according to any one of claims 1 to 6, wherein a distance between said engaging portion and said joint portion is 0.2 mm to 0.4 mm. 8. The coil component according to any one of claims 1 to 7, wherein the distance between said conducting wire and said base portion increases from said engaging portion toward said joining portion. 9. The coil component according to any one of claims 1 to 8, wherein said insulating coating in said non-exposed portion includes said insulating coating that has shrunk due to heat when said joint is formed. a coil component according to any one of claims 1 to 9 ;
and a circuit board on which the coil component is mounted. forming a winding portion by winding a conductor wire having a core wire made of a conductor and an insulating coating covering a peripheral surface of the core wire around a part of a base portion;
a step of arranging a terminal metal plate having a metal plate main body, a joint claw extending from the metal plate main body, and a locking claw extending from the metal plate main body with a gap between the joint claw and the metal plate main body;
a step of sandwiching the conductive wire between the metal plate main body and the locking claw with the insulating coating interposed therebetween;
a step of electrically connecting the lead wire and the terminal metal plate by joining the joint claw and a portion of the conductor wire sandwiched between the metal plate main body and the joint claw;
The insulating coating of a portion of the conducting wire positioned between the engaging claw and the joining claw is shrunk toward the engaging claw by the heat generated when the joining claw and the conducting wire are joined together. The core wire located on the joint claw side is exposed between the retaining claw and the joint claw, and is in a state of floating with respect to the metal plate body, and the exposed portion and the locking claw are separated from the metal plate body. The core wire located on the side forms a non-exposed portion covered with the insulating coating, and at least a part of the portion sandwiched between the metal plate main body and the locking claw of the conductor wire is the above-mentioned A method of manufacturing a coil component, wherein the joint claw and the conductor wire are joined such that the insulating coating is thicker than before the joint claw and the conductor wire are joined.

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