JPH08115819A - Chip inductor and its manufacture - Google Patents

Abstract

PURPOSE: To provide a chip inductor in which a winding core is formed as a continuous body and in which a continuous winding can be formed and to provide its manufacturing method regarding a winding-type chip inductor. CONSTITUTION: A chip inductor is constituted of a winding part 5B, for inductance generation, in which a wire material 2 is wound respectively on the circumferential face at both ends of a rod-shaped core material 1 composed of an insulator, in which winding parts 5A, for electrode formation, provided with cross-section parts by cutting the wire material 2 along the respective edges of the core material 1 are formed respectively at a starting end and a trailing end and in which the wire material 2 is wound on the circumferential face of the core material 1, of a resin-molded part 3 which has been molded on the outer circumference of the core material 1 on which the winding part has been formed and of electrode parts 4 which are brought into close contact with, and formed on, the cross-section parts formed on the winding part for electrode formation and on the edges of the core material. Thereby, the cost of the chip inductor can be lowered due to a continuous winding, and the high reliability of the chip inductor can be obtained due to the reduction in an electrode resistance.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wire wound type chip inductor and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, this type of chip inductor has been shown in FIG.
As shown in FIGS. 5 (a) and 5 (b), a drum-shaped bobbin 41 having flanges 42 at both ends is made of an insulating resin material, a magnetic ferrite material, or the like, and is provided with an insulating coating such as polyurethane. The wire 39 is wound, and the start-and-end connecting portion 45 is brought into contact with the electrode surface 44 made of an electrically conductive material provided on the outer end surface of the collar portion 42 to make a connection electrode 43 made of a conductive resin paste or a solder material. Mechanically and electrically fixed and connected by means of a wire, and the winding portion formed by the wire 39 and the collar portion 42 are electrically and mechanically insulated by a protective film 40 coated with an insulating material such as phenol resin or epoxy resin. -It has a protected structure.

A chip inductor as shown in FIG. 16 is proposed in Japanese Patent Laid-Open No. 60-39814, which is cheaper than the conventional chip inductor shown in FIG. As shown in FIG. 16, a wire rod 47 is wound around a long winding core member 46 having coil winding groove portions dispersed in the length direction, and the wound core member 46 is filled with resin or ferrite. Resin 48
Then, the obtained long mold is cut into a desired length to form individual pieces, and the electrodes 49 are formed on the cut surfaces of the individual pieces.

[0004]

However, the above-mentioned conventional chip inductor has a drawback that it is complicated in terms of structure and construction and expensive.

Further, Japanese Patent Laid-Open No. 60-398 shown in FIG.
The chip inductor disclosed in Japanese Patent No. 14 has a complicated core shape and is difficult to form a continuous core material.
Since it is a turn, it has many problems such as complicated wiring of wires which is not suitable for low inductance products and easy disconnection.

The present invention solves the above-mentioned problems of the prior art, and enables a continuous winding using a winding core of a continuous body with a simple winding structure, an inexpensive chip inductor having excellent productivity, and a manufacturing method thereof. It is intended to provide.

[0007]

In order to solve this problem, a chip inductor according to the present invention has a rod-shaped core member made of an insulating material, and wire rods wound around the peripheral surfaces of both ends of the core member. Winding for generating inductance by winding the wire rod around the peripheral surface of the core member by providing winding parts for electrode formation having cross-sections obtained by cutting the wire rod along each end face of the core member at the beginning and the end respectively. The wire portion, the resin molded portion molded on the outer periphery of the core member on which the winding portion is formed, the cross-sectional portion provided on the winding portion for forming the electrode, and the end surface of the core member are closely formed. It is configured to include an electrode portion.

In this chip inductor, a plurality of winding portions are continuously formed at a desired position on a continuous rod-shaped core material, and the plurality of winding portions are continuously formed. After the resin mold is applied to the outer periphery of the above, it is cut into individual pieces centering on each of the above winding parts, and electrodes are formed on the cut surfaces that are the both end faces of the individual cut pieces. It is a thing.

[0009]

With this structure, the shape of the core material can be simplified and the wire can be easily routed, so that the quality can be stabilized.

Further, it becomes easy to form the core material as a continuous body and to carry out continuous winding, so that the productivity can be improved and the cost can be reduced.

[0011]

【Example】

(Embodiment 1) Hereinafter, a first embodiment of the present invention will be described with reference to the drawings.

FIG. 1 is a sectional view showing the structure of a chip inductor according to the same embodiment. In FIG. 1, 1 is a rod-shaped core material made of insulating resin or magnetic ferrite.
Is a wire provided with an insulating film such as polyurethane. By winding this wire 2 around the outer periphery of the core 1, a winding portion 5A for electrode formation is provided at both ends, and a winding portion 5B for inductance generation is provided. The winding portion 5A which is continuously provided in the central portion, and the winding portion 5A for forming the electrode is cut on the same plane as the end surface of the core material 1, so that the cut surface is cut at the central portion of the wire 2 over the entire circumference. It is configured with.

Reference numeral 3 denotes a resin mold molded on the outer periphery of the core material 1 which has completed the winding, and 4 denotes cutting of the end surface of the core material 1 and the wire 2 of the winding portion 5A for forming electrodes which are on the same plane. It is an electrode formed in close contact with both surfaces.

Next, a method of manufacturing the chip inductor of this embodiment having the above-mentioned structure will be described with reference to FIG.

First, a continuous long core material 1 is prepared as shown in FIG. 1 (a), and then a wire material 2 is wound around the outer periphery of the core material 1 as shown in FIG. 1 (b). The winding portion 5A for electrode formation and the winding portion 5B for inductance generation are alternately wound continuously at a predetermined position.

Next, as shown in FIG. 1 (c), a resin mold 3 is applied to the outer periphery of the core material 1 on which the winding is finished,
As shown in Fig. 2 (d), the winding portion 5B for generating the inductance is located at the center position, and is individually cut and separated as shown in Fig. 2 (d). As shown, the electrode 4 is formed to obtain a finished product.

Therefore, according to this method, the core material 1 can be used as a continuous body, and continuous winding can be performed on it.
The productivity can be greatly improved and the cost can be reduced by a simple method. Further, since the wire rod 2 is cut into individual pieces by the electrode forming winding portion 5A, the cut surface of the wire 2 becomes an arc shape and the electrode 4
It is possible to widen the contact area with and to prevent Q loss due to the electrode 4, which is also effective in terms of quality.

(Embodiment 2) A second embodiment of the present invention will be described below with reference to the drawings.

FIG. 3 is a sectional view showing the structure of the chip inductor according to the embodiment. In FIG. 3, 6 is a core material and 2 is a core material.
Is a wire rod, 7 is a winding portion, 3 is a resin mold, and 4 is an electrode.

The peripheral surface of the core material 6 is subjected to a mechanical or chemical treatment to roughen the surface,
The wire 2 wound around this surface is prevented from slipping. Therefore, even if the winding portion 7 is formed by closely winding only at the central portion of the core material 6, the wire material is formed at the corner 7A of the winding portion. I try to prevent 2 from slipping. Therefore, according to this configuration, it is possible to extremely easily form the plurality of winding portions 7 by continuously winding the wire 2 around the core material 6 of the continuous body at a predetermined interval. Is.

(Third Embodiment) A third embodiment of the present invention will be described below with reference to the drawings.

FIG. 4 is a sectional view showing the structure of the chip inductor according to the same embodiment. In FIG. 4, 1 is a core material and 8 is a core material.
Is a self-bonding wire, 3 is a resin mold, and 4 is an electrode.

In the chip inductor of this embodiment constructed as described above, the wire rod 8 having self-bonding property is used as the wire rod 8.
By winding this around the center of the core 1 while heating, the wire 8 and the core 1 are brought into close contact with each other, and the wire 8 is prevented from unraveling at the corner 8A of the winding portion. As a result, the same effect as that of the second embodiment can be obtained.

(Embodiment 4) A fourth embodiment of the present invention will be described below with reference to the drawings.

FIG. 5 is a sectional view showing the structure of the chip inductor according to the embodiment. In FIG. 5, 9 is a core material and 2 is a core material.
Is a wire rod, 3 is a resin mold, and 4 is an electrode.

Further, the core material 9 is provided with a spiral groove 9A as shown in FIG. 6, and a linear groove 9B is also provided in the longitudinal direction of the core material 9 so as to be orthogonal to the groove 9A. Has been.

By using the core material 9 thus constructed, the wire material 2 having a desired number of turns is wound around the spiral groove 9A at the central portion of the core material 9, and the start and end of the wire material 2 are longitudinally aligned. It is possible to bring the electrode 4 along the linear groove 9B. As a result, the same effect as that of the second embodiment can be obtained.

Further, by providing a plurality of linear grooves 9B in the longitudinal direction on the circumference of the core material 9, the number of turns of one turn or less can be wound, and a highly reliable low inductance product can be obtained. You can

(Fifth Embodiment) A fifth embodiment of the present invention will be described below with reference to the drawings.

FIG. 7 is a sectional view showing the structure of the chip inductor according to the embodiment. In FIG. 7, 10 is a core material,
Reference numeral 10A is a cylindrical projection provided at a constant interval in the longitudinal direction of the core material 2, 2 is a wire rod, 3 is a resin mold, and 4 is an electrode.

In the chip inductor of the embodiment thus constructed, the core material 10 is provided with the columnar projections 10A, and the wire rod 2 having a desired number of turns is wound between the columnar projections 10A. It is possible to hook the wire rod 2 on the protrusion 10A having a rectangular shape and linearly arrange the electrode 4 up to the electrode 4, and since the protrusion 10A has a cylindrical shape, it is difficult to apply a local stress to the wire rod 2 and It is possible to prevent disconnection.

The height of the columnar projection 10A is set to be equal to or higher than the radius of the wire rod 2 so that the wire rod 2 can be securely held.
Can be hooked on the protrusion 10A.

(Sixth Embodiment) A sixth embodiment of the present invention will be described below with reference to the drawings.

FIG. 8 is a sectional view showing the structure of the chip inductor according to the present embodiment. This embodiment has a structure in which one or more turns are wound around the cylindrical projection 10A of the wire 2 in addition to the structure of the above-mentioned fifth embodiment. The other configuration is the same as that of the fifth embodiment.

Further, by adopting such a structure, not only the same effect as that of the fifth embodiment can be obtained, but also the core material 1
It is possible to prevent the wire 2 wound around 0 from loosening.

(Embodiment 7) A seventh embodiment of the present invention will be described below with reference to the drawings.

FIG. 9 is a cross-sectional view showing the structure of the chip inductor according to the embodiment. In FIG. 9, 11 is a core material and 1 is a core material.
1A is a notch formed in the core material 2, 2 is a wire rod, 3 is a resin mold, and 4 is an electrode.

The wire 2 is wound around the notch 11A of the core 11 shown in FIG. 10, and the notch 11
The wire 2 is hooked at both end corners of A and wired to the electrode 4. Here, since the wire rod 2 is wound around the cutout portion 11A, the winding shape becomes hexagonal as compared with the case where it is wound around a square core, and the corner portion is wound more than a square shape when it is a square core. It is possible to obtain the effect that it is less likely that wire breakage will occur.

(Embodiment 8) An eighth embodiment of the present invention will be described below with reference to the drawings.

FIG. 11 is a sectional view showing the structure of the chip inductor according to the embodiment, and FIG. 12 is a perspective view showing a core material used in this chip inductor. 11 and 1
In FIG. 2, 12 is a core material, 12A is a comb-shaped groove provided in the core material 2, 2 is a wire material, 3 is a resin mold, and 4 is an electrode.

The wire 2 is wound around the groove 12A of the core 12 one by one, and can be wired to the electrode 4 by exactly hooking the end face angle of the groove 12A with a desired number of turns.
Similar to the fourth embodiment, it is suitable for a winding having a low inductance value.

(Ninth Embodiment) A ninth embodiment of the present invention will be described below with reference to the drawings.

FIG. 13 is a sectional view showing the structure of the chip inductor according to the embodiment, and FIG. 14 is a perspective view showing the core material used in this chip inductor. 13 and 1
In FIG. 4, 13 is a core material, 13A is a notch provided in the core material 13, 2 is a wire material, 3 is a resin mold, and 4 is an electrode.

The wire 2 is wound around the notch 13A provided in the core 13, and is wired to the electrode 4 by being caught by the end face angle of the notch 13A. This allows
Even with a round bar-shaped core material, it is possible to easily obtain the same effects as those of the seventh and eighth embodiments without complicated processing.

Further, by changing the width of the cutout portion 13A, it is possible to cope with a low inductance value as in the case of the eighth embodiment.

[0046]

As described above, in the chip inductor and the method for manufacturing the same according to the present invention, by simplifying the shape of the core material, the wire material can be easily routed and the quality can be stabilized.

Further, it is easy to make the core material a continuous body and to carry out continuous winding, so that productivity can be improved and cost can be reduced.

Further, in the structure of the first embodiment, the connection area between the electrode and the wire can be widened and the resistance value between the electrode and the winding can be lowered.

[Brief description of drawings]

FIG. 1 is a sectional view showing a configuration of a chip inductor according to a first embodiment of the present invention.

FIG. 2 is a manufacturing process diagram showing a method of manufacturing the chip inductor according to the embodiment.

FIG. 3 is a sectional view showing a configuration of a chip inductor according to a second embodiment of the present invention.

FIG. 4 is a sectional view showing the structure of a chip inductor according to a third embodiment of the present invention.

FIG. 5 is a sectional view showing the structure of a chip inductor according to a fourth embodiment of the present invention.

FIG. 6 is a front view showing a core material used in the embodiment.

FIG. 7 is a sectional view showing the structure of a chip inductor according to a fifth embodiment of the present invention.

FIG. 8 is a sectional view showing the structure of a chip inductor according to a sixth embodiment of the present invention.

FIG. 9 is a sectional view showing the structure of a chip inductor according to a seventh embodiment of the present invention.

FIG. 10 is a perspective view showing a configuration of a core material used in the same embodiment.

FIG. 11 is a sectional view showing the structure of a chip inductor according to an eighth embodiment of the present invention.

FIG. 12 is a perspective view showing a configuration of a core material used in the same embodiment.

FIG. 13 is a sectional view showing the structure of a chip inductor according to a ninth embodiment of the present invention.

FIG. 14 is a perspective view showing a configuration of a core material used in the same embodiment.

FIG. 15A is a cross-sectional view showing a configuration of a conventional chip inductor, and FIG. 15B is a side view of the same.

FIG. 16 is a sectional view showing the configuration of a conventional chip inductor.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 core material 2 wire material 3 resin mold 4 electrode 5A winding portion for electrode formation 5B inductance winding portion 6 core material 7 winding portion 8 self-bonding wire material 8A winding portion corner 9 core material 9A Spiral groove 9B Linear groove 10 Core material 10A Cylindrical protrusion 11 Core material 11A Notched portion 12 Core material 12A Comb-shaped groove 13 Core material 13A Notched portion

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Reference number within the agency FI Technical indication location H01F 17/02 4230-5E 41/04 B (72) Inventor Haruhiko Kameyama 1006 Kadoma, Kadoma, Osaka Prefecture Address: Matsushita Electric Industrial Co., Ltd.

Claims (10)

[Claims] 1. A rod-shaped core member made of an insulating material, and a wire rod wound around the peripheral surfaces of both ends of the core member, and a cross-sectional portion obtained by cutting the wire rod along each end face of the core member. A winding part for generating inductance, in which winding parts for forming electrodes are respectively provided at the beginning and the end, and the wire is wound around the peripheral surface of the core member, and an outer circumference of the core member on which the winding part is formed. A chip inductor comprising a molded resin mold part, a cross-section part provided on the winding part for forming the electrode, and an electrode part formed in close contact with the end face of the core material. 2. A rod-shaped core material made of an insulator whose surface is treated to prevent slipping, a wire material wound around the peripheral surface of the core material, and the start and end of the wire material are respectively core materials. Of the winding part, a resin mold part molded on the outer periphery of the core material on which the winding part is formed, and the start and end of the winding part and the end face of the core material. Chip inductor consisting of the electrode part. 3. A rod-shaped core member made of an insulating material, and a winding in which a self-bonding wire rod is wound around the peripheral surface of the core member, and the start and end points of the wire member are drawn to the respective end faces of the core member. A chip inductor comprising a portion, a resin mold portion molded on the outer periphery of the core material on which the winding portion is formed, and electrode portions that are formed in close contact with the start and end of the winding portion and the end surface of the core material. 4. A rod-shaped core member made of an insulating material having at least one spiral groove and at least one linear groove orthogonal to the groove on the peripheral surface, and a wire rod in the linear groove on each end face side of the core member. A winding part in which the wire rod is wound in a spiral groove in the center part while fitting the start and end ends, a resin mold part molded on the outer periphery of the core material in which the winding part is formed, and the winding wire. A chip inductor consisting of electrode portions that are formed in close contact with the beginning and end of each part and the end face of the core material. 5. A rod-shaped core member made of an insulating material provided with two columnar protrusions at predetermined intervals in the length direction, and a wire rod wound between the two columnar protrusions of the core member. A winding part that is rotated and drawn out the start and end of the wire through the projections to the respective end surfaces of the core, and a resin mold part molded on the outer periphery of the core on which the winding is formed, A chip inductor comprising electrode parts formed in close contact with the start and end of the winding part and the end face of the core material. 6. The chip inductor according to claim 5, wherein the wire material of the winding portion is wound around two cylindrical protrusions provided on the core material for one rotation or more and then drawn out to each end surface of the core material. . 7. The chip inductor according to claim 5, wherein the height of the two cylindrical protrusions provided on the core material is at least ½ of the outer diameter of the wire material forming the winding portion. 8. A rod-shaped core member made of an insulator having a cutout portion provided at the center in the length direction, and a wire rod provided on the peripheral surface of the core member by utilizing the cutout portion provided on the core member. A winding part that is wound around and draws the start and end of the wire rod to each end surface of the core member, a resin mold part molded on the outer periphery of the core member on which the winding part is formed, and the winding part. A chip inductor consisting of electrode parts that are formed in close contact with the beginning and end of the core and the end face of the core material. 9. A notch formed in the center of the core member in the longitudinal direction is formed in a plurality of comb-shaped grooves for holding and winding the wire material forming the winding wire in a fixed position. The chip inductor according to claim 8, which is 10. A resin mold is formed on the outer periphery of the core material, wherein a plurality of winding portions are continuously formed at desired positions on a continuous rod-shaped core material at regular intervals. The chip inductor according to any one of claims 1 to 9, wherein after applying the above-mentioned method, the winding is cut into individual pieces centered on each of the winding parts, and electrodes are formed on the cut surfaces that are both end surfaces of the cut individual pieces. Production method.