WO2015182374A1 - 巻線型コイル部品の製造方法 - Google Patents
巻線型コイル部品の製造方法 Download PDFInfo
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- WO2015182374A1 WO2015182374A1 PCT/JP2015/063640 JP2015063640W WO2015182374A1 WO 2015182374 A1 WO2015182374 A1 WO 2015182374A1 JP 2015063640 W JP2015063640 W JP 2015063640W WO 2015182374 A1 WO2015182374 A1 WO 2015182374A1
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- holding
- holding jig
- core member
- jig
- external electrode
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/064—Winding non-flat conductive wires, e.g. rods, cables or cords
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/09—Winding machines having two or more work holders or formers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/10—Connecting leads to windings
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/29—Terminals; Tapping arrangements for signal inductances
Definitions
- the present invention relates to a method for manufacturing a coil component, and more specifically, a core member including a columnar core portion and a pair of flange portions provided at both ends of the core portion, and one side flange of the pair of flange portions.
- the present invention relates to a method of manufacturing a coiled coil component comprising a pair of external electrodes formed on a part and the other side collar part, and a winding wound around a core part.
- Patent Document 1 proposes a method of manufacturing a wire-wound coil component as shown in FIG.
- the winding-type coil component 100 of FIG. 15 whose manufacturing method is proposed in Patent Document 1 includes a columnar core portion 102 and a pair of flange portions 103 (one side flange portion 103a, provided on both ends of the core portion 102).
- Core member 101 provided with the other side flange 103b), a pair of external electrodes 104a, 104b formed on the pair of flanges 103 (one side flange 103a, the other side flange 103b), and the core portion
- the external electrodes 104a and 104b are mounted on one side flange 103a and the other side flange 103b on which the wound coil component 100 is mounted (for example, a circuit board or the like). ).
- the external electrodes 104a and 104b face the one side flange 103a and the other side flange 103b so as not to cause problems such as deterioration of characteristics such as a magnetic field and solder wrapping around the coil (winding 105).
- No electrode is formed on the surface (inner wall surface), and the formation height of the external electrodes 104a and 104b is from the facing surface side of the one side flange 103a and the other side flange 103b toward the end surface (outer wall surface). It is formed to be higher.
- FIG. 16 shows a method for forming the above-described external electrode (hereinafter also referred to as “inclined external electrode”) in manufacturing a wire-wound coil component as shown in FIG.
- the pair of flange portions 103 one side flange portion 103a, the other side flange portion 103b
- a method of forming an inclined external electrode through a step of applying a conductive paste and a step of baking the conductive paste is shown.
- a conducting wire 212 is wound around a core portion 211 c of the core member 211, and a pair of leg portions is formed on the leg portions 211 a and 221 b on both ends of the core member 211.
- a wound-type coil component 200 is described in which the formation height of the external electrodes 213a and 213b increases from the opposing surface side of 211a and 211b toward the end surface side (outer wall surface). Then, as a method of manufacturing the wire-wound coil component 200 formed so that the external electrodes are inclined, as shown in FIG. 18, a method of forming the external electrodes 213a and 213b simultaneously on a pair of legs 211a and 211b is proposed. Has been.
- Patent Document 2 in order to apply the conductive paste for forming the external electrodes 213a and 213b simultaneously on the pair of legs 211a and 211b, first, the legs of the core member 211 are placed on the flat jig 230. Place with 211a and 211b facing up. On the other hand, a plate 231 having a V-shaped recess 231a is prepared, and a conductive paste 232 for forming external electrodes is applied thereto.
- the conductive paste is simultaneously applied to the pair of leg portions 211a and 211b,
- the external electrodes 213a and 213b are formed on the legs 211a and 211b through the firing step.
- the conductive paste 232 is applied to the pair of legs 211a and 211b at the same time.
- the moldability of the electrode material, the processing accuracy of the jigs, and the positioning of the core member Due to problems such as accuracy, there is a problem that the coating accuracy is lower and the shape accuracy of the external electrode is lower than when applying the conductive paste to each of the pair of leg portions 211a and 211b.
- the present invention solves the above-mentioned problem, and the height dimension gradually increases from the mutually facing surface side of the one side collar portion and the other side collar portion constituting the core member toward the opposite surface.
- Winding-type coil parts with externally inclined external electrodes (inclined external electrodes), which can efficiently manufacture highly reliable and highly reliable wound-type coil parts with inclined external electrodes with high shape accuracy
- the purpose is to.
- the manufacturing method of the (first) wound type coil component of the present invention is A core member having a columnar core part and a pair of flanges provided at both ends of the core part, and a pair of one side collar part and the other side collar part formed in the pair of collar parts
- a winding-type coil component comprising an external electrode and a winding wound around the winding core, wherein the winding-type coil component is mounted on the one side collar and the other side collar
- the external electrode inclined such that the height dimension gradually increases from the opposite surface side of the one side collar part to the other side collar part is formed.
- Forming the external electrode comprises: (A) The core member is held by the first holding jig having a holding force for holding the plurality of core members, and the core member of the first holding jig is held by the axis of the core portion.
- a region having a predetermined angle with respect to the holding surface, which is a main surface on the side to be formed, and the external electrode of the one side flange is to be formed by the holding of the first holding jig from the other side flange A holding step for holding in a posture protruding from the surface;
- the step of (a) is performed, and the region where the external electrode is to be formed on the one side flange projecting from the holding surface is brought into contact with the electrode material for forming the external electrode
- a rotation step in which the region to be formed is in a posture facing the first holding jig; (D) After carrying out the step (c), the core member held by the first holding jig is positioned so as to face the first holding jig. Transfer to a second holding jig having a holding force to hold, with respect to the holding surface that is the main surface of the second holding jig on the side holding the core member, the axis of the core portion The core member is placed in a posture having a predetermined angle and a region in which the external electrode of the other side flange is to be formed protrudes from the holding surface of the second holding jig from the one side flange.
- another (second) winding type coil component manufacturing method of the present invention includes: A core member having a columnar core part and a pair of flanges provided at both ends of the core part, and a pair of one side collar part and the other side collar part formed in the pair of collar parts A winding-type coil component comprising an external electrode and a winding wound around the winding core, wherein the winding-type coil component is mounted on the one side collar and the other side collar In the region close to the object, the external electrode inclined such that the height dimension gradually increases from the opposite surface side of the one side collar part to the other side collar part is formed.
- Forming the external electrode comprises: (A) The core member is held by the first holding jig having a holding force for holding the plurality of core members, and the core member of the first holding jig is held by the axis of the core portion.
- a region having a predetermined angle with respect to the holding surface, which is a main surface on the side to be formed, and the external electrode of the one side flange is to be formed by the holding of the first holding jig from the other side flange A holding step for holding in a posture protruding from the surface;
- the external side of the one side collar is brought into contact with an electrode material for forming the external electrode by contacting a region where the external electrode of the one side collar protruding from the holding surface is to be formed
- the core member held by the first holding jig is positioned so as to face the first holding jig.
- the step (d) is carried out to form the external electrode in a region where the external electrode of the other side flange projecting from the holding surface of the second holding jig is to be formed.
- another (third) winding type coil component manufacturing method of the present invention includes: A core member having a columnar core part and a pair of flanges provided at both ends of the core part, and a pair of one side collar part and the other side collar part formed in the pair of collar parts A winding-type coil component comprising an external electrode and a winding wound around the winding core, wherein the winding-type coil component is mounted on the one side collar and the other side collar In the region close to the object, the external electrode inclined such that the height dimension gradually increases from the opposite surface side of the one side collar part to the other side collar part is formed.
- Forming the external electrode comprises: (A) The core member is held by the first holding jig having a holding force for holding the plurality of core members, and the core member of the first holding jig is held by the axis of the core portion.
- a region having a predetermined angle with respect to the holding surface, which is a main surface on the side to be formed, and the external electrode of the one side flange is to be formed by the holding of the first holding jig from the other side flange A holding step for holding in a posture protruding from the surface;
- the step of (a) is performed, and the region where the external electrode is to be formed on the one side flange projecting from the holding surface is brought into contact with the electrode material for forming the external electrode
- the core member held by the first holding jig is positioned so as to face the first holding jig.
- the second holding jig is pressed against a second holding jig having a holding force to hold the second holding jig relative to the first holding jig on the main surface of the first holding jig.
- the core member is rotated, the axis of the core portion has a predetermined angle with respect to the holding surface of the second holding jig, and the outside of the other side flange portion
- a rotation step in which a region where an electrode is to be formed protrudes from the holding surface of the second holding jig from the one side flange;
- the first holding jig is separated, and the axis of the winding core portion is at a predetermined angle with respect to the holding surface of the second holding jig.
- a transfer and holding step to be (E) The step (d) is carried out to form the external electrode in a region where the external electrode of the other side flange projecting from the holding surface of the second holding jig is to be formed.
- the rotating jig has a friction resistance capable of rotating the core member on the surface of a rigid body material in the rotating step, and elasticity. It is preferable to have a structure in which a coating layer made of the provided material is provided.
- the core member can be reliably rotated and held in the intended posture, and the present invention can be effectively realized.
- the core member is rotated 180 ° around the axis of the core in the rotation step.
- the axial center direction of the core part of the core member is X
- the axis of the winding core portion rotates on the surface defined by X and Y, and the holding It is also possible to rotate the core member so that the angle with the surface changes.
- the holding force of the second holding jig is larger than the holding force of the first holding jig.
- the core member can be transferred from the first holding jig to the second holding jig without requiring a complicated configuration, and the present invention can be more effectively realized. Can do.
- the first holding jig and the second holding jig hold the core member with an adhesive force.
- the first and second holding jigs that can reliably hold the core member without requiring a complicated configuration are used to manufacture the wound coil component of the present invention.
- the method can be carried out more reliably and the wire-wound coil component can be manufactured efficiently.
- the first and second holding jigs hold the core member by adhesive force, but in some cases, it is possible to use a member that holds the core member by magnetic force. It is.
- the axial center of the said core part is the said core member with respect to the said holding surface of the said 1st holding jig and the said 2nd holding jig.
- the holding surface for holding the core member of the first holding jig and the second holding jig is inclined or inclined so that it can be held in a state having a predetermined angle. It is preferable to have a groove.
- the core member can be reliably held in a state where the axis of the core portion has a predetermined angle with respect to the holding surfaces of the first and second holding jigs.
- the present invention can be made more effective.
- the axis of the winding core part has a predetermined angle with respect to the holding surface of the first holding jig
- the one side flange part has The electrode material is applied to the region where the external electrode of the one side collar portion of the core member held on the holding surface of the first holding jig is projected so that the region where the external electrode is to be formed protrudes from the holding surface. Then, after the core member is rotated using the rotating jig, the core member is held (transferred) by the second holding jig.
- the manufacturing method of the (1st) winding type coil component of this invention since the core member is rotated by the above-mentioned method, the several core member hold
- the electrode material is applied to the region where the external electrode of the one side collar portion of the core member held by the first holding jig is to be formed. After that, before the core member is rotated, it is transferred to the second holding jig, and the transferred core member is rotated on the second holding jig using the rotating jig. After completion of the process, the core member is held by the second holding jig, and the axis of the core has a predetermined angle with respect to the holding surface of the second holding jig, The region where the external electrode is to be formed can be made to protrude from the holding surface of the second holding jig from the one side flange.
- the one side flange portion Since the region to which the electrode material is applied is located at a position facing the second holding jig at the time of transfer to the second holding jig, the rotation jig is not pressed against the area. Even when the applied electrode material has a low strength, it is possible to suppress damage and to reliably manufacture a wound coil component with high shape accuracy. Also, the portion of the second holding jig that contacts the core member is usually made of a material that is softer and more deformable than the portion of the rotating jig that contacts the core member. The risk of damage to the electrode material is reduced.
- an electrode material is applied to the region where the external electrode of the one side collar portion of the core member held by the first holding jig is to be formed. Thereafter, the core member held by the first holding jig is pressed against the second holding jig positioned so as to face the first holding jig, and the second holding jig is moved to the first holding jig. Since the core member is rotated by moving in the direction along the main surface of the first holding jig relative to the holding jig, the core part can be rotated without using the rotating jig.
- the axial center has a predetermined angle with respect to the holding surface of the second holding jig, and the region where the external electrode of the other side flange should be formed protrudes from the holding surface of the second holding jig. Is possible.
- FIG. 1 It is a figure which shows an example of the winding type coil components manufactured by the method of this invention, (a) is a front view, (b) is a side view. It is a figure explaining the manufacturing method of the winding type coil components concerning Embodiment 1 of this invention, and is a figure which shows the state which made the 1st holding jig hold
- (A) to (c) show the core member held by the first holding jig around the axis of the winding core part in one step of the method of manufacturing the wire-wound coil component according to the first embodiment of the present invention. It is a figure explaining the method to rotate.
- (A)-(e) is a figure which shows the process in which a core member is rotated around the axial center of a core part in 1 process of the manufacturing method of the winding type
- (A)-(c) demonstrates the method to transfer the core member after rotating to the 2nd holding jig in 1 process of the manufacturing method of the winding type coil components concerning Embodiment 1 of this invention. It is a figure to do.
- FIG. 1 It is a figure which shows the state which provided the electrode material to the area
- (A)-(c) shows a core after applying an electrode material to a region where an external electrode on one side flange is to be formed in one step of a method for manufacturing a wire-wound coil component according to Embodiment 2 of the present invention. It is a figure explaining the method to transfer a member to the 2nd holding jig.
- (A) to (c) are steps of manufacturing the wire-wound coil component according to the second embodiment of the present invention, in which the core member held by the second holding jig is moved around the axis of the winding core. It is a figure explaining the method to rotate.
- (A) is one process of the manufacturing method of the winding type coil components concerning Embodiment 3 of this invention. After inverting a 1st holding jig, it is 2nd so that it may face with a 1st holding jig.
- (A) is a figure explaining the method to rotate a core member around the axial center of a core part in the state shown to (b) of FIG. 10A
- (b) is the core member after rotating. It is a figure which shows the state which transferred to the 2nd holding jig. It is a figure explaining the method of rotating a winding type coil component in 1 process of the manufacturing method of the winding type coil component concerning Embodiment 4 of this invention, Comprising: It is a figure which shows the state before rotating. It is a figure explaining the method of rotating a winding type coil component in 1 process of the manufacturing method of the winding type coil component concerning Embodiment 4 of this invention, Comprising: It is a figure which shows the state after rotating.
- the winding type coil component 10 manufactured in this Embodiment 1 includes a core portion 2 and a pair of flange portions (one side flange portion 3a and the other side flange portion 3b) connected to both ends of the core portion 2. And a pair of external electrodes (external electrodes 4a and 4b) disposed on one side flange 3a and the other side flange 3b of the core member 1 and the core 2 Winding 5 is provided. Both ends of the winding 5 are connected to the external electrodes 4a and 4b by solder or the like.
- the external electrodes 4a and 4b are opposed to the one side flange 3a and the other side flange 3b so as not to cause problems such as deterioration of characteristics such as a magnetic field and solder wrapping around the coil (winding 5).
- No electrode is formed on the surface (inner wall surface), and the formation height of the external electrodes 4a and 4b is from the opposite surface side of the one side flange 3a and the other side flange 3b toward the end surface (outer wall surface). That is, the upper side of the external electrode on the side surfaces of the one side flange 3a and the other side flange 3b is inclined.
- an example in which no electrode is formed on the inner wall surface is shown, but the electrode structure is not limited to this, and if the formation height of the external electrodes 4a and 4b on the inner wall surface is lower than the outer wall surface, Alternatively, an electrode may be formed.
- a so-called H-type member having flanges 3 (3 a, 3 b) provided on both ends of the core part 2 is used, but a so-called U-shaped member as shown in FIG. 17 is used.
- an I-type (not shown) that does not include a collar portion can be used.
- a ceramic material for example, alumina, ferrite, etc.
- a metal magnetic material or the like
- silver, copper, etc. can be used as a material which comprises the external electrodes 4a and 4b.
- the present invention can also be applied to the case of manufacturing a wire-wound coil component in which the winding 5 is protected by a protective member mainly composed of a thermosetting resin such as an epoxy resin.
- a core member 1 having a core portion 2 and a pair of flange portions (one side flange portion 3a and the other side flange portion 3b) connected to both ends of the core portion 2 is prepared. To do.
- the external electrodes 4a and 4b are formed by the procedure described below.
- the first holding jig 11 having a holding force for holding the core member 1 with an adhesive force causes the core member 1 to have the axial center 2a of the core portion 2 first.
- a region R1 having a predetermined angle with respect to a holding surface (main surface on the side holding the core member 1) 11a of one holding jig 11 and where an external electrode of one side flange 3a is to be formed is the other side It holds with the attitude
- the holding surface (main surface) 11 a is a surface on which a line L ⁇ b> 1 connecting points at high altitudes on both ends of each groove 12 is located.
- the core member 1 is in a state where the axis 2 a of the core portion 2 has a predetermined angle with respect to the holding surface 11 a of the first holding jig 11.
- the groove portion 12 having the inclined side surface 12a is formed on the main surface (holding surface) 11a.
- the upper surface of the one side collar part 3a and the other side collar part 3b is detachably fixed to one side surface 12a of the groove part 12.
- a predetermined gap is provided between the other side surface facing the one side surface 12a and the outer wall surface of the other side flange portion 3b so that the core member 1 can be rotated in a rotation process described later. Is preferred.
- the first holding jig 11 is formed by bonding an adhesive silicone rubber holding member 13 having the groove 12 to a metal plate 14. As a material constituting the holding member 13, other materials such as fluoro rubber can be used.
- the first holding jig 11 is configured to hold the core member 1 on the surface in a state of being arranged in a two-dimensional matrix.
- step (B) The step (a) is performed, the core member 1 is held by the first holding jig 11, and the outside of the one side flange 3a of the core member 1 protruded downward from the holding surface 11a.
- the region R1 where the electrode is to be formed is brought into contact with the conductive paste (electrode material for forming the external electrode) 15 held on the table 16, so that as shown in FIG.
- the conductive paste 15 is applied (applied) to the region R1 where the electrode is to be formed (first electrode applying step). Thereafter, the applied conductive paste 15 is dried.
- a conductive material constituting the conductive paste various materials that can form an external electrode that can be bonded using solder or the like to an object such as an electrode of a circuit board on which a wound coil component is mounted are used. It is possible. Specifically, for example, a silver paste or a copper paste can be used. Further, as the electrode material, a resin containing a metal powder or the like can be used. The conductive paste is formed to have a uniform thickness on the table by moving the squeegee while maintaining a predetermined interval with respect to the horizontally installed table.
- the first holding jig 11 is turned upside down so that the axis 2a of the core portion 2 of the core member 1 is the first.
- the holding jig 11 has a predetermined angle with respect to the holding surface (main surface on the side holding the core member 1) 11a, and a region to which the conductive paste 15 of the one side flange 3a of the core member 1 is applied (external It is assumed that the region (R1) where the electrode is to be formed protrudes above the holding surface (main surface) 11a of the first holding jig 11 from the other side flange 3b.
- a rotating jig for rotating the core member 1 around the axis 2a of the core portion 2 so as to face the holding surface (main surface) 11a of the first holding jig 11 holding the core member 1. 31 is positioned (see FIG. 4A).
- the rotating jig 31 has a structure in which a coating layer made of a material having frictional resistance and elasticity is provided on the surface of a metal base material.
- a material for example, rubber-based material constituting the coating layer, the core member 1 is not moved (attached) from the first holding jig 11 to the rotating jig 31 side.
- One having a lower adhesive force than the holding jig 11 is used.
- the inclined portion 31 a of the rotating jig 31 is brought into contact with the core member 1.
- the rotating jig 31 is moved in the depth direction of the paper surface of FIG. 4B (the direction along the main surface 11a of the first holding jig and the longitudinal direction of the groove portion 12).
- the core member 1 is moved relative to the holding jig 11, and the axis of the core portion 2 is moved. Rotate 180 ° around core 2a. As a result, as shown in FIG.
- the region (region to which the conductive paste 15 is applied) R ⁇ b> 1 where the external electrode of the one side flange 3 a is to be formed is opposed to the first holding jig 11.
- the region R2 where the external electrode of the other side flange 3b is to be formed is also opposed to the first holding jig 11, and the region R2 where the external electrode of the other side flange 3b is to be formed is the one side
- the posture is set so as to be lower than the region (region to which the conductive paste 15 is applied) R1 in which the external electrode of the portion 3a is to be formed (rotation process).
- 5A, 5B, 5C, 5D, and 5E the core member 1 is rotated 45 ° from 0 ° to 180 ° around the axis 2a of the core portion 2 by 45 °.
- the states are shown in order.
- the core member 1 is held by the second holding jig 21 having a holding force for holding the core member 1 as shown in FIG.
- the first holding jig 11 is positioned so as to face the first holding jig 11.
- the core member 1 is transferred to the second holding jig 21 by separating the first holding jig 11 (transfer process).
- the axis 2a of the core part 2 of the core member 1 is the holding surface of the second holding jig 21 (the horizontal surface in FIG.
- the main surface 21a has a predetermined angle, and the region R2 where the external electrode of the one side flange 3b is to be formed projects downward from the holding surface 21a of the second holding jig 21 from the one side flange 3a. In this posture, the core member 1 is held by the second holding jig 21.
- the second holding jig 21 is formed by bonding an adhesive silicone rubber holding member 23 to a metal plate 24 in the same manner as the first holding jig 11 described above. Then, the main surface of the core member 1 can be held so that the axis 2a of the core 2 has a predetermined angle with respect to the holding surface (main surface which is a horizontal surface) 21a. A groove portion 22 having an inclined side surface 22a is formed in the (holding surface) 21a.
- the holding surface (main surface) 21 a is a surface on which a line L ⁇ b> 2 connecting points at high altitudes on both ends of each groove 22 is located.
- the holding member 23 constituting the second holding jig 21 a holding member having a holding force for holding the core member 1 stronger than the holding member 13 constituting the first holding jig 11 is used. Therefore, the core member 1 held by the first holding jig 11 is surely transferred to the second holding jig 21 as shown in FIG.
- a conductive paste (for forming an external electrode) in which a region R ⁇ b> 2 where the external electrode of the other side flange 3 b that protrudes downward is to be formed is held on the table 16.
- the electrode material (conductive paste) 15 is applied (applied and dried) to the region R2 where the external electrode of the other side flange 3b is to be formed (second electrode applying step).
- the core member is fired Then, by baking the conductive paste, the core member 1 having a pair of external electrodes 4a and 4b having a predetermined shape on the one side flange 3a and the other side flange 3b is obtained.
- the winding 5 is wound around the core portion 2 of the core member 1, and both ends of the winding 5 are connected to the external electrodes 4a and 4b by solder or the like, thereby having a structure as shown in FIG.
- the coil component 10 is obtained.
- the one side collar and the other side collar are opposed to each other at predetermined positions on the one side collar and the other side collar.
- a core member including an external electrode (inclined external electrode) that is inclined so that the height dimension gradually increases from the side toward the opposite surface can be reliably formed.
- the core member is rotated about the axis of the core portion by the above-described method, a plurality of core members held on the first holding jig can be simultaneously rotated together. It becomes possible to process a large amount of core members in a short time. As a result, it is possible to efficiently manufacture a wound coil component having good characteristics and high reliability, which includes an external electrode with high shape accuracy.
- a core member 1 having a core portion 2 and a pair of flange portions (one side flange portion 3a and the other side flange portion 3b) connected to both ends of the core portion 2 (see FIG. 1). ).
- the core member 1 is wound around the core by the first holding jig 11 having a holding force for holding the core member 1 with an adhesive force.
- the axis 2a of the portion 2 has a predetermined angle with respect to the holding surface (main surface on the side holding the core member 1) 11a of the first holding jig 11, and forms an external electrode of the one side flange 3a.
- the power region R1 is held in a posture protruding downward from the holding surface 11a of the first holding jig 11 from the other side flange 3b (holding step).
- the first holding jig 11 is the same as the first holding jig 11 used in the first embodiment.
- step (B) The step (a) is performed, the core member 1 is held by the first holding jig 11, and the outside of the one side flange 3a of the core member 1 protruded downward from the holding surface 11a.
- the region R1 (see FIG. 2) where the electrode is to be formed is held on the table 16 as shown in FIG. 3 (electrode material for forming the external electrode). ) 15, the conductive paste 15 is applied (applied and dried) to the region R1 where the external electrode of the one side flange 3a is to be formed (first electrode applying step).
- the first holding jig 11 is turned upside down so that the axis 2a of the core portion 2 of the core member 1 is the first.
- the holding jig 11 has a predetermined angle with respect to the holding surface (main surface on the side holding the core member 1) 11a, and a region to which the conductive paste 15 of the one side flange 3a of the core member 1 is applied (external It is assumed that the region (R1) where the electrode is to be formed protrudes above the holding surface (main surface) 11a of the first holding jig 11 from the other side flange 3b.
- the second holding jig 21 having a holding force for holding the core member 1 is positioned so as to face the inverted first holding jig 11 (FIG. 8A). And after pressing the 2nd holding jig 21 against the core member 1 hold
- the rotating jig 31 or the second holding jig 21 is moved relatively in the direction along 21a and along the longitudinal direction of the groove 22) to move the core member 1 to the axis of the core part 2. Rotate 180 degrees around the core 2a (rotation process).
- the core member 1 held by the second holding jig 21 has the axis 2 a of the core portion 2 placed on the holding surface 21 a of the second holding jig 21.
- the region R2 having a predetermined angle with respect to the outer flange 3b where the external electrode is to be formed is positioned on the side opposite to the side facing the second holding jig 21.
- the rotating jig 31 the thing of the structure similar to what was used in the above-mentioned Embodiment 1 was used.
- a material constituting the coating layer for example, rubber-based material
- a second member is used so that the core member does not move (attach) from the second holding jig 21 to the rotating jig 31 side.
- the one having lower adhesive strength than the holding jig 21 is used.
- the core member is fired Then, by baking the conductive paste, the core member 1 having a pair of external electrodes 4a and 4b having a predetermined shape on the one side flange 3a and the other side flange 3b is obtained.
- the winding 5 is wound around the core portion 2 of the core member 1, and both ends of the winding 5 are connected to the external electrodes 4a and 4b by solder or the like, thereby having a structure as shown in FIG.
- the coil component 10 is obtained.
- the surface on the opposite side from the surface side of the one side collar part and the other side collar part opposite to each other at the predetermined position of the one side collar part and the other side collar part can be reliably formed.
- the core member is rotated about the axis of the core portion by the above-described method, a plurality of core members held on the first holding jig can be simultaneously rotated together. It becomes possible to process a large amount of core members in a short time. As a result, it is possible to efficiently manufacture a wound coil component having good characteristics and high reliability, which includes an external electrode with high shape accuracy.
- the region to which the electrode material of the one side collar portion is applied is the second region. Since it is in a position facing the second holding jig (that is, a position where the rotating jig is not pressed) when it is transferred to the holding jig, the applied electrode material has low strength. Even in this case, damage can be suppressed, and an external electrode with high shape accuracy can be formed.
- the portion of the second holding jig that contacts the core member is usually made of a material that is softer and more deformable than the portion of the rotating jig that contacts the core member. This reduces the risk of damage to the electrode material.
- the rotating jig when the rotating jig is brought into contact with the core member held on the second holding jig and the core member is rotated about the axis of the core portion, the one side flange portion and the other side portion are rotated. Since the rotating jig is brought into contact with the region where the conductive paste for forming the external electrode is not formed, damage to the applied conductive paste can be suppressed.
- a core member 1 having a core portion 2 and a pair of flange portions (one side flange portion 3a and the other side flange portion 3b) connected to both ends of the core portion 2 (see FIG. 1). ).
- the external electrodes 4a and 4b are formed by the procedure described below.
- the core member 1 As in the case of the first embodiment, as shown in FIG. 2, the core member 1 is wound around the core portion by the first holding jig 11 having a holding force for holding the core member 1 with an adhesive force.
- the second shaft center 2a should have a predetermined angle with respect to the holding surface (main surface on the side holding the core member 1) 11a of the first holding jig 11, and should form an external electrode of the one side flange 3a
- the region R1 is held in a posture protruding downward from the holding surface 11a of the first holding jig 11 from the other side flange 3b (holding step).
- the first holding jig 11 is the same as the first holding jig 11 used in the first embodiment.
- step (B) The step (a) is performed, the core member 1 is held by the first holding jig 11, and the outside of the one side flange 3a of the core member 1 protruded downward from the holding surface 11a.
- the region R1 (see FIG. 2) where the electrode is to be formed is held on the table 16 as shown in FIG. 3 (electrode material for forming the external electrode). ) 15, the conductive paste 15 is applied (applied and dried) to the region R1 where the external electrode of the one side flange 3a is to be formed (first electrode applying step).
- the second holding jig 21 having a holding force for holding the core member 1 is positioned so as to face the inverted first holding jig 11 (FIG. 10A (a)). Then, as shown in FIG. 10A (b), the second holding jig 21 is brought into contact with the core member 1 held by the first holding jig 11. Also in the third embodiment, the second holding jig 21 is the same as the second holding jig 21 used in the first embodiment.
- the core member 1 is rotated by 180 ° around the axis 2a of the core part 2 (rotation process).
- the core member 1 has an axis 2a of the core 2 having a predetermined angle with respect to the holding surface (main surface) 21a of the second holding jig 21, and the external electrode of the other side flange 3b.
- the region R2 to be formed is in a posture such that it is located on the side opposite to the side facing the second holding jig 21.
- the core member is fired Then, by baking the conductive paste, the core member 1 having a pair of external electrodes 4a and 4b having a predetermined shape on the one side flange 3a and the other side flange 3b is obtained.
- the winding 5 is wound around the core portion 2 of the core member 1, and both ends of the winding 5 are connected to the external electrodes 4a and 4b by solder or the like, thereby having a structure as shown in FIG.
- the coil component 10 is obtained.
- the core member can be rotated around the axis of the winding core without using a rotating jig.
- the manufacturing process can be simplified.
- the core member 1 is rotated by 180 ° around the axis 2a of the core part 2 so that the external electrodes formed on the one side collar part and the other side collar part are
- the winding-type coil component having a structure in which the upper side is inclined on the side surfaces of the first and second flange portions is manufactured.
- the core member 1 is rotated, as shown in FIG.
- the direction of the axis 2a of the core 2 is X
- the direction perpendicular to the holding surface 11a or 21a of the first holding jig 11 or the second holding jig 21 holding the core member 1 is Y.
- the axis 2a of the core portion 2 rotates on the surface defined by X and Y (the surface corresponding to the paper surface in FIG. 11), and the angle with the holding surface 11a or 21a changes. In this way, the core member 1 can be rotated (see FIG. 12).
- the core member 1 in a state where the conductive paste 15 is applied to the region R1 where the external electrode of the one side flange 3a is to be formed is placed on the groove 12 of the first holding jig 11.
- a state before rotating using a rotating jig (not shown) (FIG. 11) and a state after rotating (FIG. 12) are shown.
- the 2nd holding jig 21 is made to contact
- the other side flange 3 b that protrudes downward is transferred from the first holding jig 11 to the second holding jig 21 and held by the second holding jig 21.
- the region R2 where the external electrode is to be formed is brought into contact with the conductive paste (electrode material for forming the external electrode) 15 held on the table 16, so that the external electrode of the other side flange 3b should be formed.
- the conductive paste 15 can be applied (applied) also to the region R2.
- the axis of the core is rotated as in the fourth embodiment, and the holding surface 1 can be efficiently manufactured even when the method of rotating so that the angle of the shaft center with respect to is changed is applied to the above-described first to third embodiments. it can.
- the first and second holding jigs have a configuration including a groove portion having an inclined slope, but a configuration having an inclined portion instead of the groove portion may be used. Is possible. In some cases, it is possible to use a holding surface that is usually flat and made of a material that can be deformed by pressing.
- the present invention is not limited to the above embodiment, and the specific configuration of the core member, the first and second holding jigs, and the specific configuration of the rotating jigs. It is possible to add various applications and modifications within the scope of the invention.
Abstract
Description
そして、このプレート231の凹部231aがコア部材211と一致するように、プレート231に塗布したペースト232をコア部材211に押し当てることにより、一対の脚部211a,211bに同時に導電ペーストを塗布し、焼成する工程を経て、脚部211a,211bに外部電極213a,213bを形成するようにしている。
柱状の巻芯部と、前記巻芯部の両端に設けられた一対の鍔部とを備えたコア部材と、前記一対の鍔部における一方側鍔部と他方側鍔部に形成された一対の外部電極と、前記巻芯部に巻回された巻線とを具備する巻線型コイル部品であって、前記一方側鍔部と前記他方側鍔部の、前記巻線型コイル部品が実装される実装対象に近い領域に、前記一方側鍔部と前記他方側鍔部の互いに対向する面側から逆側の面に向かって高さ寸法が徐々に大きくなるように傾斜した前記外部電極が形成された構造を有する巻線型コイル部品の製造方法において、
前記外部電極を形成する工程が、
(a)複数の前記コア部材を保持する保持力を備えた第1の保持治具により、前記コア部材を、前記巻芯部の軸心が前記第1の保持治具の前記コア部材を保持する側の主面である保持面に対して所定の角度を持ち、前記一方側鍔部の前記外部電極を形成すべき領域が、前記他方側鍔部より前記第1の保持治具の前記保持面から突出した姿勢で保持する保持工程と、
(b)前記(a)の工程を実施して、前記保持面から突出させた前記一方側鍔部の前記外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記一方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第1の電極付与工程と、
(c)前記(b)の工程を実施した後、前記第1の保持治具に保持された前記コア部材に、前記コア部材を回転させるための回転治具を当接させ、前記回転治具を、前記第1の保持治具に対して相対的に、前記第1の保持治具の主面に沿う方向に移動させて、前記コア部材を回転させ、前記他方側鍔部の前記外部電極を形成すべき領域が、前記第1の保持治具に対向する姿勢とする回転工程と、
(d)前記(c)の工程を実施した後、前記第1の保持治具に保持された前記コア部材を、前記第1の保持治具と正対するように位置させた、前記コア部材を保持する保持力を備えた第2の保持治具に移し替え、前記巻芯部の軸心が前記第2の保持治具の前記コア部材を保持する側の主面である保持面に対して所定の角度を持ち、前記他方側鍔部の前記外部電極を形成すべき領域が、前記一方側鍔部より前記第2の保持治具の前記保持面から突出した姿勢で、前記コア部材を前記第2の保持治具により保持する移載工程と、
(e)前記(d)の工程を実施して、前記第2の保持治具の前記保持面から突出させた前記他方側鍔部の外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記他方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第2の電極付与工程と
を備えていることを特徴としている。
柱状の巻芯部と、前記巻芯部の両端に設けられた一対の鍔部とを備えたコア部材と、前記一対の鍔部における一方側鍔部と他方側鍔部に形成された一対の外部電極と、前記巻芯部に巻回された巻線とを具備する巻線型コイル部品であって、前記一方側鍔部と前記他方側鍔部の、前記巻線型コイル部品が実装される実装対象に近い領域に、前記一方側鍔部と前記他方側鍔部の互いに対向する面側から逆側の面に向かって高さ寸法が徐々に大きくなるように傾斜した前記外部電極が形成された構造を有する巻線型コイル部品の製造方法において、
前記外部電極を形成する工程が、
(a)複数の前記コア部材を保持する保持力を備えた第1の保持治具により、前記コア部材を、前記巻芯部の軸心が前記第1の保持治具の前記コア部材を保持する側の主面である保持面に対して所定の角度を持ち、前記一方側鍔部の前記外部電極を形成すべき領域が、前記他方側鍔部より前記第1の保持治具の前記保持面から突出した姿勢で保持する保持工程と、
(b)前記保持面から突出させた前記一方側鍔部の前記外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記一方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第1の電極付与工程と、
(c)前記(b)の工程を実施した後、前記第1の保持治具に保持された前記コア部材を、前記第1の保持治具と正対するように位置させた、前記コア部材を保持する保持力を備えた第2の保持治具に移し替え、前記巻芯部の軸心が前記コア部材を保持する側の主面である保持面に対して所定の角度を持ち、前記一方側鍔部の前記電極材料が付与された領域が、前記第2の保持治具に対向する姿勢で、前記コア部材を前記第2の保持治具により保持する移載工程と、
(d)前記(c)の工程を実施した後、前記第2の保持治具に保持された前記コア部材に、前記コア部材を前記巻芯部の軸心回りに回転させるための回転治具を当接させ、前記回転治具を、前記第2の保持治具に対して相対的に、前記第2の保持治具の主面に沿う方向に移動させて、前記コア部材を回転させ、前記他方側鍔部の前記外部電極を形成すべき領域が、前記一方側鍔部より前記第2の保持治具の前記保持面から突出した状態とする回転工程と、
(e)前記(d)の工程を実施して、前記第2の保持治具の前記保持面から突出させた前記他方側鍔部の外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記他方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第2の電極付与工程と
を備えていることを特徴としている。
柱状の巻芯部と、前記巻芯部の両端に設けられた一対の鍔部とを備えたコア部材と、前記一対の鍔部における一方側鍔部と他方側鍔部に形成された一対の外部電極と、前記巻芯部に巻回された巻線とを具備する巻線型コイル部品であって、前記一方側鍔部と前記他方側鍔部の、前記巻線型コイル部品が実装される実装対象に近い領域に、前記一方側鍔部と前記他方側鍔部の互いに対向する面側から逆側の面に向かって高さ寸法が徐々に大きくなるように傾斜した前記外部電極が形成された構造を有する巻線型コイル部品の製造方法において、
前記外部電極を形成する工程が、
(a)複数の前記コア部材を保持する保持力を備えた第1の保持治具により、前記コア部材を、前記巻芯部の軸心が前記第1の保持治具の前記コア部材を保持する側の主面である保持面に対して所定の角度を持ち、前記一方側鍔部の前記外部電極を形成すべき領域が、前記他方側鍔部より前記第1の保持治具の前記保持面から突出した姿勢で保持する保持工程と、
(b)前記(a)の工程を実施して、前記保持面から突出させた前記一方側鍔部の前記外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記一方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第1の電極付与工程と、
(c)前記(b)の工程を実施した後、前記第1の保持治具に保持された前記コア部材を、前記第1の保持治具と正対するように位置させた、前記コア部材を保持する保持力を備えた第2の保持治具に押し付け、前記第2の保持治具を、前記第1の保持治具に対して相対的に、前記第1の保持治具の主面に沿う方向に移動させて、前記コア部材を回転させ、前記巻芯部の軸心が前記第2の保持治具の前記保持面に対して所定の角度を持ち、前記他方側鍔部の前記外部電極を形成すべき領域が、前記一方側鍔部より前記第2の保持治具の前記保持面から突出した状態とする回転工程と、
(d)前記(c)の工程を実施した後、前記第1の保持治具を分離し、前記巻芯部の軸心が前記第2の保持治具の前記保持面に対して所定の角度を持ち、前記他方側鍔部の前記外部電極を形成すべき領域が、前記第2の保持治具の前記保持面から突出した状態で、前記コア部材が前記第2の保持治具に保持された状態とする移載保持工程と、
(e)前記(d)の工程を実施して、前記第2の保持治具の前記保持面から突出させた前記他方側鍔部の外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記他方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第2の電極付与工程と
を備えていることを特徴としている。
そして、その状態で、他方側鍔部の外部電極を形成すべき領域に電極材料を付与することにより、一方側鍔部と他方側鍔部の所定の位置に、一方側鍔部と他方側鍔部の互いに対向する面側から逆側の面に向かって高さ寸法が徐々に大きくなるように傾斜した外部電極(以下、「傾斜外部電極」ともいう)を確実に形成することが可能になる。
この実施形態1では、図1に示すような構造を有する巻線型コイル部品(巻線型インダクタ)の製造方法を、コア部材に外部電極を形成する工程に重点をおいて説明する。
また、外部電極4a,4bを構成する材料としては銀、銅などを用いることが可能である。
また、本発明は、エポキシ樹脂などの熱硬化樹脂を主成分とする保護部材により巻線5を保護するようにした巻線型コイル部品を製造する場合にも適用することが可能である。
まず、図1に示すような、巻芯部2と該巻芯部2の両端に連接された一対の鍔部(一方側鍔部3a、他方側鍔部3b)とを有するコア部材1を用意する。
(a)それから、図2に示すように、粘着力によりコア部材1を保持する保持力を備えた第1の保持治具11により、コア部材1を、巻芯部2の軸心2aが第1の保持治具11の保持面(コア部材1を保持する側の主面)11aに対して所定の角度を持ち、一方側鍔部3aの外部電極を形成すべき領域R1が、他方側鍔部3bより第1の保持治具11の保持面11aから下方に突出した姿勢で保持する(保持工程)。
なお、図2に示した第1の保持治具11において、保持面(主面)11aとは、各溝12の両端側の、標高の高いポイントを結ぶ線L1が位置する面である。
第1の保持治具11は、上記溝部12を備えた粘着性を有するシリコーンゴム製の保持部材13を金属プレート14に接合することにより形成されている。保持部材13を構成する材料としては、フッ素ゴムなどの他の材料を用いることも可能である。
また、第1の保持治具11は、表面にコア部材1を2次元マトリックス状に配置された状態で保持できるように構成されている。
なお、導電ペーストを構成する導電材料としては、巻線型コイル部品が搭載される回路基板の電極などの対象に、はんだなどを用いて接合することが可能な外部電極を形成できる種々の材料を用いることが可能である。具体的には、例えば、銀ペースト、銅ペーストなどを用いることができる。また、電極材料としては、金属粉末を含有する樹脂などを用いることも可能である。導電ペーストは、水平に設置されたテーブルに対して所定間隔を維持しながらスキージを動かすことにより、テーブル上において均一な厚みに形成される。
なお、回転治具31は、特に図示しないが、金属製の基材の表面に、摩擦抵抗と弾力性とを備えた材料からなる被覆層を備えた構造を有している。ただし、被覆層を構成する材料(例えば、ゴム系材料)としては、コア部材1が第1の保持治具11から回転治具31側に移行(付着)してしまうことがないように、第1の保持治具11よりも粘着力の低いものが用いられている。
なお、図5(a),(b),(c),(d),(e)は、コア部材1を巻芯部2の軸心2a回りに0°から180°まで45゜ずつ回転させた状態を順に示している。
これにより、コア部材1の巻芯部2の軸心2aが、第2の保持治具21の保持面(図6(c)における水平方向の面であって、コア部材1を保持する側の主面)21aに対して所定の角度を持ち、一方側鍔部3bの外部電極を形成すべき領域R2が、一方側鍔部3aより第2の保持治具21の保持面21aから下方に突出した姿勢で、コア部材1が、第2の保持治具21保持される。
第2の保持治具21において、保持面(主面)21aとは、各溝22の両端側の、標高の高いポイントを結ぶ線L2が位置する面である。
次に、巻線型コイル部品10の他の製造方法について説明する。
実施形態と同様にして、巻芯部2と該巻芯部2の両端に連接された一対の鍔部(一方側鍔部3a、他方側鍔部3b)とを有するコア部材1(図1参照)を用意する。
(a)上記実施形態1の場合と同様に、図2に示すように、粘着力によりコア部材1を保持する保持力を備えた第1の保持治具11により、コア部材1を、巻芯部2の軸心2aが第1の保持治具11の保持面(コア部材1を保持する側の主面)11aに対して所定の角度を持ち、一方側鍔部3aの外部電極を形成すべき領域R1が、他方側鍔部3bより第1の保持治具11の保持面11aから下方に突出した姿勢で保持する(保持工程)。
この実施形態2においても、第1の保持治具11として、実施形態1で用いた第1の保持治具11と同じものを用いた。
この実施形態2においても、第2の保持治具21として、実施形態1で用いた第2の保持治具21と同じものを用いた。
次に、巻線型コイル部品10のさらに他の製造方法について説明する。
実施形態と同様にして、巻芯部2と該巻芯部2の両端に連接された一対の鍔部(一方側鍔部3a、他方側鍔部3b)とを有するコア部材1(図1参照)を用意する。
(a)上記実施形態1の場合と同様、図2に示すように、粘着力によりコア部材1を保持する保持力を備えた第1の保持治具11により、コア部材1を、巻芯部2の軸心2aが第1の保持治具11の保持面(コア部材1を保持する側の主面)11aに対して所定の角度を持ち、一方側鍔部3aの外部電極を形成すべき領域R1が、他方側鍔部3bより第1の保持治具11の保持面11aから下方に突出した姿勢で保持する(保持工程)。
この実施形態3においても、第1の保持治具11として、実施形態1で用いた第1の保持治具11と同じものを用いた。
この実施形態3においても、第2の保持治具21として、実施形態1で用いた第2の保持治具21と同じものを用いた。
上記実施形態1~3では、コア部材1を、巻芯部2の軸心2a回りに180°回転させることにより、一方側鍔部と他方側鍔部に形成された外部電極が、一方側鍔部と他方側鍔部の側面において上辺が傾斜しているような構造を有する巻線型コイル部品を製造するようにしたが、コア部材1を回転するにあたって、図11に示すように、コア部材1の巻芯部2の軸心2a方向をX、コア部材1が保持された第1の保持治具11または第2の保持治具21の保持面11aまたは21aに垂直な方向をYとした場合に、XとYとにより規定される面(図11における紙面に相当する面)上を、巻芯部2の軸心2aが回動して、保持面11aまたは21aとの間の角度が変化するように、コア部材1を回転させることも可能である(図12参照)。
2 巻芯部
2a 軸心
3a 一対の鍔部を構成する一方側鍔部
3b 一対の鍔部を構成する他方側鍔部
4a,4b 一対の外部電極
5 巻線
10 巻線型コイル部品
11 第1の保持治具
11a 第1の保持治具の保持面(主面)
12 第1の保持治具の溝部
12a 第1の保持治具の溝部の側面
13 保持部材
14 金属プレート
15 導電ペースト(外部電極を形成するための電極材料)
16 テーブル
21 第2の保持治具
21a 第2の保持治具の保持面(主面)
22 第2の保持治具の溝部
22a 第1の保持治具の溝部の側面
23 保持部材
24 金属プレート
31 回転治具
31a 傾斜部
R1 一方側鍔部の外部電極を形成すべき領域
R2 他方側鍔部の外部電極を形成すべき領域
L1 第1の保持治具の保持面を示す線
L2 第2の保持治具の保持面を示す線
X コア部材1の巻芯部の軸心方向を示す線
Y 第1の保持治具または第2の保持治具の保持面に垂直な方向を示す線
Claims (9)
- 柱状の巻芯部と、前記巻芯部の両端に設けられた一対の鍔部とを備えたコア部材と、前記一対の鍔部における一方側鍔部と他方側鍔部に形成された一対の外部電極と、前記巻芯部に巻回された巻線とを具備する巻線型コイル部品であって、前記一方側鍔部と前記他方側鍔部の、前記巻線型コイル部品が実装される実装対象に近い領域に、前記一方側鍔部と前記他方側鍔部の互いに対向する面側から逆側の面に向かって高さ寸法が徐々に大きくなるように傾斜した前記外部電極が形成された構造を有する巻線型コイル部品の製造方法において、
前記外部電極を形成する工程が、
(a)複数の前記コア部材を保持する保持力を備えた第1の保持治具により、前記コア部材を、前記巻芯部の軸心が前記第1の保持治具の前記コア部材を保持する側の主面である保持面に対して所定の角度を持ち、前記一方側鍔部の前記外部電極を形成すべき領域が、前記他方側鍔部より前記第1の保持治具の前記保持面から突出した姿勢で保持する保持工程と、
(b)前記(a)の工程を実施して、前記保持面から突出させた前記一方側鍔部の前記外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記一方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第1の電極付与工程と、
(c)前記(b)の工程を実施した後、前記第1の保持治具に保持された前記コア部材に、前記コア部材を回転させるための回転治具を当接させ、前記回転治具を、前記第1の保持治具に対して相対的に、前記第1の保持治具の主面に沿う方向に移動させて、前記コア部材を回転させ、前記他方側鍔部の前記外部電極を形成すべき領域が、前記第1の保持治具に対向する姿勢とする回転工程と、
(d)前記(c)の工程を実施した後、前記第1の保持治具に保持された前記コア部材を、前記第1の保持治具と正対するように位置させた、前記コア部材を保持する保持力を備えた第2の保持治具に移し替え、前記巻芯部の軸心が前記第2の保持治具の前記コア部材を保持する側の主面である保持面に対して所定の角度を持ち、前記他方側鍔部の前記外部電極を形成すべき領域が、前記一方側鍔部より前記第2の保持治具の前記保持面から突出した姿勢で、前記コア部材を前記第2の保持治具により保持する移載工程と、
(e)前記(d)の工程を実施して、前記第2の保持治具の前記保持面から突出させた前記他方側鍔部の外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記他方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第2の電極付与工程と
を備えていることを特徴とする巻線型コイル部品の製造方法。 - 柱状の巻芯部と、前記巻芯部の両端に設けられた一対の鍔部とを備えたコア部材と、前記一対の鍔部における一方側鍔部と他方側鍔部に形成された一対の外部電極と、前記巻芯部に巻回された巻線とを具備する巻線型コイル部品であって、前記一方側鍔部と前記他方側鍔部の、前記巻線型コイル部品が実装される実装対象に近い領域に、前記一方側鍔部と前記他方側鍔部の互いに対向する面側から逆側の面に向かって高さ寸法が徐々に大きくなるように傾斜した前記外部電極が形成された構造を有する巻線型コイル部品の製造方法において、
前記外部電極を形成する工程が、
(a)複数の前記コア部材を保持する保持力を備えた第1の保持治具により、前記コア部材を、前記巻芯部の軸心が前記第1の保持治具の前記コア部材を保持する側の主面である保持面に対して所定の角度を持ち、前記一方側鍔部の前記外部電極を形成すべき領域が、前記他方側鍔部より前記第1の保持治具の前記保持面から突出した姿勢で保持する保持工程と、
(b)前記保持面から突出させた前記一方側鍔部の前記外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記一方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第1の電極付与工程と、
(c)前記(b)の工程を実施した後、前記第1の保持治具に保持された前記コア部材を、前記第1の保持治具と正対するように位置させた、前記コア部材を保持する保持力を備えた第2の保持治具に移し替え、前記巻芯部の軸心が前記コア部材を保持する側の主面である保持面に対して所定の角度を持ち、前記一方側鍔部の前記電極材料が付与された領域が、前記第2の保持治具に対向する姿勢で、前記コア部材を前記第2の保持治具により保持する移載工程と、
(d)前記(c)の工程を実施した後、前記第2の保持治具に保持された前記コア部材に、前記コア部材を前記巻芯部の軸心回りに回転させるための回転治具を当接させ、前記回転治具を、前記第2の保持治具に対して相対的に、前記第2の保持治具の主面に沿う方向に移動させて、前記コア部材を回転させ、前記他方側鍔部の前記外部電極を形成すべき領域が、前記一方側鍔部より前記第2の保持治具の前記保持面から突出した状態とする回転工程と、
(e)前記(d)の工程を実施して、前記第2の保持治具の前記保持面から突出させた前記他方側鍔部の外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記他方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第2の電極付与工程と
を備えていることを特徴とする巻線型コイル部品の製造方法。 - 柱状の巻芯部と、前記巻芯部の両端に設けられた一対の鍔部とを備えたコア部材と、前記一対の鍔部における一方側鍔部と他方側鍔部に形成された一対の外部電極と、前記巻芯部に巻回された巻線とを具備する巻線型コイル部品であって、前記一方側鍔部と前記他方側鍔部の、前記巻線型コイル部品が実装される実装対象に近い領域に、前記一方側鍔部と前記他方側鍔部の互いに対向する面側から逆側の面に向かって高さ寸法が徐々に大きくなるように傾斜した前記外部電極が形成された構造を有する巻線型コイル部品の製造方法において、
前記外部電極を形成する工程が、
(a)複数の前記コア部材を保持する保持力を備えた第1の保持治具により、前記コア部材を、前記巻芯部の軸心が前記第1の保持治具の前記コア部材を保持する側の主面である保持面に対して所定の角度を持ち、前記一方側鍔部の前記外部電極を形成すべき領域が、前記他方側鍔部より前記第1の保持治具の前記保持面から突出した姿勢で保持する保持工程と、
(b)前記(a)の工程を実施して、前記保持面から突出させた前記一方側鍔部の前記外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記一方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第1の電極付与工程と、
(c)前記(b)の工程を実施した後、前記第1の保持治具に保持された前記コア部材を、前記第1の保持治具と正対するように位置させた、前記コア部材を保持する保持力を備えた第2の保持治具に押し付け、前記第2の保持治具を、前記第1の保持治具に対して相対的に、前記第1の保持治具の主面に沿う方向に移動させて、前記コア部材を回転させ、前記巻芯部の軸心が前記第2の保持治具の前記保持面に対して所定の角度を持ち、前記他方側鍔部の前記外部電極を形成すべき領域が、前記一方側鍔部より前記第2の保持治具の前記保持面から突出した状態とする回転工程と、
(d)前記(c)の工程を実施した後、前記第1の保持治具を分離し、前記巻芯部の軸心が前記第2の保持治具の前記保持面に対して所定の角度を持ち、前記他方側鍔部の前記外部電極を形成すべき領域が、前記第2の保持治具の前記保持面から突出した状態で、前記コア部材が前記第2の保持治具に保持された状態とする移載工程と、
(e)前記(d)の工程を実施して、前記第2の保持治具の前記保持面から突出させた前記他方側鍔部の外部電極を形成すべき領域を、前記外部電極を形成するための電極材料に触れさせることにより、前記他方側鍔部の前記外部電極を形成すべき領域に電極材料を付与する第2の電極付与工程と
を備えていることを特徴とする巻線型コイル部品の製造方法。 - 前記回転治具が、剛体材料の表面に、前記回転工程において、前記コア部材を回転させることが可能な摩擦抵抗と、弾力性とを備えた材料からなる被覆層が配設された構造を有するものであることを特徴とする請求項1または2記載の巻線型コイル部品の製造方法。
- 前記回転工程において、前記コア部材を前記巻芯部の軸心回りに180°回転させることを特徴とする請求項1~4のいずれかに記載の巻線型コイル部品の製造方法。
- 前記回転工程において、前記コア部材の前記巻芯部の軸心方向をX、前記コア部材が保持された前記第1の保持治具または前記第2の保持治具の前記保持面に垂直な方向をYとした場合に、前記XとYとにより規定される面上を、前記巻芯部の軸心が回動して、前記保持面との間の角度が変化するように、前記コア部材を回転させることを特徴とする請求項1~4のいずれかに記載の巻線型コイル部品の製造方法。
- 前記第2の保持治具の保持力が、前記第1の保持治具の保持力より大きいことを特徴とする請求項1~6のいずれかに記載の巻線型コイル部品の製造方法。
- 前記第1の保持治具および前記第2の保持治具が、粘着力により着脱可能に前記コア部材を保持するものであることを特徴とする請求項1~7のいずれかに記載の巻線型コイル部品の製造方法。
- 前記コア部材を、前記巻芯部の軸心が前記第1の保持治具および前記第2の保持治具の前記保持面に対して所定の角度を持った状態で保持することができるように、前記第1の保持治具および前記第2の保持治具の、前記コア部材を保持する前記保持面が傾斜部または側面が傾斜した溝部を有していることを特徴とする請求項1~8のいずれかに記載の巻線型コイル部品の製造方法。
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US10395824B2 (en) | 2019-08-27 |
CN106415755B (zh) | 2017-12-15 |
CN106415755A (zh) | 2017-02-15 |
JPWO2015182374A1 (ja) | 2017-04-20 |
US20170076861A1 (en) | 2017-03-16 |
KR101804186B1 (ko) | 2017-12-04 |
KR20160145731A (ko) | 2016-12-20 |
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