WO2017086626A1

WO2017086626A1 - Choke coil and manufacturing method therefor

Info

Publication number: WO2017086626A1
Application number: PCT/KR2016/012306
Authority: WO
Inventors: 박인길; 노태형; 김경태; 김상현
Original assignee: 주식회사 모다이노칩
Priority date: 2015-11-18
Filing date: 2016-10-28
Publication date: 2017-05-26

Abstract

The present invention provides a choke coil comprising: a core having a flange provided at both end parts thereof; a terminal electrode coupled to one part of the flange; a wire wound around the core and having an end part withdrawn toward an upper side of the terminal electrode; and a welding part provided at an upper part of the terminal electrode, wherein the terminal electrode comprises an upper surface and a lower surface vertically facing each other and a side surface provided at one side between the upper surface and the lower surface, and the flange has an inclined region formed between a first surface and a second surface respectively corresponding to the upper surface and the side surface of the terminal electrode and between the first surface and a third surface facing the second surface.

Description

Choke Coils and Manufacturing Method

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to choke coils, and more particularly, to a choke coil mounted on a vehicle and the like and capable of securing stable characteristics and a method of manufacturing the same.

Conventionally, a terminal electrode was formed by plating or soldering on the flange of a drum core as a choke coil, and a pair of wire was wound around the drum core, and the terminal of the wire was soldered to the terminal electrode. In addition, the terminal electrode formed by plating or soldering must be mounted on the wiring board of the vehicle by soldering.

However, when the conventional choke coil is mounted on a vehicle, reliability of a wide temperature range should be ensured, but defects such as detachment of the terminal electrode from the wiring board or cracking of the drum core are generated.

Therefore, in recent years, a choke coil is manufactured by inserting a "c" shaped terminal electrode into a flange and fastening it, fixing a terminal end of the wire with a part of the terminal electrode, and forming a weld on the terminal electrode by using laser welding or arc welding. have.

By the way, a part of the terminal located on the upper part of the wire is directly irradiated with the laser and melted by the laser energy to form a welded part. It will take away and will cause weldability to fall. In addition, heat generated when the weld is formed may be transferred to the wire wound on the drum core so that the wire may be disconnected or shorted.

On the other hand, the terminal electrode and the core connected to the wiring board are spaced apart in order to ensure heat resistance due to the difference in thermal expansion between the core and the terminal electrode, and thus, the 'c'-shaped terminal electrode is not formed when a severe shock or vibration occurs. The flange can be released in the direction. That is, the flange may be separated from the terminal electrode in the direction exposed by the "-" shaped terminal electrode. In the case of vehicle products, vibrations and shocks are often required and high reliability is required. When cracks occur in the fillet part of the terminal electrode surrounding the core against vibration in the horizontal direction of the board, a disconnection occurs and a fatal defect is caused. This can happen.

(Prior art document)

Japanese Patent Publication No. 2003-022916

The present invention provides a choke coil and a method of manufacturing the same that can improve the temperature and vibration characteristics.

The present invention provides a choke coil and a method of manufacturing the same that can prevent deformation of the terminal electrode under the wire when forming a weld.

The present invention provides a choke coil and a method of manufacturing the same, which can reduce heat transfer to a wire when forming a weld, thereby preventing disconnection or short circuit of the wire wound on the core.

Choke coil according to an aspect of the present invention includes a core provided with a flange at both ends; A terminal electrode coupled to a portion of the flange; A wire wound around the core and having a distal end drawn above the terminal electrode; And a welding part provided at an upper portion of the terminal electrode, wherein the terminal electrode includes an upper surface and a lower surface facing each other up and down, and a side surface provided at one side between the upper surface and the lower surface, and the flange is the terminal electrode. An inclined region is formed between the first and second surfaces respectively corresponding to the top and side surfaces of the second surface, and between the first and second surfaces opposing the second surface.

It is formed on the upper surface of the terminal electrode, and further comprises an opening in which the wire is located.

The opening is formed to be wider than the width of the wire, it is formed shorter than the length of the wire seated on the upper surface.

And a stepped portion formed on the bottom surface of the terminal electrode and a stepped portion formed on the bottom surface of the flange, wherein the protrusion is engaged with the stepped portion.

The semiconductor device may further include an insulating layer provided on at least one region between the welding portion and the terminal electrode.

A first and a second extension part formed to be spaced apart from each other on the upper surface of the terminal electrode, wherein the second extension part has a shape in which an area through which the wire passes is concave and protrudes outwardly thereof.

According to another aspect of the present invention, a choke coil includes a core having flanges at both ends thereof; A terminal electrode coupled to a portion of the flange; First and second extensions formed on the upper surface of the terminal electrode to be spaced apart from each other; A wire wound around the core and having a distal end drawn above the terminal electrode; A weld portion formed on the second extension portion of the terminal electrode; And an insulating layer provided in at least one region between the welding portion and the terminal electrode.

And an opening formed on an upper surface of the terminal electrode and positioned above the wire, wherein the opening is formed to have a width wider than that of the wire and is shorter than a length of the wire seated on the upper surface. .

The flange has an inclined region formed between the first and second surfaces corresponding to the top and side surfaces of the terminal electrode, and between the third and first surfaces opposing the second surface.

The second extension part has a shape in which an area through which the wire passes is concave and an outer side thereof protrudes convexly.

The wire includes a conductive wire and an insulating coating surrounding the conductive wire, and the insulating layer is formed by the insulating coating.

The flange includes a first region in contact with the core and a second region in which the terminal electrode is coupled, and the first region is formed higher than the second region.

The terminal electrode is shorter in length than the lower surface of the upper surface from the side surface.

An upper surface of the terminal electrode is formed in a rectangular plate shape and a first side is connected to a side surface, and a second side provided on one side of the first side is in contact between the first and second regions of the flange.

The first extension part guides or temporarily fixes the drawing of the wire, and the second extension part is bent in one direction to fix the wire and form the welding part.

The inclined region is formed with a width of 0.05 mm to 0.25 mm.

The inclined region and the upper surface of the terminal electrode have a distance of 0.05 mm to 0.25 mm.

According to another aspect of the present invention, a method of manufacturing a choke coil includes: coupling a terminal electrode to a flange provided at both ends of a core; Winding a wire to surround the core and drawing the wire to the outside of the terminal electrode through the terminal electrode; Removing at least a portion of the coating of the wire outside the terminal electrode; And forming a weld on the terminal electrode by using laser welding.

The method may further include bending a wire positioned outside the terminal electrode to the upper side of the terminal electrode before forming the welding part.

The wire is drawn out to be guided to the first extension part formed on the upper surface of the terminal electrode, and the second extension part spaced apart from the first extension part is bent to fix the wire.

The second extension part is formed in a shape in which the area where the wire passes is concave and protrudes outwardly thereof, and the second extension part is bent so that the protruding area deviates from the side surface of the terminal electrode.

The wire and at least a portion of the second extension from which at least a portion of the sheath has been removed form the weld.

The wire is provided between the welding portion and the terminal electrode without peeling the insulating coating.

In the choke coil according to the embodiments of the present invention, flanges are provided at both ends of the core around which the wire is wound, and a terminal electrode having, for example, a "c" shape, is fastened to the second region of the flange. In addition, an inclined surface (or rounded surface) is formed between the upper surface, the front surface, and the rear surface of the second region of the flange to facilitate fastening of the terminal electrode, and to prevent disconnection of the wire drawn out to the upper surface of the terminal electrode. . Therefore, assembly property can be improved and productivity and quality can be improved.

In addition, since the opening is formed in the upper surface of the terminal electrode, the energy of the laser irradiated to form the weld can be suppressed from being conducted to the upper surface of the terminal electrode through the wire. Therefore, it is possible to prevent deformation of the upper surface of the terminal electrode due to heat generated during laser irradiation, to form a welded portion with optimal energy, and to prevent a short circuit by reducing thermal energy conducted by the wound wire.

In addition, a stepped portion is formed on a lower surface of the second region of the flange to which the terminal electrode is fastened, and a protrusion is formed in the lower portion of the terminal electrode in accordance with the stepped portion so that the protrusion is closely coupled to the stepped portion to further secure the coupling between the terminal electrode and the flange. can do. Therefore, separation of the terminal electrode and the flange can be prevented even by vibration in the X, Y, and Z directions of a vehicle equipped with the choke coil.

On the other hand, excessive welding can be prevented by making the insulating layer by insulation coating of a wire remain between a weld part and the wire below it, and between a wire and the terminal electrode below it.

1 and 2 are an exploded perspective view and a combined perspective view of the choke coil according to the first embodiment of the present invention.

3 is an exploded perspective view of the choke coil according to the first embodiment of the present invention before formation of a welded portion;

4 is a structural diagram of a terminal electrode of the choke coil according to the first embodiment of the present invention.

5 and 6 are structural views of the terminal electrode of the choke coil according to the modified examples of the first embodiment of the present invention.

7 and 8 are an exploded perspective view and a combined perspective view of the choke coil according to a second embodiment of the present invention.

9 is an exploded perspective view of a choke coil before forming a welded part according to the second embodiment of the present invention;

10 is a structural diagram of a terminal electrode of the choke coil according to the second embodiment of the present invention.

11 to 17 are perspective views illustrating a method of manufacturing a choke coil according to a first embodiment of the present invention.

18 and 19 are an exploded perspective view and a combined perspective view of the choke coil according to a third embodiment of the present invention.

20 is an exploded perspective view of a choke coil before forming a welded part according to the third embodiment of the present invention;

21 is a structural diagram of a terminal electrode of the choke coil according to the third embodiment of the present invention.

22 to 27 are perspective views illustrating a method of manufacturing a choke coil according to a third embodiment of the present invention.

28 is a cross-sectional image of a welded portion and a lower side of the choke coil according to the third embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but may be implemented in various forms, and only the embodiments are intended to complete the disclosure of the present invention and to those skilled in the art. It is provided for complete information.

1 is an exploded perspective view of a choke coil according to a first embodiment of the present invention, Figure 2 is a combined perspective view. 3 is an exploded perspective view of the choke coil before the welded part is formed according to the first embodiment of the present invention. 4 to 6 are structural diagrams of the terminal electrode of the choke coil according to the first embodiment and modified examples thereof.

1 to 6, the vehicle choke coil according to the first embodiment of the present invention is provided at both ends of the core 100, the wire 200 wound around the core 100, and the core 100. A flange 300 having both sides lower than the center portion, a terminal electrode 400 fastened to both sides of the flange 300, a welding part 500 formed on the terminal electrode 400, and a core 100. It may include a cover 600 provided in the upper portion.

1. 코어1. Core

The core 100 may be provided in a substantially hexahedral shape, and the wire 200 may be wound so as to contact and surround the core 100. For example, the core 100 has a substantially rectangular cross-sectional shape in each of the longitudinal direction (X direction) and the width direction (Y direction), and may be provided larger than the Y direction in the X direction. That is, the core 100 includes first and second surfaces (ie, front and rear surfaces) that face each other in the X direction, third and fourth surfaces (ie, two sides) that face each other in the Y direction, and a Z direction. The fifth and sixth surfaces (that is, the upper and lower surfaces) opposed to each other may be provided, respectively, and the distance between the first and second surfaces may be greater than the width of the third and fourth surfaces. In addition, the core 100 may be formed so that the corner portion is rounded or has a predetermined slope. That is, the corner portions between the third to sixth surfaces (that is, between the two side surfaces, the upper surface and the lower surface) may be formed to be rounded or have a predetermined slope. As the corners of the core 100 are formed to be round in this manner, when the wires 200 are wound, the wires 200 may be prevented from being broken by sharp edges. Of course, the core 100 may be provided in a cylindrical shape, or may be provided in a polyhedral shape. For example, the core 100 may form a polygon having a pentagram or more in a plane or a cross section in the Y direction, and may be provided to have a predetermined length in the X direction. The flange 300 may be provided at both ends of the core 100, that is, the first and second surfaces in the X direction. Meanwhile, the core 100 may be made of ferrite material. Ferrite materials include nickel ferrite (Ni ferrite), zinc ferrite (Zn Ferrite), copper ferrite (Cu Ferrite), manganese ferrite (Mn Ferrite), cobalt ferrite (Co Ferrite), barium ferrite (Ba Ferrite) and nickel-zinc- One or more or one or more oxide magnetic materials thereof selected from the group consisting of copper magnetic materials (Ni-Zn-Cu Ferrite) may be used. The core 100 may be manufactured by mixing the ferrite material with a polymer, for example, and then molding the ferrite material into a predetermined shape such as a hexahedron.

2. 와이어2. Wire

The wire 200 may be provided to surround the core 100. That is, the wire 200 may be provided to surround the core 100 in the X direction from one side to the other side, for example, from the first surface to the second surface direction. In addition, the wire 200 may surround the core 100, and both ends of the wire 200 may be drawn out above the terminal electrode 400 fastened to the flange 300. The wire 200 may be wound on at least one layer on the core 100. For example, the wire 200 may include a first wire that is in contact with the core 100 and is wound, and a second wire that is in contact with the first wire and is wound thereon. In this case, the first wire may extend to an upper portion of the terminal electrode 400 fastened to the two flanges 300 opposite to each other, and the second wire may be opposite to each other without the first wire extending. It may extend to an upper portion of the terminal electrode 400 fastened to the two flanges (300). Meanwhile, the wire 200 may be made of a conductive material, and an insulating material may be coated to surround the wire 200. For example, the wire 200 may be formed such that a metal wire such as copper is formed to a predetermined thickness, and an insulating material such as resin covers the same. The insulating coating may be used alone, in combination of at least two or more of polyurethane, polyester, polyesterimide, polyamideimide, polyimide and the like. For example, the insulation coating may use a mixture of polyester and polyamide or laminate them. On the other hand, the end of the wire 200 in contact with the upper terminal electrode 400, the insulating coating is completely removed can expose the metal wire. The insulating coating can be irradiated with at least two lasers to completely remove it. For example, after irradiating the primary laser to the end of the wire 200, the portion irradiated with the primary laser may be rotated to irradiate the secondary laser to completely remove the insulation coating. Since the insulation coating at the end of the wire 200 is completely removed, there is no insulation coating between the terminal electrode 400 and the wire 200.

3. 플랜지3. Flange

The flanges 300 are provided at both ends of the core 100 in the X direction. The flange 300 includes a first region 310 in contact with the core 100 and a second region 320 provided at both sides of the first region 310 in the Y direction and not in contact with the core 100. can do. The first and

second regions

310 and 320 of the flange 300 may be formed to have a predetermined width, width, and height, respectively. That is, the first and second surfaces (i.e., front and rear) facing each other in the X direction have a predetermined width, and the third and fourth surfaces (i.e., both sides) facing each other in the Y direction have a predetermined width. The first and

second regions

310 and 320 may be formed such that the fifth and sixth surfaces (ie, the lower surface and the upper surface) facing each other in the Z direction have a predetermined height. In other words, the first surface becomes the front surface in the X direction from the direction in which the terminal electrode 400 is inserted, and the second surface opposite to the rear surface becomes the rear surface. Accordingly, the core 100 is in contact with the second surface, that is, the rear surface of the first region 310, and the second region 320 is in contact with the third and fourth surfaces (ie, both sides) of the first region 310. do. Similarly, in the second region 320, the first surface is the front surface in the X direction from the direction in which the terminal electrode 400 is inserted, and the second surface facing the core 100 is the rear surface. Meanwhile, the first region 310 may be formed higher than the second region 320. That is, after the welding part 500 is formed, the first area 310 is in contact with the lower surface of the cover part 600, and the second area 320 is such that the welding part 500 is not in contact with the cover part 600. First and

second regions

310 and 320 may be formed at a height. In this case, the first area 310 may be formed to have a height such that the welding part 500 does not contact the cover part 600 in consideration of the height of the second area 320 and the height of the welding part 500. In addition, the first region 310 may have a width and a width greater than that of the second region 320. Accordingly, a step may be formed between the top surface of the first region 310 and the top surface of the second region 320, and a step may be formed between the front surface of the first region 310 and the front surface of the second region 320. have.

A terminal electrode 400 having a "c" shape is fastened to the second region 320 of the flange 300. That is, the terminal electrode 400 is inserted from one side in the X direction to the other side and fastened to the second region 320 of the flange 300. In this case, a predetermined inclination (ie, inclination) may be provided between the upper surface of the second region 320 and the surface (that is, the front surface) in the direction in which the terminal electrode 400 is coupled. That is, the second region 320 may have an inclined region having a predetermined slope between the front surface and the upper surface, that is, between the first surface and the sixth surface. In other words, an edge may not be formed between the front surface and the upper surface, and may have a predetermined slope. In this case, the inclined region may be rounded to have a predetermined curvature, or may be formed to have a predetermined inclined from the upper surface to the front surface. As such, a predetermined inclination is formed between the front surface and the upper surface so that the upper surface of the terminal electrode 400 moves along the inclination, and thus, the terminal electrode 400 may be more easily fastened.

In addition, the second region 320 of the flange 300 has a first inclined region having a predetermined width formed between the front surface and the upper surface (that is, between the first surface and the sixth surface), as well as between the rear surface and the upper surface (that is, the second surface). A second inclined region having a predetermined width may also be formed on the surface and the sixth surface). In this case, the second inclined region may be rounded to have a predetermined curvature, or may be formed to have a predetermined inclined from an upper surface to a rear surface. Since a predetermined inclination is formed between the rear surface and the upper surface, the wire 200 drawn out to the terminal electrode 400 is guided along the rounded portion, thereby preventing disconnection of the wire 200 and peeling of the coating. That is, when an edge is formed between the rear surface and the upper surface of the second region 320 of the flange 300 which is contacted and drawn out of the wire 200, the wire 200 is cut off at the corner part when the wire 200 is drawn out. Although the coating of the wire 200 may be peeled off or the wire 200 may be disconnected, disconnection of the wire 200 drawn out may be prevented by forming the portion round.

Meanwhile, the second inclined region between the rear surface and the upper surface of the second region 320 (that is, between the second and sixth surfaces) may be formed, for example, with a width of 0.05 mm to 0.25 mm. That is, the distance between the first virtual line extending upward from the vertical rear surface (ie, the second surface) and the second virtual line extending upward from the boundary of the horizontal upper surface (ie, the sixth surface) and the second sloped area is an example. For example, it may be 0.05 mm to 0.25 mm. In addition, the distance from the boundary of the horizontal upper surface (ie, the sixth surface) and the second inclined region to the outer side (the second side to be described later) of the upper surface 410 of the terminal electrode 400 facing the example is illustrated. For example, it may be 0.05 mm to 0.25 mm. That is, the distance between the upper surface of the second region 320 of the flange 300 and the outer side of the upper surface 410 of the terminal electrode 400 (ie, the second side) from the boundary of the second inclined region is for example. 0.05 mm to 0.25 mm. At this time, as the distance from the outer side of the upper surface 410 of the terminal electrode 400 to the boundary region is greater than 0.25 mm, the size of the upper surface 410 of the terminal electrode 400 is reduced, and accordingly Since the size of the weld 500 formed on the surface 410 may be limited, it is preferable to maintain 0.25 mm or less. In addition, when the distance between the outer side of the upper surface 410 of the terminal electrode 400 and the boundary region is less than 0.05 mm or the upper surface 410 is formed to cover the second inclined region, the wire 200 is drawn out. Is cut on the edge of the second side of the upper surface 410, the wire 200 may be disconnected and the peeling of the coating may occur, so the distance between the outer side of the upper surface 410 of the terminal electrode 400 and the boundary region is 0.25 mm. The farther it exceeds the size of the upper surface 410 of the terminal electrode 400 is reduced, and thus the size of the weld portion 500 formed on the upper surface 410 may be limited to maintain 0.05 mm or more It is preferable.

In addition, the bending angle of the wire 200 may be adjusted according to the width of the second inclined region of the second region 320, the width of the stepped portion, and the thickness of the upper surface 410 of the terminal electrode 400. For example, when the thickness of the upper surface 410 of the terminal electrode 400 is 0.1 mm, and the width of the second inclined region and the stepped portion is 0.05 mm, 0.1 mm, 0.15 mm, 0.2 mm, and 0.25 mm, the wire 200 The bending angles of may be 40 °, 37 °, 34 °, 32 ° and 31 °, respectively. In addition, when the thickness of the upper surface 410 of the terminal electrode 400 is 0.15 mm and the width of the second inclined region and the stepped portion is 0.05 mm, 0.1 mm, 0.15 mm, 0.2 mm, and 0.25 mm, the wire 200 is bent. The angles can be 42 °, 39 °, 37 °, 35 ° and 34 °, respectively. The angle of bending of the drawn wire 200 is suitably 31 ° to 42 ° with respect to the upper surface of the second region 320 of the flange 300, and the upper surface 410 of the terminal electrode 400 is tangent to the round region. If it is out of the range, it can be less than 31 °. If the bending angle is larger than this, the wire 200 drawn out may be difficult to be guided by the first extension part 412 of the terminal electrode 400.

4. 단자 전극4. Terminal electrode

The terminal electrode 400 is inserted into and fastened to the second region 320 of the flange 300, and the welding part 500 is formed by fixing the wire 200 thereon. The terminal electrode 400 may be formed in an approximately "c" shape to be inserted into the flange 300 and fastened. That is, the terminal electrode 400 includes an upper surface 410 and a lower surface 420 and side surfaces 430 provided to connect them. Accordingly, the upper surface 410, the lower surface 420 and the side surface 430 may form a substantially "c" shape. Here, the upper surface 410 may be provided in a substantially rectangular plate shape. That is, the upper surface 410 has a first side in contact with the side surface 430, a second side facing the first side, and first and second regions of the flange 300 between the first and second sides. The third side may contact the stepped

portions

310 and 320, and the fourth side may face the third side. In addition, the lower surface 420 may be provided in a substantially rectangular plate shape having first to fourth sides corresponding to the first to fourth sides of the upper surface 410, and the side surface 430 may have an upper surface. It may be provided in a substantially rectangular plate shape having a height corresponding to the distance between the 410 and the lower surface 420. The terminal electrode 400 is inserted into the second area 320 of the flange 300 from an open area facing the side surface 430, and an upper surface 410 and a lower surface 420 of the flange 300 are formed. The upper and lower surfaces of the second region 320 are in contact with each other, and the side surface 430 is in contact with the front surface of the second region 320, so that the terminal electrode 400 is fastened to the flange 300. In this case, since a predetermined inclination is formed between the upper surface and the front surface of the second region 320 of the flange 300, the upper surface 410 of the terminal electrode 400 may move to the upper surface of the flange 300 along the inclined surface. . In addition, the side surface 430, the upper surface 410 and the lower surface 420 of the terminal electrode 400 may form a right angle. However, between the side surface 430 and the upper surface 410 and the lower surface 420 of the terminal electrode 400 in order to further increase the coupling force by the pressing force of any one of the upper surface 410 and the lower surface 420. It may have an acute angle of 90 degrees or less, for example, an angle of about 88 degrees.

Meanwhile, the terminal electrode 400 may have a lower surface 420 larger than the upper surface 410. The lower surface 420 may be formed to cover the entire lower surface of the second region 320 of the flange 300, and the upper surface 410 may be formed to cover a portion of the upper surface of the second region 320. That is, the second region 320 of the flange 300 has a second inclined region formed roundly between the rear surface and the upper surface, and the upper surface 410 of the terminal electrode 400 is formed of the upper and second inclined regions. It may be formed to the boundary or smaller than it. When the upper surface 410 is formed larger than the second inclined region, a space is formed between the upper surface 410 and the second inclined region, and the wire 200 is formed along the one surface of the upper surface 410. This is because the wire 200 may be peeled off or disconnected by the edge of the upper surface 410.

In addition, first and

second extension parts

411 and 412 may be formed on the top surface 410 of the terminal electrode 400 to fix an end of the wire 200. The first extension 411 temporarily fixes the end of the wire 200, and the second extension 412 fixes the end of the wire 200 and forms a weld 500 together with the wire 200. That is, a part of the wire 200 and the second extension part 412 may be melted to form a weld part 500.

The first extension part 411 may be formed on the other side opposite to one side of the upper surface 410 in contact with the side surface 430 of the terminal electrode 400. That is, the first extension part 411 may be formed on the second side opposite to the first side contacting the side surface 430 of the upper surface 410. In addition, the first extension 411 may be formed adjacent to the stepped portion between the first and

second regions

310 and 320 of the flange 300. That is, the first extension part 411 may be formed in a predetermined width from the corner area between the second side and the third side to the third side. The first extension part 411 may be formed to extend from a third side of the upper surface 410 to a predetermined height and then extend in one direction again. That is, the first extension part 411 has a height formed from the upper surface 410 to a predetermined height, and opposite to the first area 310 of the flange 300 from the end of the height part, that is, of the upper surface 410. The horizontal portion may be formed to extend in the fourth side direction. Accordingly, the first extension part 411 may be formed in a “-” shape in the fourth side direction, for example. As such, since the first extension part 411 is formed adjacent to the step of the flange 300, the wire 200 may be guided and drawn out by the height part and the horizontal part of the first extension part 411. That is, since the wire 200 may be guided between the height portion and the horizontal portion of the first extension portion 411 having a "b" shape, it is possible to prevent the wire 200 from being separated. In addition, the height of the first extension part 411 may be bent in a direction in which the wire 200 is drawn out, that is, in a direction opposite to the core 100. Accordingly, the horizontal portion of the first extension part 411 contacts the upper surface 410 between a direction perpendicular to the drawing direction of the wire 200, that is, between the third and fourth sides of the upper surface 410, so that the horizontal portion is connected to the wire. The 200 will be temporarily fixed.

The second extension part 412 may be provided to be spaced apart from the first extension part 411. For example, the second extension part 412 may be formed on the third side of the upper surface 410 of the terminal electrode 400 in contact with the step of the flange 300. That is, the second extension part 412 may include a height part provided at a predetermined height upward in a predetermined area of the third side of the upper surface 410, and a horizontal part formed to a predetermined size from an end of the height part. At this time, the horizontal portion may be formed wider than the width of the height portion. That is, the horizontal part of the second extension part 412 may be formed larger than the size of the first extension part 411 in consideration of the size of the welding part 500, for example, of the second extension part 412. The horizontal portion may be formed to widen in the first side direction from the height portion. In addition, the second extension part 412 may be bent in a direction orthogonal to the bending direction of the first extension part 411. That is, the height portion of the first extension portion 411 is bent from the second side of the upper surface 410 in the first side direction, the second extension portion 412 is fourth from the third side of the upper surface 410 It is bent in the side direction. Therefore, the horizontal part of the first extension part 411 and the horizontal part of the second extension part 412 fix the wire 200 in the same direction. As such, the wire 200 may be contacted and fixed on the upper surface 410 of the terminal electrode 400 by the first and

second extensions

411 and 412.

Meanwhile, as shown in FIG. 5, an opening 413 may be formed in the upper surface 410 of the terminal electrode 400. The opening 413 has a predetermined width and length, and the wire 200 may be positioned above the opening 413. That is, since the opening 413 is formed, the upper surface of the second region 320 of the flange 300 may be exposed under the wire 200. Here, the opening 413 may be formed to have a width wider than the width of the wire 200, and may be formed to have a length shorter than the length of the wire 200 seated on the upper surface 410. Accordingly, the wire 200 floats on the opening 413, and the tip of the wire 200 may contact the upper surface 410 of the terminal electrode 400. That is, the wire 200 may contact with a predetermined width from the most end of the wire 200 and a part of the wire 200 may float on the opening 413. Of course, some of the wires 200 may be contacted on the flange 300 through the openings 413. In this way, the wire 200 and the second extension part 412 are positioned on the opening 413, and the welding part 500 may be formed by melting the wire 200 and the second extension part 412 by laser irradiation. That is, the welding part 500 may be positioned above the opening 413. As the opening 413 is formed in the upper surface 410 of the terminal electrode 400, the energy of the laser during the laser irradiation for forming the welding part 500 is transferred to the upper surface of the terminal electrode 400 through the wire 200. It is possible to suppress the conduction to 410. Therefore, the deformation of the upper surface 410 of the terminal electrode 400 due to the heat generated during the laser irradiation can be prevented and the weld portion 500 can be formed with optimal energy. In addition, it is possible to reduce the thermal energy conducted to the wound wire 200 to prevent a short circuit. In addition, an air layer formed by the opening 413 may be formed between the weld 500 and the flange 300, so that a rapid cooling effect may be expected after the weld 500 is formed, and the shape of the stable weld 500 may be maintained.

In addition, a portion of the welding part 500 formed while the wire 200 and the second extension part 412 of the terminal electrode 400 are welded is positioned at the opening 413 of the terminal electrode 400, thereby being generated after welding. The height of the weld 500 may be lowered. Therefore, the height space area in the Z direction of the weld part 500 can be utilized to the maximum, thereby miniaturizing the product and designing a low profile.

In addition, as shown in FIG. 6, a stepped portion 330 may be formed on a lower surface of the second region 320 of the flange 300. That is, the stepped portion 330 may be formed between one side surface and the bottom surface of the second region 320 that is not in contact with the first region 310. The stepped portion 330 may be formed by, for example, removing a portion of one side of the second region 320. In this case, the stepped portion 330 between the side surface and the bottom surface of the second region 320 may form a right angle and may form a predetermined slope. The protrusion 421 protruding upward may be formed at the edge of the lower surface 420 of the terminal electrode 400 to correspond to the stepped portion 330. The protrusion 421 may be formed at a height corresponding to the stepped portion 221 formed on the bottom surface of the second region 320 of the flange 300. The stepped portion 330 is formed on the lower surface of the second region 320, and the protrusion 421 is provided under the terminal electrode 400 in accordance with the stepped portion 330, so that the protrusion 421 is formed on the stepped portion 330. In close contact with the terminal electrode 400, the terminal electrode 400 and the flange 300 may be more firmly coupled. That is, when the protrusion 421 is not formed, the vibrations in the X and Z directions may be separated from the terminal electrode 400 by the side surface 430, the upper surface 410, and the lower surface 420 of the terminal electrode 400. Although the flange 300 is not separated, the flange 300 may be separated from the terminal electrode 400 by the vibration in the Y direction. However, in addition to the upper surface 410, the lower surface 420, and the side surface 430 of the terminal electrode 400, the protrusion 421 is in contact with the flange 300 such that the contact surface of the terminal electrode 400 and the flange 300 is present. This increases, and thus the terminal electrode 400 may be more strongly fastened, thereby preventing the terminal electrode 400 and the flange 300 from being separated even by vibrations in the X, Y, and Z directions. In addition, the protrusion 421 is formed to form two fillets in the X direction and the Y direction when the product is mounted on the board, when the vibration or strong impact on the board is coupled to the terminal electrode 400 mounted on the board Detachment of the core 100 and the product can be prevented. In addition, two fillets of the terminal electrode 400 are formed so that even if a crack is generated between the terminal face and the solder fillet in one direction, the terminal face and the solder fillet in the cross direction are maintained so that disconnection does not occur on the product. Performance can be implemented to ensure high reliability.

5. 용접부5. Weldment

The weld part 500 is formed on the terminal electrode 400 fastened to the second region 320 of the flange 300. The welding part 500 may be formed by irradiating a laser on the second extension part 412 while being fixed by the first and

second extension parts

411 and 412 on the terminal electrode 400. That is, the weld part 500 may be formed by melting the wire 200 and the second extension part 412. In addition, the welding part 500 may be formed in a sphere shape. The weld 500 may be formed at a height lower than that of the first region 310 of the flange 300, and thus the weld 500 may not be in contact with the cover 600.

6. 덮개부6. Cover

The cover part 600 may be provided on an upper portion of the core 100 to which the wire 200 is wound and the terminal electrode 400 is fastened. The cover part 600 may be provided in a substantially rectangular plate shape having a predetermined thickness. In this case, the lower surface of the cover portion 600 may contact the upper portion of the first region 310 of the flange 300 and may be spaced apart from the weld portion 500. Of course, the cover part 600 may be provided in various forms such that one region is spaced apart from the welding part 500. For example, the first region 310 and the weld portion 500 of the flange 300 are formed at the same height, and the cover portion 600 is formed to protrude from the lower center portion, so that the protruding portion is formed in the first region 310. The welding part 500 may not be in contact with the upper part of the. In addition, the cover 600 may be formed with a recessed portion outside the central portion in the Y direction, for example, a portion corresponding to the second region 320 of the flange 300.

As described above, the choke coil according to the first embodiment of the present invention is provided with flanges 300 at both ends of the core 100 to which the wire 200 is wound, and in the second region 320 of the flange 300. The terminal electrode 400 of the "c" shape is fastened. In addition, an inclined surface (or a rounded surface) is formed between the upper surface, the front surface, and the rear surface of the second region 320 of the flange 300 to facilitate the fastening of the terminal electrode 400, and the upper portion of the terminal electrode 400. Disconnection of the wire 200 drawn out to the surface 410 may be prevented. In addition, since the opening 413 is formed in the upper surface 410 of the terminal electrode 400, the energy of the laser during the laser irradiation for forming the welding part 500 is applied to the upper portion of the terminal electrode 400 through the wire 200. Conduction to the face 410 can be suppressed. Therefore, it is possible to prevent the deformation of the upper surface 410 of the terminal electrode 400 by the heat generated during the laser irradiation and to form the weld 500 with the optimal energy, which is conducted to the wound wire 200 The thermal energy can be reduced to prevent short circuit.

7 is an exploded perspective view of a choke coil according to a second embodiment of the present invention, and FIG. 8 is a combined perspective view. 9 is an exploded perspective view of the choke coil before the welded part is formed according to the second embodiment of the present invention. 10 is a structural diagram of a terminal electrode of the choke coil according to the second embodiment of the present invention.

7 to 10, the choke coil for a vehicle according to the second embodiment of the present invention is provided at both ends of the core 100, the wire 200 wound around the core 100, and the core 100. A flange 300 having a second height 320 provided at a lower height on both sides of the first region 310 and the first region 320 in contact with the core 100, and fastened to both sides of the flange 300 and flanged. The terminal electrode 400 having the protrusion 421 engaged with the stepped portion 330 of the 300, the welding part 500 formed on the terminal electrode 400, and a cover part provided on the core 100. 600, and may further include a stepped portion 330 provided below the second region 320 of the flange 300. That is, in the second embodiment of the present invention, the opening 413 is formed in the upper surface 410 of the terminal electrode 400, and the stepped portion 330 is formed under the second region 320 of the flange 300. The protrusion 421 may be formed on the lower surface 420 corresponding to the stepped portion 330 of the terminal electrode 400.

Referring to FIG. 11, the core 100 and the cover part 600 having the flange 300 coupled to both ends are manufactured. The core 100 has a substantially rectangular cross-sectional shape in each of the longitudinal direction (X direction) and the width direction (Y direction), and may be provided in a substantially hexahedral shape larger than the Y direction in the X direction. In addition, the core 100 may be formed so that the corner portion is rounded or has a predetermined slope. The flange 300 is provided at both ends of the core 100 in the X direction, and may be manufactured integrally with the core 100 or may be separately manufactured and combined. The flange 300 may have a first region 310 in contact with the core 100 provided at both sides of the first region 310 to be higher than a second region 320 not in contact with the core 100. In addition, a predetermined inclined or rounded surface may be formed in the second region 320 between the upper surface and the surface (ie, the front surface) of the direction in which the terminal electrode 400 is coupled, and between the upper surface and the rear surface. On the other hand, the cover 600 may be provided in a substantially rectangular plate shape having a predetermined thickness.

Referring to FIG. 12, the terminal electrode 400 is inserted into the second region 320 of the flange 300 to couple the terminal electrode 400 to the flange 300. To this end, the terminal electrode 400 may be formed in a substantially "C" shape. That is, the terminal electrode 400 may have an approximately "c" shape including an upper surface 410 and a lower surface 420 facing each other in the Z direction and a side surface 430 provided therebetween. In addition, a protrusion (not shown) protruding upward may be formed at an edge of the lower surface 420 of the terminal electrode 400. Correspondingly, a predetermined stepped portion (not shown) may be formed on the lower surface of the second region 320 of the flange 320. That is, a stepped portion may be formed between one side surface and a bottom surface of the second region 320 that is not in contact with the first region 310. In this case, the protrusion of the terminal electrode 400 may be formed at a height corresponding to the stepped portion formed on the lower surface of the second region 320 of the flange 300. The terminal electrode 400 is inserted into the second area 320 of the flange 300 from an open area facing the side surface 430, and an upper surface 410 and a lower surface 420 of the flange 300 are formed. The upper and lower surfaces of the second region 320 are in contact with each other, and the side surface 430 is in contact with the front surface of the second region 320, so that the terminal electrode 400 is fastened to the flange 300. In this case, since a predetermined inclination is formed between the upper surface and the front surface of the second region 320 of the flange 300, the upper surface 410 of the terminal electrode 400 may move to the upper surface of the flange 300 along the inclined surface. . In addition, the protruding portion provided below the terminal electrode 400 may be in close contact with the step formed on the lower surface of the second region 320 so that the terminal electrode 400 may be coupled. In addition to the side, top and bottom surfaces of the terminal electrode 400, the protruding portion contacts the flange 300, thereby increasing the contact surface between the terminal electrode 400 and the flange 300, thereby further increasing the terminal electrode 400. Can be fastened strongly. Meanwhile, an opening 413 may be formed in the upper surface 410 of the terminal electrode 400.

Referring to FIG. 13, the wire 200 is wound around the core 100. That is, the wire 200 may wrap the core 100 from one side to the other side in the X direction. The wire 200 may include a first wire wound in contact with the core 100 and a second wire wound in contact with the first wire. The first wire may extend to the top of the terminal electrode 400 fastened to two flanges 300 opposite both ends, and the second wire may have two flanges opposite to each other without the first wire extending from both ends. It may extend to the upper portion of the terminal electrode 400 fastened to the (300). Meanwhile, the wire 200 may be made of a conductive material, and an insulating material may be coated to surround the wire 200. For example, the wire 200 may be formed such that a metal wire such as copper is formed to a predetermined thickness, and an insulating material such as resin covers the same. After the wire 200 is wound, the coating of the distal end of the wire 200 is peeled off. The distal end of the wire 200 is stripped so that all the covering surrounding the metal wire can be removed. To this end, a laser is provided on the upper side of the wire 200 to irradiate the upper side of the wire 200, and then rotate the wire 200 so that the area not irradiated with the laser is upward, and irradiate the laser again.

14 and 15, the end of the wire 200, that is, the end of the stripped wire 200, is drawn out to the upper portion of the terminal electrode 400. In this case, since the upper surface, the front surface, and the rear surface of the second region 320 of the flange 300 are rounded, the wire 200 is drawn out to the upper surface 410 of the terminal electrode 400 along the rounded region. In addition, since the first extension part 411 having a substantially “a” shape is formed on the upper surface 410 of the terminal electrode 400, the wire 200 is guided between the height part and the horizontal part. The upper surface 410 of the terminal electrode 400 is positioned. At this time, the wire 200 is seated over the opening 413. Therefore, a part of the wire 200 is positioned on the opening 413. On the other hand, when the opening is formed in the upper surface 410 of the terminal electrode 400, the wire 200 is drawn out to pass the upper side of the opening. After the wire 200 is seated in this manner, the first extension part 411 is bent to temporarily fix the wire 200. Next, the second extension part 412 is bent to fix the wire 200.

Referring to FIG. 16, the welding part 500 is formed by irradiating a laser toward the second extension part 412. That is, the second extension part 412 and the wire 200 are melted by laser irradiation, and a spherical weld part 500 is formed on the upper surface 410 of the terminal electrode 400. Here, when an opening is formed in the upper surface 410 of the terminal electrode 400, the welding part 500 may be formed above the opening. An opening is formed in the upper surface 410 of the terminal electrode 400, so that energy from the laser irradiated to form the weld 500 is conducted to the upper surface 410 of the terminal electrode 400 through the wire 200. Can be suppressed. Therefore, the deformation of the upper surface 410 of the terminal electrode 400 due to the heat generated during the laser irradiation can be prevented and the weld portion 500 can be formed with optimal energy. In addition, it is possible to reduce the thermal energy conducted to the wound wire 200 to prevent a short circuit. In addition, an air layer formed by the opening between the weld 500 and the flange 300 may be expected to provide a rapid cooling effect after forming the weld 500, and maintain a stable shape of the weld 500.

Referring to FIG. 17, the cover part 600 is covered to contact the upper portion of the first region 310 of the flange 300.

18 is an exploded perspective view of a choke coil according to a third embodiment of the present invention, and FIG. 19 is a combined perspective view. 20 is an exploded perspective view of a choke coil before forming a welded part according to a third exemplary embodiment of the present invention, and FIG. 21 is a structural diagram of a terminal electrode.

18 and 21, the choke coil according to the third embodiment of the present invention is provided at both ends of the core 100, the wire 200 wound around the core 100, and the core 100. A flange 300 provided at a lower height than the central portion, a terminal electrode 400 fastened to both sides of the flange 300, a welding portion 500 formed on the terminal electrode 400, and an upper portion of the core 100. It may include a cover 600 provided in. Here, in the third embodiment of the present invention, the core 100, the wire 200, the flange 300, and the like have the same configuration, and the shape of the terminal electrode 400 and the welding part 500 is different. Therefore, the third embodiment of the present invention will be described with reference to the contents that differ from the first and second embodiments of the present invention.

The core 100 may be provided in a substantially hexahedral shape, and the wire 200 may be wound so as to contact and surround the core 100. For example, the core 100 may include first and second faces (ie, front and rear) facing each other in the X direction, third and fourth faces (ie, two sides) facing each other in the Y direction, Fifth and sixth faces (ie, upper and lower surfaces) opposed to each other in the Z direction may be provided, respectively, and the distance between the first and second surfaces may be greater than the width of the third and fourth surfaces. In addition, the core 100 may be formed so that the corner portion is rounded or has a predetermined slope. That is, the corner portions between the third to sixth surfaces (that is, between the two side surfaces, the upper surface and the lower surface) may be formed to be rounded or have a predetermined slope. The flange 300 may be provided at both ends of the core 100, that is, the first and second surfaces in the X direction.

The wire 200 may be provided to surround the core 100. In addition, the wire 200 may surround the core 100 and be led out to an upper end of the terminal electrode 400 fastened to the flange 300. Meanwhile, at the time of manufacture, the wire 200 may be drawn out past the terminal electrode 400 so that an end thereof may be located outside the terminal electrode 400. That is, before the welding part 500 is formed, the wire 200 may be drawn out so that a predetermined length is located on the terminal electrode 400 from the end to the inside and a predetermined length is located outside the terminal electrode 400 from the end to the end. Meanwhile, the wire 200 may be made of a conductive material, and an insulating material may be coated to surround the wire 200. However, in the choke coil according to the third embodiment of the present invention, the insulating material is not removed from the region where the wire 200 contacts the upper portion of the terminal electrode 400, and the insulating material of the end region deviated outside the terminal electrode 400. Is removed. That is, at least one portion of the coating may be removed by irradiating at least one laser to an end portion of the wire 400 positioned outside the terminal electrode 400 before the welding part 500 is formed. In other words, the upper end of the wire 400 positioned outside the terminal electrode 400 may be irradiated with the laser from the upper side to remove the upper side of the coating, and the lower side of the coating may remain, and the upper side and the lower side of the side may be irradiated with the laser. To completely remove the coating at the end of the wire 400. Of course, the lower side of the wire 400 may be removed by irradiating a laser from the lower side, and the upper side may be left. As a result, according to the third embodiment of the present invention, at least part of the insulating coating may be removed by the laser irradiation method at the end of the wire 200 from the direction in which the wire 200 is drawn out. In this way, the wire 200 positioned on the terminal electrode 400 does not remove the insulating coating, but partially removes the insulating coating of the end of the wire 200 positioned outside the terminal electrode 400, thereby forming the weld part 500. Between the 200 and the terminal electrode 400 is an insulating layer by the insulating coating of the wire 400. In addition, the insulating layer remains in at least one other area such as at least one area of the welded part 500. That is, in the third embodiment of the present invention, there is a wire 200 and a terminal electrode 400 under the weld 500, between the weld 500 and the wire 200, and between the wire 200 and the terminal electrode ( An insulating layer may remain between 400). In addition, an insulating layer may remain on the surface of the weld part 500 or the like. As a result, in the third embodiment of the present invention, an insulation layer may exist in a plurality of regions around the weld 500. This is because the welding portion 500 is removed while the insulation coating of the wire 200 between the weld portion 500 and the terminal electrode 400 is not removed and the insulation coating of the wire 200 in the region outside the terminal electrode 400 is removed. Because it is formed.

The flanges 300 are provided at both ends of the core 100 in the X direction. The flange 300 may include a first region 310 in contact with the core 100 and a second region 320 provided at both sides of the first region 310 in the Y direction and not in contact with the core 100. Can be. The flange 300 has a first and second surfaces (ie, front and rear) facing each other in the X direction and have a predetermined width, and third and fourth surfaces (ie, both sides) facing each other in the Y direction. The first and

second regions

310 and 320 may be formed so that the fifth and sixth surfaces (that is, the lower surface and the upper surface) having the predetermined width and opposed to each other in the Z direction have the predetermined height. A terminal electrode 400 having a "c" shape is fastened to the second region 320 of the flange 300.

The terminal electrode 400 is inserted into and fastened to the second region 320 of the flange 300, and the wire 200 is seated on the upper portion of the flange 300, and the welding part 500 is formed. The terminal electrode 400 may be formed in an approximately "c" shape to be inserted into the flange 300 and fastened. That is, the terminal electrode 400 includes an upper surface 410 and a lower surface 420 spaced apart in the vertical direction and side surfaces 430 provided to connect them. Accordingly, the upper surface 410, the lower surface 420 and the side surface 430 may form a substantially "c" shape. Here, the upper surface 410 may be provided in a substantially rectangular plate shape. That is, the upper surface 410 has a first side in contact with the side surface 430, a second side facing the first side, and first and second regions of the flange 300 between the first and second sides. The third side may contact the stepped

portions

310 and 320, and the fourth side may face the third side. In addition, the lower surface 420 may be provided in a substantially rectangular plate shape having first to fourth sides corresponding to the first to fourth sides of the upper surface 410, and the side surface 430 may have an upper surface. It may be provided in a substantially rectangular plate shape having a height corresponding to the distance between the 410 and the lower surface 420.

In addition, the upper surface 410 of the terminal electrode 400 to fix the first extension portion 411 for guiding the drawing of the wire 200, and to fix a region of the wire 200 to form a weld portion 500 A second extension 412 may be formed. That is, the first extension part 411 guides the withdrawal of the wire 200, and the second extension part 412 fixes the wire 200 positioned on the terminal electrode 400 and together with the wire 200. The weld part 500 is formed. In other words, a part of the wire 200 and the second extension part 412 may be melted to form a weld part 500.

second regions

310 and 320 of the flange 300. That is, the first extension part 411 may be formed in a predetermined width from the corner area between the second side and the third side to the second side. The first extension part 411 may be formed to extend to a predetermined height from the second side of the upper surface 410. That is, the first extension part 411 may be formed to have a predetermined height from the upper surface 410 and may have the same width. In addition, the first extension part 411 may be vertically formed from the upper surface 410, or may be formed to have a predetermined curvature in the direction of the core 100. That is, the first extension part 411 is formed such that the lower part contacts the second side of the upper surface 410 and the upper part faces the opposite direction of the core 100, and the area between the lower part and the upper part is directed toward the core 100. It may be formed to have a predetermined bend convex. Here, the first extension part 411 serves as a guide when the wire 200 is drawn out, and may not be bent. Of course, the first extension part 411 may be formed in the same shape as the first extension part 411 described in the first and second embodiments of the present invention. That is, the first extension portion 411 has a height portion formed at a predetermined height from the upper surface 410, and in a direction opposite to the first region 310 of the flange 300 from the end of the height portion, that is, of the upper surface 410. The horizontal portion may be formed to extend in the fourth side direction. Accordingly, the first extension part 411 may be formed in, for example, a “A” shape in the fourth side direction, and may be bent in a direction in which the wire 200 is pulled out, that is, in a direction opposite to the core 100. You can also temporarily fix it.

The second extension part 412 may be provided to be spaced apart from the first extension part 411. For example, the second extension part 412 may be formed on the third side of the upper surface 410 of the terminal electrode 400 in contact with the step of the flange 300. That is, the second extension part 412 may include a height part provided at a predetermined height upward in a predetermined area of the third side of the upper surface 410, and a horizontal part formed to a predetermined size from an end of the height part. At this time, the horizontal portion may be formed wider than the width of the height portion. In addition, the second extension portion 412 may have a horizontal portion formed in a “U” shape at the end, and a height portion and a horizontal portion may be formed in a substantially “F” shape. That is, the horizontal portion may be formed in a substantially “U” shape such that a groove is formed in an area where the wire 200 passes in a direction opposite to the core 100, and protrusions are formed on both sides. In this case, the protrusions at both sides of the groove may extend outward from the terminal electrode 400. That is, assuming that the portion protruding in the shape of “U” extends in the vertical direction from the side surface 430 of the terminal electrode 400, it may extend to an area beyond the side surface 430 of the terminal electrode 400. have. The second extension part 412 is bent from the third side of the upper surface 410 in the fourth side direction. Accordingly, the second extension portion 412 passes through the wire portion 200 in the groove portion at the “U” shaped portion, and protrusions on both sides thereof extend beyond the side surface 430. As such, the wire 200 may be contacted and fixed on the upper surface 410 of the terminal electrode 400 by the second extension part 412. In addition, since the protruding region of the second extension portion 412 protrudes outside the side surface 430 of the terminal electrode 400, the protruding portion of the terminal electrode 400 and the wire 200 may be joined by laser welding. The wire 200 on the upper side of the terminal electrode 400 may not be peeled off to prevent excessive welding.

Meanwhile, as shown in FIG. 5, an opening 413 may be formed in the upper surface 410 of the terminal electrode 400. 6 and 7, the protrusion 421 may be formed on the lower surface 420 of the terminal electrode 400, and accordingly, the second portion of the flange 300 may be formed as illustrated in FIG. 7. A stepped portion 330 may be formed on the bottom surface of the region 320. That is, in the third embodiment of the present invention, the opening and the stepped portion may be formed in the terminal electrode 400 as described in the first and second embodiments of the present invention.

The weld part 500 is formed on the terminal electrode 400 fastened to the second region 320 of the flange 300. The welding part 500 lasers the second extension part 412 while the wire 200 is fixed by the second extension part 412 on the terminal electrode 400 and the end thereof is located outside the terminal electrode 400. Can be irradiated and formed. That is, by irradiating a laser to the “U” shaped portion of the second extension portion 412 in the state where the wire 200 extends outside the terminal electrode 400, the end of the wire 200 is melted and dropped. The wire 200 and the second extension part 412 may be melted on the extension part 412 to form a weld part 500. Accordingly, the insulation layer by the insulation coating remains on the wire 200 below the weld portion 500, and thus the weld portion 500, the wire 200, and the terminal electrode 400 may be divided by the insulation layer. That is, an insulating layer may remain between the wire 200 and the terminal electrode 400 under the weld 500 and between the weld 500 and the wire 200. In addition, an insulating layer may remain on the surface of the weld part 500 or the like. Meanwhile, the weld 500 may be formed at a height lower than that of the first region 310 of the flange 300, and thus the weld 500 may not be in contact with the cover 600.

The cover part 600 may be provided on the core 100 to which the wire 200 is wound and the terminal electrode 400 is fastened, and may be provided in a substantially rectangular plate shape having a predetermined thickness.

22 to 27 are perspective views illustrating a method of manufacturing a choke coil according to a third embodiment of the present invention. 28 is a cross-sectional image of a welded portion of a choke coil manufactured according to a third embodiment of the present invention and a lower region thereof. The manufacturing method of the choke coil according to the third embodiment of the present invention will be described below with reference to a part different from the manufacturing method of the first embodiment of the present invention.

Referring to FIG. 22, a core 100 having a flange 300 coupled to both ends is manufactured, and a cover part 600 and a terminal electrode 400 are manufactured, respectively. Next, the terminal electrode 400 is inserted into the second region 320 of the flange 300 to couple the terminal electrode 400 to the flange 300.

Referring to FIG. 23, the wire 200 is wound around the core 100. That is, the wire 200 may wrap the core 100 from one side to the other side in the X direction. The wire 200 may include a first wire wound in contact with the core 100 and a second wire wound in contact with the first wire. The first wire may extend to the top of the terminal electrode 400 fastened to two flanges 300 opposite both ends, and the second wire may have two flanges opposite to each other without the first wire extending from both ends. It may extend to the upper portion of the terminal electrode 400 fastened to the (300). In this case, the wire 200 may be guided and drawn out by the first extension part 411 provided on the upper surface 410 of the terminal electrode 400. In addition, the wire 200 may extend out of the side surface 430 of the terminal electrode 400 to be out of the terminal electrode 400. That is, the terminal of the wire 200 may be located outside the terminal electrode 400. Here, the size of the welding part 500 may be adjusted according to the length of the wire 200 located outside the terminal electrode 400, for example, 1 times the diameter of the wire 200. To 5 times the length. That is, the length of the wire 200 extending outward from an area perpendicular to the side surface 430 of the terminal electrode 400 may be formed to be 1 to 5 times the diameter of the wire 200. When the length of the outside of the terminal electrode 400 is less than the above range, the size of the welding part 500 is small or the welding part 500 is not formed, so that the junction area between the wire 200 and the terminal electrode 400 is smaller than that of the wire 200. It may be smaller than the cross-sectional area, and if it exceeds the above range, the size of the weld part 500 may be increased, so that the wire 200 may remain even after forming the weld part 500 or higher than the first area 310 of the flange 300. Can be.

Referring to FIG. 24, after the wire 200 is drawn out, the second extension part 412 is bent to fix the wire 200. In addition, at least a portion of the cover of the terminal located at the end of the wire 200, that is, the terminal electrode 400 is removed. For example, the upper coating of the wire 200 is removed by irradiating a laser from above, or the lower coating of the wire 200 is removed by irradiating a laser from below. That is, the covering of the area | region to which a laser is irradiated from the upper side or the area | region where a laser is irradiated from the lower side is removed. Of course, the coating of the wire 200 can be completely removed by irradiating the laser twice from the upper side and the lower side. Meanwhile, when the laser is irradiated from the upper side, the coating of the wire 200 may be removed to the region exposed by the “U” -shaped portion of the second extension portion 412, that is, the concave portion.

Referring to FIG. 25, the wire 200, which is selectively drawn out of the terminal electrode 400 to remove the cover, may be bent above the second extension part 412. That is, as shown in FIG. 24, the welding part 500 may be formed by irradiating a laser as shown in FIG. 26 while the wire 200 is drawn outward, and as shown in FIG. 25, the wire ( The bent part 500 may be formed after the 200 is bent upward.

Referring to FIG. 26, a welding part 500 is formed by irradiating a laser toward the second extension part 412. That is, the second extension part 412 and the wire 200 are melted by laser irradiation, and a spherical weld part 500 is formed on the upper surface 410 of the terminal electrode 400. In this case, the laser beam may be focused on an area formed in a “U” shape of the second extension part 412. In this case, as shown in FIG. 24, when the wire 200 is drawn out of the terminal electrode 400, the end of the wire 200 positioned outside the terminal electrode 400 melts and is dropped while the second extension part ( The weld 500 is formed by melting the second extension 412 and the wire 200 on the 412. In addition, as shown in FIG. 25, when the wire 200 is bent above the terminal electrode 400 and the laser is irradiated, the wire located on the second extension 412 melts directly to the terminal electrode 400. By dissipating heat, the fusion of the wire 200 and the terminal electrode 400 proceeds rapidly. As a result, the laser heat is divided into the wire 200 and the terminal electrode 400 so that stable welding is possible. The weld 500 of the choke coil thus formed and a cross-sectional image of the lower side thereof are illustrated in FIG. 28. As shown, the end of the wire 200 is melted together with the second extension 412 of the terminal electrode 400 to form a weld 500, and insulated between the weld 500 and the terminal electrode 400. It can be seen that the layer (A) remains. This is because the wire 200 without the insulation coating remaining between the weld part 500 and the terminal electrode 400 remains. That is, since the wire 200 positioned below the second extension part 412 is not peeled off, the coating may be partially maintained even after the welding part 500 is formed by laser irradiation.

Referring to FIG. 27, the cover part 600 is covered to contact the upper portion of the first region 310 of the flange 300.

On the other hand, although the technical spirit of the present invention has been described in detail according to the above embodiment, it should be noted that the above embodiment is for the purpose of explanation and not for the limitation. In addition, those skilled in the art will understand that various embodiments are possible within the scope of the technical idea of the present invention.

Claims

Cores provided with flanges at both ends;

A terminal electrode coupled to a portion of the flange;

A wire wound around the core and having a distal end drawn above the terminal electrode; And

It includes a welding portion provided on the terminal electrode,

The terminal electrode includes an upper surface and a lower surface facing each other up and down, and side surfaces provided on one side between the upper surface and the lower surface,

The flange is a choke coil having an inclined region formed between the first surface and the second surface corresponding to the upper surface and the side surface of the terminal electrode, respectively, and the third surface and the first surface facing the second surface.
The choke coil of claim 1, further comprising an opening formed on an upper surface of the terminal electrode, wherein the wire is positioned upward.
The choke coil of claim 2, wherein the opening is formed to have a width wider than that of the wire and is shorter than a length of the wire seated on the upper surface.
The choke coil according to claim 1 or 2, further comprising a protrusion formed on the bottom surface of the terminal electrode, and a stepped portion formed on the bottom surface of the flange, wherein the protrusion is engaged with the step portion.
The choke coil according to claim 1 or 2, further comprising an insulating layer provided in at least one region between the welding portion and the terminal electrode.
The method according to claim 1 or claim 2, comprising a first and second extensions formed on the upper surface of the terminal electrode so as to be spaced apart from each other, wherein the second extension portion is concave and the convex protruding outside the area where the wire passes; Choke coils in shape.
Cores provided with flanges at both ends;

A terminal electrode coupled to a portion of the flange;

First and second extensions formed to be spaced apart from one surface of the terminal electrode;

A wire wound around the core and having a distal end drawn above the terminal electrode;

A weld portion formed on the second extension portion of the terminal electrode; And

The choke coil including an insulating layer provided in at least one region between the welding portion and the terminal electrode.
The wire of claim 7, further comprising an opening formed on an upper surface of the terminal electrode and positioned above the wire, wherein the opening is formed to have a width wider than that of the wire and is seated on the upper surface. Choke coils formed shorter than their length.
8. The inclined region of claim 7, wherein the flange has an inclined region between the first and second surfaces corresponding to the top and side surfaces of the terminal electrode, and the third and first surfaces opposing the second surface, respectively. Formed choke coil.
The choke coil of claim 7, wherein the second extension part has a shape in which an area through which the wire passes is concave and an outer side thereof protrudes convexly.
The choke coil of claim 7, wherein the wire includes a conductive wire and an insulating coating surrounding the conductive wire, wherein the insulating layer is formed by the insulating coating.
The choke coil according to any one of claims 7 to 11, further comprising a protrusion formed on the bottom surface of the terminal electrode, and a stepped portion formed on the bottom surface of the flange, wherein the protrusion is engaged with the step portion.
The choke coil according to claim 1 or 9, wherein the flange comprises a first region in contact with the core and a second region in which the terminal electrode is coupled, wherein the first region is formed higher than the second region.
The choke coil of claim 13, wherein the terminal electrode is shorter in length than the lower surface of the upper surface from the side surface.
The method according to claim 14, wherein the upper surface of the terminal electrode is formed in a rectangular plate shape is a first side is connected to the side and the second side provided on one side of the first side is in contact between the first and second regions of the flange Choke coil.
The choke coil according to claim 15, wherein the first extension part guides or temporarily fixes the drawing of the wire, and the second extension part is bent in one direction to fix the wire and form the weld part.
The choke coil of claim 16, wherein the inclined region is formed in a width of 0.05 mm to 0.25 mm.
The choke coil according to claim 17, wherein the inclined region and the upper surface of the terminal electrode have a distance of 0.05 mm to 0.25 mm.
Coupling terminal electrodes to flanges provided at both ends of the core;

Winding a wire to surround the core and drawing the wire to the outside of the terminal electrode through the terminal electrode;

Removing at least a portion of the coating of the wire outside the terminal electrode; And

Method of manufacturing a choke coil comprising the step of forming a weld on the terminal electrode by using laser welding.
20. The method of claim 19, further comprising bending a wire positioned outside the terminal electrode to the upper side of the terminal electrode before forming the welded part.
21. The choke coil according to claim 19 or 20, wherein the wire is drawn out to guide the first extension formed on the upper surface of the terminal electrode, and the second coil is bent from the first extension to fix the wire. Method of preparation.
22. The choke coil of claim 21, wherein the second extension part is formed in a shape in which an area through which the wire passes is concave and protrudes outwardly, and the second extension part bends the second extension part so as to deviate from the side surface of the terminal electrode. Method of preparation.
23. The method of claim 22, wherein at least a portion of the wire from which at least a portion of the sheath has been removed and at least a portion of the second extension form the weld.
The method of manufacturing a choke coil according to claim 23, wherein the wire is provided with no insulation coating peeled between the welding portion and the terminal electrode.