KR101246526B1 - Inductor and method for manufacturing the same - Google Patents

Abstract

assignment
Provided is a winding-type inductor which facilitates drawing out or wiring of conductive wires while avoiding damages caused by the edges of the core and sleeve when taking out the conductive wires from the core.
Solution
A core 3 wound around the conductor wire 2 and a sleeve 4 having an outer shape having a rectangular shape, and two tip portions on both ends of the conductive wire drawn outward from the core, respectively, are spaced apart from the lower surface of the sleeve. In the inductor 1, which is formed by welding each electrode to a wider conductive surface than the outer diameter of the conductive wire, respectively formed in the two portions of the conductive line, the edge portion 24 in the circumferential direction in which the inner circumferential surface and the lower surface of the sleeve 4 intersect. ), The portions located inside the two conductive surfaces, respectively, are chamfered with a width larger than the outer diameter of the conductive line 2 so that the inclined surface 20 is formed, and the conductive line is connected to the conductive surface through the inclined surface. Configured.

Description

INDUCTOR AND MANUFACTURING METHOD THEREOF {INDUCTOR AND METHOD FOR MANUFACTURING THE SAME}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inductor and a method for manufacturing the same. In particular, an inductor composed of a core having a flange at upper and lower ends and a conductive wire wound thereon, and a sleeve having a rectangular shape surrounding the same. It is about.

Conventionally, an inductor using a wound core is known. For example, in JP-A-5-50706, a solid-state in which a conductive wire is wound as a surface-mount inductor. It is found that the core and the sleeve surrounding the core have a circular shape, and that they are integrally bonded on a resin substrate having a specific shape and structure. And there, the electrode is comprised so that the electrically conductive surface extended toward the outer two directions from the center part of the upper surface of a board | substrate may extend through the end surface of a board | substrate to the back surface.

The inductor having such a structure has a structure in which two leading ends (both ends) of the conductive wire wound on the core are respectively soldered to the conductive surface, so that the connection between the leading end of the conductive wire and the conductive surface is easy. In the case where the inductor is mounted on the electronic circuit board, it is possible to facilitate the installation of the inductor at a predetermined position on the electronic circuit board.

Japanese Utility Model Publication No. 5-50706

However, in accordance with the miniaturization and high performance of electronic components, inductors have recently faced the necessity to have a height of 1.5 mm or less and to have a compact structure and to be mounted on an electronic circuit board. In order to improve the positioning accuracy with respect to the land of the board | substrate, and to improve the workability of positioning, the stationary stability with respect to an electronic circuit board, etc., the conventional inductor as mentioned above was requested | required. Esau still had a problem that he could not fully meet the demand.

Therefore, the present inventors have made intensive studies on the practical use of an inductor capable of meeting such demands. Firstly, while specifying the relative relationship between the shape of the sleeve surrounding the core to which the conductive wire is wound and the core accommodated therein, First, it was found that the tip of the electrodeled conductive wire may be welded to a specific position of the sleeve. First, it was proposed as Japanese Patent Application No. 2009-57835.

That is, in the inductor which consists of the core by which the conductive wire is wound, and the sleeve which surrounds the core, which has an upper-lower flange at the upper-lower end, it uses the sleeve which forms a square shape as this sleeve, The front ends of each of the conductive wires drawn outward are welded to the conductive surface having a wider width than the outer diameter of the conductive wire, which is formed on the lower surface of two opposite corners of the sleeve, and is electroded. An inductor is specified, which makes it possible to provide an inductor with a low profile and a compact shape and structure.

However, the present inventors have studied the inductor proposed above in more detail. As a result, when the both ends of the conductive wire wound on the core are taken out and welded to the conductive surface formed on the sleeve, the conductive wire is the core. However, there is a problem in the automation of the work because the workability in drawing and wiring the conductive wire is not sufficient due to the bending and drawing out by the corner portion of the sleeve, or the conduction wire is not sufficient through the gap between the core and the sleeve. It became clear.

Therefore, the present invention has been made in view of the above circumstances, and the problem to be solved is that the edges of the core and the sleeve are further removed when the conductive wire is taken out from the core while fully enjoying the advantages of the above-described source. It is an object of the present invention to provide a winding type inductor that facilitates the drawing or wiring work of such conductive lines while avoiding damage to the conductive lines as much as possible.

And in order to solve the said subject or the subject grasped | ascertained from description or drawing of the whole specification, although this invention can be implemented suitably in various aspects as listed below, Moreover, each aspect described below Can be employed in any combination. In addition, it is obvious that the aspects and technical features of the present invention are not limited to those described below, but can be recognized based on the description of the entire specification and the invention disclosed in the drawings.

(1) A conductive wire wound core having an upper and lower flange at upper and lower ends, and a sleeve surrounding the core, wherein the sleeve is formed in a rectangular shape, and is respectively outward from the core. In the inductor formed by welding two lead portions on both sides of the derived conductive wires on two conductive parts spaced apart from the lower surface of the sleeve, respectively, on the wider conductive surface than the outer diameter of the conductive wire, and forming an electrode. Of the portions in the circumferential direction where the inner circumferential surface and the lower surface intersect, the portions positioned respectively inside the two conductive surfaces are chamfered with a width W greater than the outer diameter of the conductive line, so that two inclined surfaces are formed. And an induction part of the conductive line is connected to the conductive surface, respectively.

(2) The inductor according to the above aspect (1), wherein the shortest distance Q between the inclined surface formed on the sleeve and the upper edge P1 of the lower flange is in the range of 1.1 times to 10 times the outer diameter of the conductive wire.

(3) The inductor according to the above aspect (2), wherein the inclined surface has an elevation angle (θ) within a range of 30 degrees to 85 degrees.

(4) The inductor according to any one of the above aspects (1) to (3), wherein the outer peripheral portion of the sleeve is partially cut in thickness and a cutout portion is formed.

(5) At least one outer lead-out part of the conductive wire wound on the core is lowered, and the middle of the outer lead-out part is bent, and the tip of the outer lead-out part is the conductive surface of the sleeve. The inductor according to any one of the above aspects (1) to (4), which is adapted to extend toward.

(6) The position on the horizontal plane which bends the middle of the outer lead-out part of the said conductive line is on the imaginary line L1, L2 extended on a horizontal plane along the centerline in the width direction of the inclined surface formed in the said sleeve, or it The inductor as described in said aspect (5) which is a position which adjoins.

(7) The inductor according to any one of the aspects (1) to (6), wherein an outer shape of the upper and lower flanges of the core is circular, and an inner shape of the sleeve is circular.

(8) The inductor according to the aspect (7), wherein an outer diameter of the upper flange of the core is equal to or larger than an outer diameter of the lower flange.

(9) The inductor according to any one of the aspects (1) to (8), wherein the core is disposed in a non-contact state with respect to the sleeve.

(10) In the above aspects (1) to (9), wherein an upper surface of the upper flange of the core and an upper surface of the sleeve are faced, and an adhesive layer is coated on their upper face so as to be faced. Inductor as described in any one.

(11) The inductor according to the aspect (10), wherein a part of the adhesive layer penetrates into an annular gap between the upper flange and the sleeve to join both members.

(12) A part of the adhesive layer penetrates into the annular gap between the upper flange and the sleeve to form a drooping portion, and joins both members, and the upper surface of the upper flange and the The inductor according to the aspect (10) or the aspect (l1), wherein the adhesive layer overlaid on the upper surface of the sleeve slightly falls on the annular gap to form an annular recess.

(13) The aspect (1) to the aspect (12) in which the conductive material constituting the conductive surface is wound and fixed from the lower surface of the sleeve to the outer circumferential surface, thereby preventing or preventing peeling of the conductive surface to the sleeve. The inductor described in any one of

(14) A method of manufacturing the inductor according to any one of the above aspects (1) to (13), wherein the step of holding the sleeve having the inclined surface formed in a supporting recess of the support type and the lower surface of the sleeve A step of forming a conductive surface in two spaced apart portions, a step of inserting the core wound with conductive wires into an inner hole of the sleeve on which the conductive surface is formed, and two ends of the conductive wire wound around the core Forming the inductor intermediate by welding each of the two derived portions to the conductive surface, a cutting step of cutting the free end side portions of both ends of the welded conductive line from the inductor intermediate, and the inductor intermediate A method of manufacturing an inductor, comprising: applying an adhesive to the upper surface of the core and the sleeve, thereby at least bonding the core and the sleeve. .

According to such a configuration according to the present invention, an inductor with a low profile and compact shape and structure can be advantageously realized, and the tip of the electroded conductive wire when mounting the inductor on an electronic circuit board is advantageously realized. It is an excellent feature that it is possible to provide a wound type inductor with a structure that can easily recognize a position. And in addition to this, an inclined surface is formed in the lower edge portion of the inner circumferential surface of the sleeve corresponding to the wiring position of the conductive wire drawn outward from the core, and the conductive wire passes through the inclined surface to the conductive surface of the lower surface of the sleeve, At the point where the connection is made, by the edge of the core or the edge of the sleeve, the bending of the conductive wire at a large bending angle can be effectively suppressed or prevented, whereby the damage of the conductive wire can be effectively avoided. Will be.

In addition, the inclined surface formed in such a sleeve allows a large space between the sleeve and the core to be secured. Therefore, the conductive wires extracted from the core are led out by using such a large space as the wiring passage, so that the conductive The drawing work or the wiring work can be easily performed, and by doing so, the workability of the wiring can be improved, thereby greatly contributing to the automation realization of the inductor assembly work.

1 is a partially broken perspective explanatory view showing an example of an inductor according to the present invention.
FIG. 2 is a bottom explanatory diagram of the inductor shown in FIG. 1.
FIG. 3 is an AA cross-sectional explanatory diagram in FIG. 2.
Fig. 4 is a cross-sectional explanatory view showing one step of the manufacturing method of the inductor according to the present invention, showing a state where a conductive surface is formed at flat bottom portions of corner portions of the sleeve held in the first support die. .
Fig. 5 is a cross-sectional explanatory view showing one step of the manufacturing method according to the present invention, and shows a state in which a core wound with a line is accommodated in a sleeve held in a first supporting die.
6 is a cross-sectional explanatory view showing one step of the manufacturing method according to the present invention. From the state shown in FIG. The state which is made is shown.
Fig. 7 is a cross-sectional explanatory diagram showing one step of the manufacturing method according to the present invention, in which an adhesive is applied to the upper surface of the inductor intermediate held in the second support type, the core and the sleeve are integrated to complete the inductor. It is shown.
FIG. 8 is a partial perspective explanatory view showing a form in which a sleeve is dropped and accommodated in the plurality of accommodation holes using a template as a support die. FIG.
9 is a perspective explanatory diagram of a state shown in FIG. 7.
FIG. 10 is an enlarged explanatory view of part B in FIG. 7.
FIG. 11: is explanatory drawing of the bottom surface corresponding to FIG. 2 which shows the other aspect of the conductive surface formed in the lower surface of a sleeve.
FIG. 12: is bottom surface explanatory drawing corresponding to FIG. 2 which shows another aspect of the conductive surface formed in the lower surface of a sleeve.
It is a perspective partial view for demonstrating the preferable form of the inclined surface formed in the sleeve which concerns on this invention.

EMBODIMENT OF THE INVENTION Hereinafter, in order to make this invention clear more concretely, embodiment of this invention is described in detail, referring drawings.

First, a representative example of the inductor according to the present invention is schematically shown in FIGS. In the figure, the inductor 1 basically consists of a core 3 on which the conductive wire 2 is wound, and a sleeve 4 surrounding the core 3. In addition, the core 3 and the sleeve 4 are formed of a known magnetic material such as ferrite. In addition, as the known magnetic material, an insulating material such as Ni-based ferrite is generally used, but in the inductor 1 of the example, conductive Mn-based ferrite having higher inductance than Ni-based ferrite is used. It is a structure which can be used advantageously as a material of the core 3. That is, although the details will be described later, in the situation where the core 3 and the sleeve 4 are in a non-contact state, the two tips of the conductive wires 2 drawn from the core 3 are made of an insulating Ni-based ferrite. Since the structures respectively connected to the two conductive surfaces 13a and 13b of the sleeve 4 are adopted, the two leading ends do not conduct with each other, and thus the conductive Mn system is used as the material of the core 3. Ferrite can be adopted.

And in such an inductor 1, advantageously, the height of the core 3, ie, the height of the up-down direction in FIG. 3, is 1.5 mm or less, preferably 1.0 mm or less, more preferably 0.85 mm or less. It is configured to be. In addition, the outer shape of the upper and lower flanges 5 and 6 and the inner shape of the sleeve 4 formed at the upper and lower ends of the core 3 constituting the inductor 1 are circular. In addition, in this aspect, the diameter of the lower flange 6 present in the lower end is smaller than the diameter of the upper flange 5 present in the upper end of the core 3, and as described later, the core 3 Consideration can be made to facilitate the derivation (extension) of the conductive wire (2) to the outside, in other words, to facilitate the withdrawal or take-out operation and operation, and to contribute to suppressing or eliminating the occurrence of problems in such operation and operation. It is becoming.

In addition, in the conventional low-profile inductor, a so-called stacked inductor, in which a curved conductive line is printed on the plane of a plurality of ferrite substrates, has become mainstream, but in such an inductor, further improvement in inductor characteristics cannot be expected. In the present invention, the height of the core 3 is advantageously lower than 1.5 mm, which is advantageously 1.5 mm or less, so that the inductor characteristics can be further improved. Therefore, the present invention has a great feature in that it is made of a compact inductor for practical use of a winding type inductor and a low inductor type, especially the inductor having a height of 1.5 mm or less.

Moreover, in such an inductor 1, the sleeve 4 which accommodates and surrounds the core 3 has the square shape, and the inner hole is formed in the circumferential surface, and gives a round inner shape, have. Since the inner hole penetrates from the upper surface to the lower surface of the sleeve 4 and does not have a conventional structure formed by forming a bottom portion (closed portion) in the core receiving hole of the sleeve, the thickness of the entire inductor can be reduced. In this way, the structure contributes to low magnification. In addition, if a non-penetrating sleeve is used instead of such a sleeve 4, if the core is inserted into such a non-penetrating sleeve, inevitably one collar of the core contacts the bottom of the core receiving hole of the sleeve. In this case, the inductance, which is one of the important characteristics of the inductor, is affected, but the sleeve 4 and the core 3 do not come into contact with each other by using the sleeve 4 of the through-hole sleeve structure. This is because deterioration of inductance can be advantageously avoided. Also in this respect, it can be said that employment of the sleeve 4 which penetrated the inner hole is preferable. It goes without saying that the through-sleeve sleeve is easier to process in the manufacturing stage than the non-penetrating sleeve.

In addition, this sleeve 4 is formed to have the same height as that of the core 3, as is apparent from FIG. 3, whereby the upper surface 9 of the sleeve 4 has an upper portion of the core 3. Configured to substantially face with the top surface 7 of the flange 5 and the bottom surface 10 of the sleeve 4 to substantially face the bottom surface 8 of the lower flange 6 of the core 3. It is. Here, substantially flat is considered to be substantially flat, taking into account that the height of the sleeve 4 and the core 3 is shifted to some extent, for example, about 0.1 mm, due to unavoidable causes such as variation during manufacture. In the present specification, such a state is simply referred to simply as "face one".

And in the lower surface (bottom surface; 10) of the sleeve 4, as shown in FIG. 2, the conductive surface 13a of an isosceles triangle triangular shape at right angles to the two corner parts 12a and 12b which oppose each other, respectively. , 13b) is formed using a known conductive material. In addition, there exist methods, such as a dip, sputtering, and metal terminal formation, in the formation of the electrode which provides these electroconductive surfaces 13a and 13b, but the printing method is employ | adopted in this embodiment. Here, the method of printing formation is employ | adopted for the following reason. That is, the conductive surface 13a, 13b can be formed in many sleeve 4 simultaneously by making the lower surface 10 of the sleeve 4 face upward, and arrange | positioning many pieces, and productivity is very high. Because it gets better. In addition, when the electrode shape on the mounting board side is changed, it is necessary to change the electrode shape of the sleeve 4 in accordance with it, but the correspondence becomes difficult in the metal terminal generally used. However, it is because it can change easily into a required shape as it is print formation. In addition, since the thickness can be controlled by using the printing formation method, there is an advantage that the thickness of the conductive surface can be reduced, which is convenient for reducing the inductor.

Moreover, as shown in FIG. 3, the said electrically-conductive surface 13a, 13b printed by the sleeve 4 is wound up from the lower surface 10 of the sleeve 4 to the outer peripheral surface 16 as shown in FIG. By sticking, peeling from the sleeve 4 of these electrically conductive surfaces 13a and 13b can be suppressed or prevented effectively. In addition, with respect to the conductive surfaces 13a and 13b printed and formed on the lower surface 10 of such a sleeve 4, two of the conductive wires 2 drawn out from the outside of the core 3 and outwards, respectively, respectively. The outer lead-out portions 14a and 14b are arranged and heated and pressurized, so that these conductive surfaces 13a and 13b and the conductive lines 2 are welded and connected, so that the electrodes 15a and 15b of the inductor 1 are respectively. It is formed. In addition, at least the conductive lines 2 of these conductive surfaces 13a and 13b for the welding of the two outer leading portions 14a and 14b of the corresponding conductive lines 2 to the conductive surfaces 13a and 13b. The width | variety of the arrangement | positioning part of the outer lead-out part 14a, 14b has become wider than the outer diameter of the electrically conductive line 2, and the two outer lead-out part 14a of such a conductive line 2 , 14b), the welding sites are welded in a flattened form as shown in FIG. 2.

In this way, in the inductor 1, the conductive wire 2 wound around the core 3 includes two corner portions (2) of the sleeve 4 facing each other between the core 3 and the sleeve 4. At the position on the substantially imaginary line L1 connecting 12a and 12b, after descending from the upper side downward, it bends at the edge part of the inner peripheral surface side below the sleeve 4, and it is two corner parts 12a and 12b, respectively. ) Extends outward in the radial direction and is welded to the conductive surfaces 13a and 13b, respectively. At this time, in order to weld the conductive wire 2 with sufficient strength, it is necessary to secure a certain amount of space, but the sleeve 4 is formed by making the outer peripheral surface of the sleeve 4 rectangular and the inner hole circular. ), It is possible to secure a sufficient space for welding the conductive lines.

By the way, at the time of wiring for guiding the two outer lead-out portions 14a, 14b of the conductive wire 2 drawn out from the core 3 to the corresponding conductive surfaces 13a, 13b, respectively, the core 3 The conductive wires 2 drawn out are in sliding contact with the edge of the outer circumferential surface 17 of the lower flange 6 of the lower flange 6 or the edge of the circumferential direction where the inner circumferential surface 18 and the lower surface 10 of the sleeve 4 intersect. It may cause damage. For this reason, as shown to FIG. 2, FIG. 3, and FIG. 13 here, two electroconductive surfaces 13a among the edge parts 24 of the circumferential direction which the inner peripheral surface 18 and the lower surface 10 of the sleeve 4 intersect. , The conductive surfaces 13a and 13b which are located in the opposing gaps of the 13b, in other words, on the virtual line L1 and are widened at predetermined widths on both sides thereof, and the lower flange of the core 3. 6) the site | part (inner side part) located in between is chamfered by the width W larger than the outer diameter of the conductive line 2, and the inclined surface 20 is formed, and passes through this inclined surface 20, and the conductive line 2 Two outer lead-out portions 14a and 14b of are wired so as to be led to the conductive surfaces 13a and 13b, respectively. The inclined surface 20 is formed by cutting the lower corner portion 24 of the inner circumferential surface 18 of the sleeve 4 to a predetermined width, thereby forming a wiring recess having a predetermined depth. It is supposed to be.

In this way, the lower edge 24 of the lower portion of the inner circumferential surface 18 in the portion of the lower surface 10 positioned between the corner portions 12a and 12b in the sleeve 4 is chamfered, and the inclined surface 20 As a result of this formation, the space formed between the inner circumferential surface 18 of the sleeve 4 and the outer circumferential surface 17 of the lower flange 6 of the core 3 becomes large, and thus the conductive wire 2 drawn out from the core 3 is thereby enlarged. ) Does not bend at sharp angles, and through the inclined surface 20 at a gentle angle, in other words, through the wiring recess formed by the inclined surface 20, the outer lead-out portions 14a and 14b are each electrically conductive. It is guided onto the faces 13a and 13b. In this way, the damage of the conductive wire 2 can be effectively suppressed or avoided, and the drawing (takeout) of the conductive wire 2 and the wiring work can be advantageously performed.

Moreover, the inclined surface 20 in which the wiring part of the electrically conductive wire 2 in the circumferential edge part 24 which the inner peripheral surface 18 of such the sleeve 4 and the lower surface 10 cross | intersects is chamfered and formed. Although it is a flat inclined surface here, even if it becomes an inwardly curved inclined curved surface (R surface), as shown in FIG. 13, it does not interfere at all and can enjoy the same effect. In addition, since the place where this inclined surface is formed is not limited to the vicinity of a corner part, but becomes the vicinity of the lead-out area | region of a conductive line according to the objective, the formation place of an inclined surface also changes according to the place where a conductive line is derived.

Moreover, when this inclined surface 20 is comprised by the inclined plane like an example, the distance Q used as the shortest distance between this inclined plane 20 and the upper edge P1 of the lower flange 6 ) Is preferably within a range of 1.1 times to 10 times the outer diameter of the conductive wire 2, more preferably 1.2 times to 5 times, whereby the action and effect are exhibited better as described above. Will be. If the gap is too narrow, drawing of the conductive wire 2 or wiring work becomes difficult, and if too wide, the overall shape of the inductor 1 may be increased. However, the said distance Q is made into the shortest distance between the virtual inclination line 21 and the said edge P1, when a slope is a curved surface. In addition, as shown in FIG. 13, the virtual inclination line 21 here is the edge which is the point which is furthest from the sleeve inner peripheral surface in the curve formed in which the inclined surface 20 and the lower surface 10 of the sleeve 4 cross | intersect. P2) and the virtual inclined line which connects the line which fell perpendicularly along the sleeve inner peripheral surface from the virtual edge part 24 in which the inclined surface 20 was formed, and the edge P4 which the inclined surface 20 crossed | intersected are shown.

In addition, as an elevation angle θ formed by such an inclined plane 20 or an imaginary oblique line 21 with respect to the bottom surface 10 of the sleeve 4, it is generally 30 degrees to 85 degrees, preferably 45 degrees to It is preferable that it is an angle within the range of 80 degrees. If the inclination angle θ is too small, the bending angle of the conductive line 2 may be increased. On the other hand, when an excessively large angle θ is adopted, the inclination plane 20 is formed. There exists a possibility that the effect by one thing may become insufficient.

In addition, the said edge P2 is located so that it may be located close to the inner direction of half or less of the length between the inner peripheral surface 18 of the sleeve 4, and the outermost end P3 of the corner parts 12a and 12b. In other words, the edge P2 is located away from the inner circumferential surface 18 at a distance shorter than 1/2 of the length between the position of the inner circumferential surface 18 and the outermost end P3 in the virtual line L1. have. When the position of the edge P2 of this inclined surface 20 becomes too close to the outermost end P3 of the corner parts 12a and 12b, the formation area of the conductive surfaces 13a and 13b becomes small and the conductive lines 2 This is because there is a risk of disturbing the welding of the two outer lead-out portions 14a and 14b.

In the sleeve 4, as shown in FIGS. 1 and 2, a partial thickness of the outer surface portion of any one of the four corner portions 12a, 12b, 12c, and 12d is shown. The cut part is formed, and the cutout part 11 which opens outward is formed. The formation of the cutouts 11 makes it easier to recognize the positions of the conductive surfaces 13a and 13b formed on the lower surface of the sleeve 4, and in addition, the sleeve 4, which has a rectangular shape, may be connected to the inductor 1. In the manufacturing process, when the sleeve 4 is dropped and held in each of the plurality of receiving holes of the template to be supported, the arrangement and positioning of the sleeve 4 are facilitated, thereby facilitating the automation. In addition, even in the product management process, the operation becomes easy.

By the way, as shown in FIG. 2, the shape of the said notch part 11 has the virtual line L3 which connects the corner part 12d with the notch part 11, and the corner part 12c which mutually opposes. It is preferable to set it as an asymmetrical shape as a center. If the virtual line L3 is a line symmetrical shape, the surface and the back surface of the sleeve 4 may be indistinguishable, and when the sleeve 4 is dropped into the receiving hole of the template, The side facing and the inside facing are mixed. In addition, this cutout part 11 is provided in the corner part in order to suppress the characteristic deterioration of the inductor 1 to the minimum, but the installation place is not limited to a corner part. In addition, the cutout part 11 should just be a place and shape which can accommodate the front and back in the accommodation hole of the said template, ie, the shape of the sleeve 4 including the cutout part 11 is a thing of the sleeve 4 What is necessary is just a shape which becomes asymmetric also in any of the two virtual lines L1 and L3 which generate | occur | produce the opposing corner part subsequently.

Moreover, in such an inductor 1, as shown in FIG. 1 and FIG. 3, in the form which accommodated the core 3 in the inner hole which provides the inner peripheral surface 18 of the sleeve 4, the core ( 3) and the adhesive agent are apply | coated on the upper surfaces 7 and 9 of the sleeve 4, and the adhesive bond layer 23 of predetermined thickness is formed, and the core 3 and the sleeve 4 are integrated. . Moreover, by application | coating of such an adhesive agent, an adhesive flows in the clearance gap between the outer peripheral surface 19 of the upper flange 5 of the core 3, and the inner peripheral surface 18 of the sleeve 4, as shown in FIG. By sticking to the outer circumferential surface 19 and the inner circumferential surface 18, the drooping portion 23a is formed, whereby the core 3 and the sleeve 4 can be more firmly integrated. Further, by the formation of the drooping portion 23a of the adhesive layer 23, the annular recess 23b is formed on the upper surface of the adhesive layer 23 corresponding to the drooping portion 23a. It is formed corresponding to the gap between the upper flange portion 5 and the sleeve (4). However, the annular recess 23b is not necessarily formed, and may not be formed depending on the degree of the gap between the sleeve 4 and the core 3, but such an annular recess 23b is provided. With or without, the effect of this invention is not influenced substantially at all.

And such an inductor 1 will be advantageously manufactured according to a process, for example, as shown to FIGS. 4-7.

That is, at the time of assembling the core 3 and the sleeve 4, first, a first supporting die 30 for accommodating and holding the sleeve 4 is prepared, and in the accommodation hole 31, FIG. 4. As shown, the sleeve 4 in which the inclined surfaces 20 and 20 of the predetermined width are formed at the opposite position of the lower edge portion 24 of the inner circumferential surface 18 is accommodated with its lower surface (bottom surface; 10) facing up. , Is set. Here, the depth of the accommodating hole 31 of the 1st support die 30 becomes shallow from the axial height of the sleeve 4, As a result, as shown in a figure, the sleeve ( The lower part of 4) protrudes upwards. In the lower surface 10 of the lower part 10 which protrudes upward of the set sleeve 4, a conductive material known in the horizontal plane portions of the two corner portions 12a, 12b of the sleeve 4 facing each other. By using, the conductive surfaces 13a and 13b that are wider than the outer diameter of the conductive line 2 are formed to be printed in the shape of a right-angled isosceles triangle as shown in FIG. 2. In addition, by forming the conductive surfaces 13a and 13b by such printing, the conductive material is wound around and fixed to the outer peripheral surface 16 of the sleeve 4, and as a result, as shown in FIG. Is formed.

In addition, as the 1st support type | mold 30 targets only one sleeve 4, as shown in FIG. 8, many accommodating holes for accommodating and holding many sleeves 4 ( It is also possible to use the template 40 on which the 41 is formed. In the case of using this template 40, a technique for industrially advantageously forming the conductive surfaces 13a and 13b at the same time with respect to the plurality of sleeves 4 accommodated and set in the receiving hole 41 is advantageously used. Will be employed. Moreover, when accommodating and holding the many sleeve 4 in the accommodation hole 41 of the template 40, respectively, the notch part 11 is formed in the corner part 12d in the sleeve 4, On the other hand, since the projection part 42 corresponding to this cutout part 11 is formed in the accommodation hole 41 of the template 40, many sleeve 4 accommodated in the accommodation hole 41 is cut out. The projection 42 enters the binding portion 11 so that the projections 42 are always aligned in one direction and accommodated and retained, whereby the conductive surfaces 13a and 13b have corner portions 12a of the bottom surface 10 of the sleeve 4. , 12b) to be formed correctly.

And thus, with respect to the sleeve 4 in which the electroconductive surfaces 13a and 13b are formed, in the state which hold | maintained in the 1st support die 30, the upper and lower flanges 5 and 6 at the upper and lower ends in the inner hole. As shown in FIG. 5, the core 3, on which the conductive wire 2 having the coil 2) is wound, is inserted and arranged with the upper flange 5 downward.

Subsequently, the outer leading portions 14a and 14b at both ends of the conductive wire 2 wound on the core 3 are led outward toward the conductive surfaces 13a and 13b formed on the sleeve 4, respectively. As shown in FIG. 6, the outer lead-out portions 14a and 14b and the conductive surfaces 13a and 13b of the conductive wire 2 are melt-pressed and welded by being heated and pressurized in a closed state, whereby the sleeve ( An inductor intermediate 32 is formed in which 4) and the core 3 are connected by a conductive line 2.

Moreover, the free end side part in the outer lead-out part 14a, 14b of this welded conductive wire 2 is cut off from the inductor intermediate body 32, and is removed. In addition, the cut part of the free end side part of this electrically conductive wire 2 tension | strengthens the outer lead | leader part 14a, 14b of the electrically conductive wire 2 with respect to the inductor intermediate body 32, and it cut | disconnects (breaks) from the weld part. In addition to the above, it is performed by cutting and removing a predetermined portion of the outer lead-out portions 14a and 14b of the conductive wire 2 using an appropriate cutting tool.

Thereafter, the inductor intermediate 32 is inverted up and down, and as shown in FIG. 7, the upper surface 7 of the inductor intermediate 32, in other words, the upper surface 7 of the upper flange 5 of the core 3. The adhesive 23 is applied in a state where the upper surface 9 of the sleeve 4 and the upper surface are flattened, so that the core 3 and the sleeve 4 are bonded to the adhesive layer 23 having a predetermined thickness in the upper surface portion thereof. It is fixed by and integrated. Thereby, as shown in FIG. 7 or FIG. 9, the target inductor 1 can be completed.

Further, by applying the adhesive 23 to the upper surface of the middle of the inductor, the adhesive 23 is expanded in the gap between the upper flange 5 of the core 3 and the sleeve 4 as shown in FIG. 10. Flows in, and thus the drooping portion 23a of the adhesive layer 23 is formed, which joins between the upper flange 5 of the core 3 and the sleeve 4 by the drooping portion 23a. The area is increased, whereby the joining and integrating the core 3 and the sleeve 4 can be made more firm. In addition, with the formation of the drooping portion 23a, an annular recess 23b corresponding thereto is formed.

Thus, although the minimum process required for manufacturing the example inductor 1 has been described, it is also possible to further increase the production efficiency by changing the order as necessary and adding the necessary processes. Moreover, in the inductor 1 obtained in this way, it differs from the conventional thing by the point that the conductive surface 13a, 13b which is a component of an external electrode is formed in the lower surface 10 of the sleeve 4, and a conductive surface The substrate for forming the substrate becomes completely unnecessary, and as a result, the inductor 1 according to the present invention becomes a low one, which is controlled by the height of the core 3. In addition, the inductor 1 is extended from the core 3 to the conductive surfaces 13a and 13b at the shortest distance and the degree of accommodation thereof is also simplified. Is very compact.

As mentioned above, although typical embodiment of this invention was described in detail, it is only an illustration to the last, This invention is not interpreted at all limitedly by the specific technique which concerns on such embodiment, Based on the knowledge of a person skilled in the art, It can be practiced in the aspect which added various changes, correction, improvement, etc., and it is natural that all is understood that it belongs to the scope of the present invention, unless the embodiment departs from the meaning of this invention. Do.

For example, the two conductive surfaces 13a and 13b should just be formed independently by the two site | parts which spaced apart from each other in the lower surface 10 of the sleeve 4, In addition to the arrangement form mentioned above, FIG. It can also be set as the arrangement form as shown to. In FIG. 11, the shapes of the conductive surfaces 13a and 13b printed on the lower surface (bottom surface; 10) of the sleeve 4 include each other including at least one corner portion of the lower surface 10 of the sleeve 4. The strip | belt-shaped conductive surface formed in the site | part which opposes is arrange | positioned in parallel with each other, and is formed.

Moreover, other embodiment which concerns on arrangement formation of the electrically conductive surface is shown in FIG. In the lower surface (bottom surface; 10) of the sleeve 4, the central portions 43a and 43b of one side of two mutually opposing quadrangles are replaced on or near a virtual line L2 that virtually connects them. In other words, the conductive surfaces 13a and 13b are formed in the sleeve inner peripheral surface side portion located inside the conductive surfaces 13a and 13b (on the core 3 side). In this case, the inclined surface 20 formed in the lead-out site | part of a conductive wire and the sleeve inner peripheral surface becomes a position on the said virtual line L2 or near it. However, since the welding area of the conductive wire in the position above or near the said virtual line L2 becomes narrow compared with the welding area in a corner part, it is difficult to ensure the area sufficient for welding a conductive wire. In the case of adopting this embodiment in a small inductor, attention is to be paid to the welding strength of the conductive wire. Therefore, such embodiment shown in FIG. 12 can be said to be a preferable aspect with respect to a large inductor.

1: inductor 2: conductive line
3: core 4: sleeve
5: upper flange 6: lower flange
7, 9: upper surface 8, 10; if
11: notch part 12a, 12b, 12c, 12d: corner part
13a, 13b: conductive surface 14a, 14b: outer lead area
15a, 15b: Electrode 16: outer peripheral surface
18: inner peripheral surface 20: inclined surface
21: virtual oblique line 23: adhesive layer
24: corner portion 30: first support type
31, 41: hole 32: inductor intermediate
34: second support type 40: template
42: protrusions 43a, 43b: center of one side of the rectangle

Claims (15)

A core 3 wound around the conductive wire 2 having upper and lower flanges 5 and 6 at the upper and lower ends thereof, and a sleeve 4 which encloses and encloses the core in an internal hole, and as the sleeve 4 And wider than the outer diameter of the conductive wire, each of the two leading parts of both ends of the conductive wire drawn outward from the core and formed at two spaced apart portions of the lower surface of the sleeve, using a sleeve having a rectangular shape. In the inductor which is respectively welded to the conductive surfaces 13a and 13b and formed into an electrode, among the portions 24 in the circumferential direction where the inner circumferential surface 18 and the lower surface 10 of the sleeve 4 intersect, 2 a single conductive surface regions, each located on the inside with respect to the (13a, 13b) is chamfered by a width greater than the outer diameter (W) of the conductive line (2), the additional derived the conductive lines in accordance with the place for deriving the said conductive surface 2 Two inclined surfaces 20 are formed, Passing these inclined surfaces, the lead portion of the conductive line is connected to the conductive surface, respectively, while the outer peripheral portion of any one of the corner portions 12a, 12b, 12c, 12d of the sleeve 4 is partially cut in thickness, and the sleeve An inductor characterized in that a cutout portion (11) having an asymmetrical shape is formed in any of two imaginary lines (L1 and L3) which are subsequently formed at opposite corner portions of the inductor. The method of claim 1,
The inductor in which the shortest distance Q between the inclined surface 20 formed in the sleeve 4 and the upper edge P1 of the lower flange 6 is in the range of 1.1 times to 10 times the outer diameter of the conductive wire 2. . The method of claim 2,
And the inclined surface has an elevation angle [theta] in the range of 30 to 85 degrees. delete The method according to any one of claims 1 to 3,
At least one of the outer lead-out portions 14a, 14b of the conductive wire 2 wound around the core 3 is dropped, and the middle of the outer lead-out portion is bent, and An inductor having a tip portion extending toward the conductive surface of the sleeve. The method of claim 5, wherein
The position on the horizontal plane which bends the middle of the outer lead-out portions 14a and 14b of the conductive line 2 is an imaginary extension on the horizontal plane along the center line in the width direction of the inclined surface 20 formed in the sleeve. Inductor in position on or near line (L1, L2). The method according to any one of claims 1 to 3,
An inductor in which the outer shape of the upper and lower flanges (5, 6) of the core (3) is circular, and the inner shape of the sleeve (4) is circular. The method of claim 7, wherein
The outer diameter of the upper flange (5) of the core (3) is equal to or larger than the outer diameter of the lower flange (6). The method according to any one of claims 1 to 3,
An inductor with said core disposed in a non-contact state relative to said sleeve. The method according to any one of claims 1 to 3,
An inductor in which the upper surface 7 of the upper flange 5 of the core 3 and the upper surface 9 of the sleeve 4 are faced, and the adhesive layer 23 is coated on their upper face. . 11. The method of claim 10,
A part of the adhesive layer (23) penetrates into the annular gap between the upper flange (5) and the sleeve (4) and joins both members. 11. The method of claim 10,
A part of the adhesive layer 23 penetrates into the annular gap between the upper flange 5 and the sleeve 4 to form a drooping portion 23a, and joins both members, The inductor layer which has been covered so as to face the upper surface 7 of the flange 5 and the upper surface 9 of the sleeve 4 falls slightly on the annular gap to form an annular recess 23b. . The method according to any one of claims 1 to 3,
The conductive material constituting the conductive surfaces 13a and 13b is wound and fixed from the lower surface 10 of the sleeve 4 to the outer circumferential surface 16, thereby peeling off the conductive surfaces 13a and 13b to the sleeve. An inductor adapted to suppress or inhibit. delete A method of manufacturing the inductor according to any one of claims 1 to 3,
The template 40 provided with the accommodation hole 41 in which the protrusion part 42 corresponding to the cutout part 11 formed in the corner part of the sleeve 4 in which the said inclined surface 20 was formed is formed, A step of allowing the sleeve to be aligned with the lower surface of the template so as to be in an upper side, and to be maintained;
Forming conductive surfaces 13a and 13b in two spaced apart portions of the lower surface of the sleeve,
Inserting the core 3 wound around the conductive wire into the inner hole of the sleeve 4 on which the conductive surface is formed such that its upper flange 5 is lowered, and
Welding two lead portions on both ends of the conductive wire wound on the core to the conductive surface to form an inductor intermediate 32;
A cutting step of cutting the free end side portions of both ends of the welded conductive line from the inductor intermediate;
And inverting the inductor intermediate up and down, applying an adhesive to the upper surface of the core and the sleeve constituting the inductor intermediate, and integrating these cores and the sleeve at least.

Images