WO2023176738A1 - Composant de bobine et procédé permettant de fabriquer un composant de bobine - Google Patents

Composant de bobine et procédé permettant de fabriquer un composant de bobine Download PDF

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Publication number
WO2023176738A1
WO2023176738A1 PCT/JP2023/009392 JP2023009392W WO2023176738A1 WO 2023176738 A1 WO2023176738 A1 WO 2023176738A1 JP 2023009392 W JP2023009392 W JP 2023009392W WO 2023176738 A1 WO2023176738 A1 WO 2023176738A1
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WIPO (PCT)
Prior art keywords
coil
electrode terminal
main surface
pin member
recess
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PCT/JP2023/009392
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English (en)
Japanese (ja)
Inventor
達哉 佐々木
信 長谷川
勇治 五十嵐
健司 奈良
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株式会社村田製作所
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Application filed by 株式会社村田製作所 filed Critical 株式会社村田製作所
Publication of WO2023176738A1 publication Critical patent/WO2023176738A1/fr

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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
    • 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

Definitions

  • the present disclosure relates to a coil component and a method for manufacturing the coil component.
  • This coil component includes a rod-shaped core, a wire wound around the rod-shaped core, and electrode terminals provided at both ends of the rod-shaped core.
  • the wire is wound (twisted) around the electrode terminal and connected by soldering.
  • the wires are connected by being tied around the electrode terminals, so the electrode terminals may be deformed when the wires are tied around the electrode terminals or due to residual stress remaining in the tied wires. There is a risk of it getting lost.
  • the electrode terminal is deformed, making it difficult to tie the wire together.
  • a bending bulge occurs in the wire, which creates a gap between the wire and the electrode terminal, and there is a possibility that connection stability and miniaturization cannot be achieved.
  • an object of the present disclosure is to provide a coil component and a method for manufacturing the coil component that can be connected to an electrode terminal without the need to wind the coil.
  • a coil component that is one aspect of the present disclosure includes: coil and A plate-shaped electrode terminal, a first connecting member connecting the first end of the coil and the electrode terminal,
  • the electrode terminal includes a coil connection part connected to the first end of the coil
  • the coil connecting portion includes a first main surface, a second main surface opposite to the first main surface, and a side surface connecting the first main surface and the second main surface
  • the coil connecting portion has a first recess that opens to the first main surface, the second main surface, and the side surface
  • the first end portion of the coil is disposed only on the first main surface side of the coil connecting portion to face the first main surface, and when viewed from a direction perpendicular to the first main surface, arranged so as to overlap with the first recess, At least a portion of the first connecting member is located within the first recess and is in contact with an inner surface of the first recess.
  • the first end of the coil and the electrode terminal are arranged such that the first end is disposed only on the first main surface side of the coil connecting portion of the electrode terminal and faces the first main surface. Since the coil is connected, the coil is not connected around the electrode terminal.
  • "tying" means winding the coil around the electrode terminal.
  • the first connecting member since at least a portion of the first connecting member is located within the first recess of the electrode terminal, the first connecting member can be observed from the second main surface side of the coil connecting portion. Thereby, the state of connection between the coil and the electrode terminal can be easily visually inspected.
  • the first connecting member is a welded portion where the first end of the coil and the coil connecting portion of the electrode terminal are welded.
  • the strength of the connection between the coil and the electrode terminal can be increased. Furthermore, the electrical resistance between the coil and the electrode terminal can be reduced. Thereby, the electrical resistance of the coil component can be lowered.
  • the circumferential surface of the first end of the coil has a flat surface, The flat surface faces the first main surface.
  • the flat surface of the first end of the coil is connected to the electrode terminal via the first connecting member. Therefore, since the contact area between the first end of the coil and the electrode terminal can be increased, the mechanical strength between the coil and the electrode terminal can be improved. Furthermore, since the cross-sectional area of the electrical path between the coil and the electrode terminal becomes larger, the electrical resistance of the coil component can be reduced.
  • the coil includes a plurality of straight pin members and a plurality of bent pin members, The straight pin members and the bent pin members are alternately connected to form a spiral of the coil,
  • the plurality of straight pin members include an endmost straight pin member located at the farthest end of at least one side of the coil in the axial direction, the first end of the coil includes the endmost straight pin member;
  • the peripheral surface of the endmost linear pin member faces the first main surface and overlaps with the first recess when viewed from a direction perpendicular to the first main surface,
  • the first connecting member connects the electrode terminal and the peripheral surface of the endmost straight pin member.
  • the plurality of straight pin members and the plurality of bent pin members are alternately connected to form the spiral of the coil, when the coil is wound around the core, Coils can be wound closely together.
  • the coil component further comprising a second connecting member connecting the first end of the coil and the electrode terminal,
  • the coil connecting portion has a second recess that opens to the first main surface, the second main surface, and the side surface
  • the plurality of bending pin members include adjacent bending pin members connected adjacent to the endmost straight pin member, The end face of the end of the end of the straight pin member and the circumferential surface of the end of the adjacent bend of the pin member are connected to each other, and the first end of the coil further includes the adjacent folding pin member;
  • the end surface of the adjacent bending pin member on the side to which the endmost straight pin member is connected faces the first main surface and, when viewed from a direction orthogonal to the first main surface, has the second recess. overlaps with the inner surface of At least a portion of the second connecting member is located within the second recess and contacts an inner surface of the second recess,
  • the second connecting member connects the electrode terminal and the end surface of the adjacent bending pin member.
  • the mechanical strength between the coil and the electrode terminal can be further improved. Furthermore, since the cross-sectional area of the electrical path between the coil and the electrode terminal becomes larger, the electrical resistance of the coil component can be further reduced.
  • the coil includes a plurality of straight pin members and a plurality of bent pin members, The straight pin members and the bent pin members are alternately connected to form a spiral of the coil,
  • the plurality of bending pin members include an endmost bending pin member located at the farthest end of at least one side of the coil in the axial direction, the first end of the coil includes the endmost bending pin member;
  • an end surface opposite to the side to which the straight pin member is connected faces the first main surface, and when viewed from a direction perpendicular to the first main surface, arranged so as to overlap with the first recess,
  • the first connecting member connects the electrode terminal and the end surface of the endmost bending pin member.
  • the plurality of straight pin members and the plurality of bent pin members are alternately connected to form the spiral of the coil, when the coil is wound around the core, Coils can be wound closely together.
  • the electrode terminal further includes a mounting part mounted on a mounting board, and a relay part connecting the coil connecting part and the mounting part,
  • the coil connecting portion and the mounting portion do not exist on the same plane and do not overlap when viewed from a direction perpendicular to the first main surface.
  • the relay part and the coil connection part are easily bent with the mounting part as a fulcrum, it is possible to impart springiness to the electrode terminal in a direction perpendicular to the first main surface of the coil connection part. .
  • the coil connecting portion and the first end of the coil can be brought into contact with each other more reliably, thereby improving the connection stability between the coil and the electrode terminal. can be improved.
  • the stress applied to the first connection member or the second connection member can be reduced due to the springiness of the electrode terminal, and the reliability of the coil component can be improved.
  • the electrode terminal is elastically deformable so that the coil connecting portion can swing in a direction perpendicular to the first main surface.
  • connection stability between the coil and the electrode terminal can be further improved. Moreover, even when an external impact is applied to the coil component, the stress applied to the first connection member or the second connection member can be further reduced, and the reliability of the coil component can be further improved.
  • the first end of the coil is disposed only on the first main surface side of the coil connection part of the electrode terminal so as to face the first main surface, and when viewed from the direction perpendicular to the first main surface, the electrode terminal a step of arranging the recess so as to overlap with a first recess provided in the recess; irradiating at least a portion of the inner surface of the first recess with a laser from the second main surface side of the coil connecting portion to form a first connecting member; Equipped with.
  • the coil can be connected to the electrode terminal without being entwined.
  • the coil components can be made smaller.
  • a coil component that is one aspect of the present disclosure includes: coil and A plate-shaped electrode terminal, a first connecting member connecting the first end of the coil and the electrode terminal,
  • the electrode terminal includes a coil connecting part connected to the first end of the coil, a mounting part mounted on a mounting board, and a relay part connecting the coil connecting part and the mounting part.
  • the coil connecting portion includes a first main surface and a second main surface opposite to the first main surface, The first end portion of the coil is disposed only on the first main surface side of the coil connecting portion and faces the first main surface, The coil connecting portion and the mounting portion do not exist on the same plane and do not overlap when viewed from a direction perpendicular to the first main surface.
  • the first end of the coil and the electrode terminal are arranged such that the first end is disposed only on the first main surface side of the coil connecting portion of the electrode terminal and faces the first main surface. Since the coil is connected, the coil is not connected around the electrode terminal. Therefore, it is possible to prevent deformation of the electrode terminal due to coil binding work or residual stress of the coil. Thereby, a thick coil can be connected to a thin electrode terminal, and an electrode terminal that can be easily bent and a coil that can handle a large current can be used. In addition, since the coil is not tied around the electrode terminal, no bending bulge occurs in the coil, which makes it difficult to create a gap between the coil and the electrode terminal, making it possible to achieve connection stability and miniaturization.
  • the relay part and the coil The connection part becomes easily bent. Thereby, it is possible to impart springiness to the electrode terminal in a direction perpendicular to the first main surface of the coil connecting portion.
  • the coil connecting portion and the first end of the coil can be brought into contact more reliably, resulting in stable connection between the coil and the electrode terminal. can be improved.
  • the stress applied to the first connection member can be reduced due to the springiness of the electrode terminal, and the reliability of the coil component can be improved.
  • the coil component and the method for manufacturing the coil component which are one aspect of the present disclosure, it is possible to connect the coil to the electrode terminal without having to wrap the coil.
  • FIG. 1 is a top perspective view showing a coil component according to a first embodiment of the present invention.
  • FIG. 3 is a bottom perspective view of the coil component. It is a top perspective view showing the inside of a coil component. It is an exploded perspective view of a coil component.
  • FIG. 3 is a schematic cross-sectional view of a coil component.
  • FIG. 3 is a schematic cross-sectional view of a coil component.
  • FIG. 3 is a schematic plan view partially showing an electrode terminal before connection to a coil.
  • FIG. 8 is a sectional view taken along line VIII-VIII in FIG. 7;
  • FIG. 3 is a schematic plan view partially showing a connection portion between a coil and an electrode terminal.
  • FIG. 9 is a sectional view taken along line XX in FIG. 9; FIG.
  • FIG. 3 is a schematic plan view illustrating a method of connecting a coil and an electrode terminal.
  • FIG. 3 is a schematic plan view illustrating a method of connecting a coil and an electrode terminal.
  • FIG. 7 is a schematic cross-sectional view partially showing a coil component of a second embodiment. It is a schematic plan view which partially shows the coil component of 3rd Embodiment. It is a schematic plan view which partially shows the coil component of 4th Embodiment. It is a schematic plan view which partially shows the coil component of 5th Embodiment.
  • FIG. 1 is a top perspective view showing a coil component according to an embodiment of the present invention.
  • FIG. 2 is a bottom perspective view of the coil component.
  • FIG. 3 is a top perspective view showing the inside of the coil component.
  • FIG. 4 is an exploded perspective view of the coil component.
  • the coil component 1 includes a case 2, an inductor element L housed in the case 2, first to fourth electrode terminals 51 to 54 attached to the case 2, and an inductor element L housed in the case 2. It has a first connecting member 81 that connects the element L and the first to fourth electrode terminals 51 to 54, and a resin member 90 disposed inside the case 2.
  • the coil component 1 is, for example, a common mode choke coil.
  • the inductor element L includes an annular core 3, a first coil 41 and a second coil 42 wound around the core 3, and a core cover 60 attached to the core 3.
  • the case 2 has a bottom plate part 21 and a box part 22 that covers the bottom plate part 21.
  • the case 2 is made of a material that has strength and heat resistance, and is preferably made of a material that is flame retardant.
  • the case 2 is made of a resin such as PPS (polyphenylene sulfide), LCP (liquid crystal polymer), or PPA (polyphthalamide), or ceramics.
  • the bottom plate part 21 includes a bottom part 210 including a first main surface 210a and a second main surface 210b facing each other, and a side wall part 211 provided along the outer periphery of the bottom part 210 on the first main surface 210a of the bottom part 210.
  • the bottom plate part 21 has a recess 215, and the recess 215 is surrounded by the bottom part 210 and the side wall part 211.
  • the side wall portion 211 is provided continuously in the circumferential direction, but may be provided intermittently in the circumferential direction.
  • the bottom portion 210 has a plurality of openings 216 passing through the first main surface 210a and the second main surface 210b.
  • the plurality of openings 216 are provided at positions corresponding to the first to fourth electrode terminals 51 to 54. In this embodiment, there are four openings 216, but the number can be increased or decreased as desired.
  • An inductor element L is arranged on the bottom plate part 21. That is, the core 3 is arranged in the bottom plate part 21 so that the central axis of the core 3 is perpendicular to the first main surface 210a of the bottom part 210.
  • the central axis of the core 3 refers to the central axis of the inner diameter hole of the core 3.
  • the shape of the case 2 (the bottom plate part 21 and the box part 22) is rectangular when viewed from the central axis direction of the core 3. In this embodiment, the shape of case 2 is rectangular.
  • the lateral direction of the case 2 viewed from the central axis direction of the core 3 is defined as the X direction
  • the longitudinal direction of the case 2 viewed from the central axial direction of the core 3 is defined as the Y direction
  • the height direction of case 2 which is a direction perpendicular to , is defined as the Z direction.
  • the bottom plate part 21 and the box part 22 of the case 2 are arranged facing each other in the Z direction, the bottom plate part 21 is on the lower side and the box part 22 is on the upper side, the upper side is in the forward direction of the Z direction, and the lower side is in the Z direction.
  • the direction is the opposite direction.
  • the direction from the first main surface 210a toward the core 3 is defined as the upward direction.
  • the bottom plate portion 21 of the case 2 has a square shape, the length of the case 2 in the X direction and the length of the case 2 in the Y direction are the same.
  • the box part 22 is attached to the bottom plate part 21 so as to cover the inductor element L. That is, the core 3 and the coils 41 and 42 are surrounded by the box part 22 and are not exposed to the outside. Therefore, the inductor element L can be protected from the outside.
  • the first to fourth electrode terminals 51 to 54 are attached to the bottom plate portion 21.
  • the first electrode terminal 51 and the second electrode terminal 52 are located at two corners of the bottom plate portion 21 facing each other in the Y direction
  • the third electrode terminal 53 and the fourth electrode terminal 54 are located at two corners of the bottom plate portion 21 facing each other in the Y direction. It is located in two corners.
  • the first electrode terminal 51 and the third electrode terminal 53 face each other in the X direction
  • the second electrode terminal 52 and the fourth electrode terminal 54 face each other in the X direction.
  • the core 3 is a toroidal core, and the shape of the core 3 is oval (track shape) when viewed from the central axis direction.
  • the core 3 When viewed from the central axis direction, the core 3 includes a pair of longitudinal parts 31 extending along the long axis and opposing each other in the short axis direction, and a pair of short parts 31 extending along the short axis and opposing each other in the long axis direction. 32.
  • the shape of the core 3 may be rectangular, elliptical, or circular when viewed from the central axis direction.
  • the core 3 is composed of, for example, a ceramic core such as ferrite, or a magnetic core made of iron-based powder molding or nanocrystalline foil.
  • the core 3 has a first end surface 301 and a second end surface 302 that face each other in the central axis direction, and an inner circumferential surface 303 and an outer circumferential surface 304.
  • the first end surface 301 is the lower end surface of the core 3 and faces the first main surface 210a of the bottom plate portion 21.
  • the second end surface 302 is the upper end surface of the core 3 and faces the inner surface of the box portion 22.
  • the core 3 is housed in the case 2 so that the long axis direction of the core 3 coincides with the Y direction.
  • the shape of the cross section perpendicular to the circumferential direction when viewed from the central axis direction of the core 3 is rectangular.
  • the first end surface 301 and the second end surface 302 are arranged perpendicularly to the central axis direction of the core 3.
  • the inner circumferential surface 303 and the outer circumferential surface 304 are arranged parallel to the central axis direction of the core 3.
  • vertical is not limited to a completely vertical state, but also includes a substantially vertical state.
  • parallel is not limited to a completely parallel state, but also includes a substantially parallel state.
  • the lower part of the core 3 is covered with a core cover 60. That is, a portion of the core 3 on the bottom plate portion 21 side is covered by the core cover 60. Note that it is sufficient that at least a portion of the core 3 on the bottom plate portion 21 side is covered by the core cover 60, and the entire core 3 may be covered by the core cover 60.
  • the core cover 60 is made of a super engineering plastic such as LCP, PPA, or PPS, which improves the heat resistance, insulation, and workability of the core cover 60.
  • the core cover 60 is formed in an annular shape and has an annular recess 61 that covers the lower portion of the core 3. By fitting the lower portion of the core 3 into the annular recess 61 of the core cover 60, the core cover 60 can be attached to the core 3.
  • the resin member 90 is disposed within the recess 215 of the bottom plate portion 21 and contacts the bottom plate portion 21 and the inductor element L.
  • a material for the resin member 90 for example, thermosetting epoxy resin can be used.
  • the first coil 41 is wound around the core 3 and the core cover 60 between the first electrode terminal 51 and the second electrode terminal 52. One end of the first coil 41 is connected to the first electrode terminal 51. The other end of the first coil 41 is connected to a second electrode terminal 52.
  • the second coil 42 is wound around the core 3 and the core cover 60 between the third electrode terminal 53 and the fourth electrode terminal 54.
  • One end of the second coil 42 is connected to a third electrode terminal 53.
  • the other end of the second coil 42 is connected to a fourth electrode terminal 54.
  • the first coil 41 and the second coil 42 are wound helically around the core 3 along the circumferential direction of the core 3 as viewed from the central axis direction of the core 3. Specifically, the first coil 41 is wound around one longitudinal part 31 of the core 3 along the longitudinal direction of the core 3, and the second coil 42 is wound around the other longitudinal part 31 of the core 3. 3 along the long axis direction.
  • the winding axis of the first coil 41 and the winding axis of the second coil 42 run in parallel.
  • the first coil 41 and the second coil 42 are symmetrical with respect to the long axis of the core 3.
  • the number of turns of the first coil 41 and the number of turns of the second coil 42 are the same.
  • the winding direction of the first coil 41 around the core 3 and the winding direction of the second coil 42 around the core 3 are opposite directions. In other words, the winding direction of the first coil 41 from the first electrode terminal 51 to the second electrode terminal 52 is opposite to the winding direction of the second coil 42 from the third electrode terminal 53 to the fourth electrode terminal 54. direction.
  • the common mode current flows from the first electrode terminal 51 to the second electrode terminal 52 in the first coil 41, and from the third electrode terminal 53 to the fourth electrode terminal 54 in the second coil 42, That is, the first to fourth electrode terminals 51 to 54 are connected so that the current flows in the same direction.
  • a common mode current flows through the first coil 41
  • a first magnetic flux is generated by the first coil 41 in the core 3.
  • a common mode current flows through the second coil 42 a second magnetic flux is generated in the core 3 in a direction in which the first magnetic flux and the core 3 strengthen each other. Therefore, the first coil 41 and core 3 and the second coil 42 and core 3 act as inductance components, and noise is removed from the common mode current.
  • the first coil 41 is formed by connecting a plurality of pin members by, for example, welding such as laser welding or spot welding. Note that FIG. 3 does not show a state in which a plurality of pin members are actually welded, but a state in which a plurality of pin members are assembled.
  • the plurality of pin members are not printed wiring or conductive wires, but are rod-shaped members.
  • the pin member has rigidity. Specifically, in a cross section perpendicular to the circumferential direction of the core 3, the pin member extends around the outer circumference of the core passing through the first end surface 301, second end surface 302, inner circumferential surface 303, and outer circumferential surface 304 of the core 3. Because it is shorter than the length of a 100-minute length and has high rigidity, it is difficult to bend.
  • the plurality of pin members include a bent pin member 410 bent into a substantially U-shape, a straight pin member 412 and an end straight pin member 411 extending in a substantially straight line.
  • the first coil 41 includes, in order from one end to the other, an endmost straight pin member 411 on one end side (one side), a plurality of sets of bent pin members 410 and a straight pin member 412, and an endmost straight pin member 411 on the other end side (the other side).
  • An end straight pin member 411 is included.
  • the endmost straight pin member 411 is a straight pin member located at the end of the first coil 41 in the axial direction.
  • the endmost straight pin member 411 and the straight pin member 412 have the same shape.
  • the present invention is not limited thereto, and the endmost straight pin member 411 and the straight pin member 412 may have different shapes.
  • the length of the endmost straight pin member 411 in the extending direction may be shorter than the length of the straight pin member 412 in the extending direction.
  • the bending pin member 410 As shown in FIG.
  • the spring index Ks of member 410 is smaller than 3.6.
  • the spring index Ks can be expressed by the radius of curvature R1, R2 of the bending pin member/the wire diameter r of the bending pin member. In this way, the bending pin member 410 has high rigidity and is difficult to bend.
  • the bent pin members 410 and the straight pin members 412 are alternately connected by welding, such as laser welding or spot welding, for example.
  • One end of a straight pin member 412 is connected to one end of the bending pin member 410, and the other end of the straight pin member 412 is connected to one end of another bending pin member 410.
  • the plurality of bending pin members 410 and the straight pin members 412 are connected, and the plurality of connected bending pin members 410 and the straight pin members 412 are arranged in a spiral around the core 3. In other words, one set of bending pin member 410 and straight pin member 412 constitutes one turn.
  • the bending pin member 410 is arranged in parallel along each of the second end surface 302, inner peripheral surface 303, and outer peripheral surface 304 of the core 3.
  • the bending pin member 410 is arranged so that an imaginary line connecting both ends of the bending pin member 410 in the extending direction is perpendicular to the axial direction of the first coil 41 .
  • the bending pin member 410 is arranged so that a plane including the center line of the bending pin member 410 is parallel to a plane (XZ plane) orthogonal to the axial direction of the first coil 41.
  • the straight pin member 412 is arranged parallel to the first end surface 301 of the core 3 .
  • the straight pin member 412 is slightly inclined in the Y direction and extends in the X direction.
  • the endmost straight pin member 411 is arranged parallel to the first end surface 301 of the core 3 .
  • the endmost straight pin member 411 extends in a direction parallel to the straight pin member 412.
  • the bending pin members 410 of adjacent turns are fixed to each other by an adhesive member 70. Thereby, the state in which the plurality of bending pin members 410 are attached to the core 3 can be made stable. Similarly, the adjacent endmost straight pin member 411 and the straight pin member 412 are fixed by the adhesive member 70, and the adjacent straight pin member 412 is fixed by the adhesive member 70. As a result, the attachment state of the plurality of endmost straight pin members 411 and straight pin members 412 to the core 3 can be made stable.
  • the first electrode terminal 51 is connected to one endmost straight pin member 411, and the one endmost straight pin member 411 is connected to one end of the bent pin member 410 of the turn next to the one endmost straight pin member 411. Connected. A part of the first electrode terminal 51 (a relay part and a coil connection part to be described later) enters into the case 2, and the peripheral surface of one of the endmost straight pin members 411 is connected to the first electrode terminal 51. Specifically, a portion of the first electrode terminal 51 passes through the opening 216 and is connected to the circumferential surface of one of the endmost straight pin members 411 . In short, the first coil 41 and the first electrode terminal 51 are electrically connected via the opening 216.
  • the second electrode terminal 52 is connected to the other endmost straight pin member 411, and the other endmost straight pin member 411 is connected to one end of the bent pin member 410 of the turn next to the other endmost straight pin member 411. Connected. A part of the second electrode terminal 52 (a relay part and a coil connection part to be described later) enters into the case 2, and the peripheral surface of the other endmost straight pin member 411 is connected to the second electrode terminal 52. Specifically, a portion of the second electrode terminal 52 passes through the opening 216 and is connected to the peripheral surface of the other endmost straight pin member 411 . In short, the first coil 41 and the second electrode terminal 52 are electrically connected via the opening 216.
  • the second coil 42 is composed of a plurality of pin members.
  • the second coil 42 includes, in order from one end to the other, the most straight pin member 421 on one end (one side), the plurality of sets of bent pin members 420 and straight pin members 422, and the other end (on the other side).
  • the endmost straight pin member 421 is included.
  • Bent pin members 420 and straight pin members 422 are alternately connected and wound around the core 3 . That is, the plurality of bent pin members 420 and the straight pin members 422 are connected, and the connected plurality of bent pin members 420 and the straight pin members 422 are spirally wound around the core 3.
  • the third electrode terminal 53 is connected to one endmost straight pin member 421, and the one endmost straight pin member 421 is connected to one end of the bent pin member 420 of the turn next to the one endmost straight pin member 421. Connected. A part of the third electrode terminal 53 (a relay part and a coil connection part to be described later) enters into the case 2, and the peripheral surface of one of the endmost straight pin members 421 is connected to the third electrode terminal 53. Specifically, a portion of the third electrode terminal 53 passes through the opening 216 and is connected to the circumferential surface of one of the endmost straight pin members 421 . In short, the second coil 42 and the third electrode terminal 53 are electrically connected via the opening 216.
  • the fourth electrode terminal 54 is connected to the other endmost straight pin member 421, and the other endmost straight pin member 421 is connected to one end of the bent pin member 420 of the turn next to the other endmost straight pin member 421. Connected. A part of the fourth electrode terminal 54 (a relay part and a coil connection part to be described later) enters into the case 2, and the peripheral surface of the other endmost straight pin member 421 is connected to the fourth electrode terminal 54. Specifically, the fourth electrode terminal 54 passes through the opening 216 and is connected to the peripheral surface of the other endmost straight pin member 421 . In short, the second coil 42 and the fourth electrode terminal 54 are electrically connected via the opening 216.
  • the first coil 41 and the second coil 42 each include a conductor portion and a coating covering a portion of the conductor portion.
  • the conductor portion is, for example, a copper wire
  • the coating is, for example, a polyamide-imide resin.
  • the thickness of the coating is, for example, 0.02 to 0.04 mm.
  • the endmost straight pin members 411, 421 are composed of conductor portions 411a, 421a without a coating.
  • the straight pin members 412, 422 are composed of conductor portions 412a, 422a without a coating.
  • the bending pin members 410, 420 are composed of conductor portions 410a, 420a and coatings 410b, 420b.
  • the conductor portions 410a, 420a are exposed from the coatings 410b, 420b. That is, the endmost straight pin members 411, 421, the straight pin members 412, 422, and the bent pin members 410, 420 are welded to each other at the exposed conductor parts 411a, 421a, 412a, 422a, 410a, 420a. There is.
  • the conductor parts that are not covered with these films, that is, the conductor parts that are exposed from the films (without a film) can be electrically connected to the outside.
  • FIG. 6 is an XZ cross-sectional view passing through the center of the coil component 1 in the Y direction.
  • the box portion 22 is omitted.
  • the ends of adjacent pin members have welded parts welded to each other.
  • a welded part refers to a part that melts during welding and then hardens.
  • the first coil 41 has a first welded portion w11 and a second welded portion w12. More specifically, in adjacent turns in the first coil 41, the straight pin member 412 and the bent pin member 410 of one turn are the same as the one conductor portion 412a of the straight pin member 412 and the bent pin member 410.
  • the conductor portions 410a are welded to each other to form a first welded portion w11, and the straight pin member 412 and the bent pin member 410 of the other turn are connected to the other conductor portion 412a of the straight pin member 412 and the bent pin.
  • the conductor portion 410a of the member is welded together to form a second welded portion w12.
  • FIG. 6 shows a turn composed of the straight pin member 412 and the bent pin member 410 of the first coil 41
  • the turn is composed of the straight pin member 411 and the bent pin member 410.
  • the endmost straight pin member 411 is welded at the conductor portion 410a of the bent pin member 410 connected to the conductor portion 411a, forming a first weld portion w11 or a second weld portion w12.
  • the second coil 42 has a first weld part w21 and a second weld part w22. Similarly to the first coil 41, in the second coil 42, in adjacent turns, the straight pin member 422 and the bent pin member 420 of one turn are connected to the one conductor portion 422a of the straight pin member 422.
  • the conductor portion 420a of the pin member 420 is welded to form a first welded portion w21, and the straight pin member 422 and the bent pin member 420 of the other turn are welded to the other conductor portion 422a of the straight pin member 422.
  • the conductor portion 420a of the bending pin member is welded to form a second welded portion w22.
  • the endmost straight pin member 421 is welded at the conductor portion 420a of the bent pin member 420 connected to the conductor portion 421a, forming a first welded portion w21 or a second welded portion w22.
  • the first welded portion w21 and the second welded portion w22 of the second coil 42 have the same configuration as the first welded portion w11 and the second welded portion w12 of the first coil 41, and the description thereof will be omitted.
  • the core cover 60 exists between the core 3 and the conductor portions and welded portions exposed from the coatings of the coils 41 and 42. Thereby, the conductor portions and welded portions of the coils 41 and 42 and the core 3 can be more reliably insulated.
  • the core cover 60 is provided over the first end surface 301 of the core 3 , a portion of the inner circumferential surface 303 of the core 3 , and a portion of the outer circumferential surface 304 of the core 3 .
  • the core cover 60 includes a first portion 60a facing the inner peripheral surface 303 of the core 3, a second portion 60b facing the outer peripheral surface 304 of the core 3, and a third portion 60c facing the first end surface 301 of the core 3. and has.
  • the core cover 60 is indirectly connected to the core 3. That is, the core cover 60 is not directly connected to the core 3 , and more specifically, the core cover 60 is connected to the core 3 via the core support member 80 .
  • the core support member 80 By connecting the core support member 80 to a part of the core 3, the stress applied to the core 3 from the core cover 60 can be reduced, and deterioration of the magnetic properties of the core 3 can be suppressed. In other words, it is possible to suppress a decrease in the inductance value due to magnetostriction.
  • the core cover 60 may be simply fitted into the core 3 without being connected to the core 3 via the core support member 80.
  • the core support member 80 is provided between the first end surface 301 of the core 3 and the third portion 60c of the core cover 60. Thereby, the influence of magnetostriction on the core 3 can be reduced, and the state in which the core cover 60 is attached to the core 3 can be made stable.
  • Examples of the material for the core support member 80 include soft resins such as urethane resin and silicone resin. By providing such a soft resin, the influence of magnetostriction can be reduced.
  • the core support member 80 is provided in the entire area between the first end surface 301 of the core 3 and the third portion 60c of the core cover 60, but it may be provided only in a part. . Further, in FIG. 6, the core support member 80 is provided between the first end surface 301 of the core 3 and the third portion 60c of the core cover 60, but the core support member 80 is provided between the inner peripheral surface 303 of the core 3 and the core cover 60. 60, or between the outer circumferential surface 304 of the core 3 and the second portion 60b of the core cover 60. may be provided.
  • the inductor element L is arranged in the recess 215 so that the conductor portions of the coils 41 and 42 exposed from the coating are located on the first main surface 210a side.
  • the resin member 90 is fixed in the recess 215, fixes the inductor element L to the bottom plate part 21, and covers at least a part of the conductor part exposed from the coating in the coils 41 and 42. Preferably, the resin member 90 covers all of the conductor portions.
  • the resin member 90 is made of, for example, a thermosetting resin, it is fixed to the inductor element L and the bottom plate portion 21 by curing.
  • the resin member 90 is applied to the inner surface of the recess 215, a portion of the first portion 60a of the core cover 60, a portion of the second portion 60b of the core cover 60, and a portion of the third portion 60c of the core cover 60.
  • the conductor portions 411a, 412a, 410a that are in contact with each other and are exposed from the coating 410b of the first coil 41 and the conductor portions 421a, 422a, 420a that are exposed from the coating 420b of the second coil 42 are covered.
  • the resin member 90 also covers the welded portions w11, w12, w21, and w22 of the coils 41 and 42.
  • the resin member 90 Since the resin member 90 is fixed in the recess 215 of the bottom plate part 21, the resin member 90 is stably fixed to the bottom plate part 21, so that the resin member 90 can attach the inductor element L to the bottom plate part 21. Can be stably fixed. Further, in the manufacturing process of the coil component 1, when filling the recess 215 with the liquid resin member 90, the liquid resin member 90 can be retained in the recess 215, and the inductor element L is attached to the bottom plate portion 21 by the resin member 90. can be securely fixed. Furthermore, since the resin member 90 covers the conductor portions exposed from the coatings of the coils 41 and 42, problems such as electrical shorts with the outside can be prevented. Furthermore, when the coil component 1 receives an external force such as a vibration impact, the resin member 90 can absorb the impact and protect the coils 41 and 42.
  • FIG. 7 is a schematic plan view partially showing the second electrode terminal 52 before connection to the first coil 41.
  • FIG. 7 shows the second electrode terminal 52 after the first coil 41 is assembled to the bottom plate part 21 and before the first coil 41 and the second electrode terminal 52 are connected by, for example, welding.
  • FIG. 8 is a sectional view taken along line VIII-VIII in FIG. 7. Note that the second electrode terminal 52 will be described below, but since the configurations of the first electrode terminal 51, third electrode terminal 53, and fourth electrode terminal 54 are similar to the configuration of the second electrode terminal 52, the details thereof will be omitted. Further explanations will be omitted.
  • the second electrode terminal 52 is a plate-shaped terminal.
  • the thickness of the second electrode terminal 52 is, for example, 0.3 mm.
  • the second electrode terminal 52 connects a coil connecting portion 521 connected to the first end of the first coil 41, a mounting portion 522 mounted on a mounting board (not shown), and connecting the coil connecting portion 521 and the mounting portion 522. and a fillet portion 524 connected to the end of the mounting portion 522 on the opposite side to the side to which the relay portion 523 is connected.
  • the coil connecting portion 521 and the relay portion 523 extend from the mounting portion 522 in the reverse Y direction.
  • the thickness direction of the coil connecting portion 521 and the mounting portion 522 is parallel to the Z direction.
  • the width direction which is a direction perpendicular to the extending direction of the coil connecting portion 521 and the relay portion 523, is parallel to the X direction.
  • the coil connecting portion 521 is shaped like a flat plate parallel to the XY plane.
  • the coil connecting portion 521 includes a first main surface 52s1, a second main surface 52s2 facing the first main surface 52s1, and a side surface 52s3 connecting the first main surface 52s1 and the second main surface 52s2.
  • the coil connecting portion 521 has a first recess C1 that opens to the first main surface 52s1, the second main surface 52s2, and the side surface 52s3, a wide portion 52W, and a narrow portion 52N.
  • the first recess C1 is arranged between the wide part 52W and the narrow part 52N, and adjacent to the wide part 52W and the narrow part 52N.
  • the coil connecting portion 521 has a shape that is bifurcated at the distal end side in the extending direction (Y direction) of the coil connecting portion 521 and the relay portion 523 when viewed from the direction (Z direction) perpendicular to the first principal surface 52s1. has been done.
  • the second electrode terminal 52 is a pre-opening type terminal.
  • the first recess C1 when viewed from a direction perpendicular to the first main surface 52s1, the first recess C1 includes a part of the side surface 52s3 on the distal end side in the extending direction of the coil connecting portion 521 (distal end surface), and the first main surface 52s1 and the second main surface 52s2 are open. Furthermore, when viewed from a direction perpendicular to the first main surface 52s1, the first recess C1 is shaped to be part of an oval (track shape) whose long axis is parallel to the Y direction.
  • the width of the wide portion 52W in the X direction is wider than that of the narrow portion 52N.
  • the wide portion 52W is arranged closer to the first end of the first coil 41 than the narrow portion 52N.
  • the wide portion 52W is arranged closer to the side wall portion 211 of the bottom plate portion 21 than the narrow portion 52N in the X direction.
  • the width of the narrow portion 52N in the X direction is narrower than that of the wide portion 52W.
  • the narrow portion 52N is located closer to the center of the bottom plate portion 21 than the wide portion 52W in the X direction.
  • the maximum length L1 of the narrow portion 52N in the Y direction is preferably 50% or more of the maximum length L0 of the coil connecting portion 521 in the Y direction.
  • the distance L4 between the narrow portion 52N and the wide portion 52W is preferably 20% or more of the maximum width W0 of the coil connecting portion 521 in the X direction.
  • the area of the inner surface C1f of the first recess C1 is sufficiently large due to the above-mentioned dimensional relationship. Therefore, a sufficiently wide area that can be irradiated with laser can be secured.
  • the maximum width W1 of the narrow portion 52N in the X direction is smaller than the maximum width W2 of the wide portion 52W in the X direction.
  • the heat capacity of the narrow portion 52N becomes smaller than the heat capacity of the wide portion 52W. Therefore, for example, when laser welding the peripheral surface of the endmost straight pin member 411 of the first coil 41 and the second electrode terminal 52, when the second electrode terminal 52 is irradiated with the laser, the narrow portion 52N with a small heat capacity The side parts will melt more easily. As a result, much heat is transmitted to the endmost straight pin member 411 side, and the heat can be released to the endmost straight pin member 411 side, so that the thermal influence on the mounting portion 522 can be reduced.
  • the maximum length L2 of the wide portion 52W in the Y direction is shorter than the maximum length L1 of the narrow portion 52N in the Y direction. Thereby, it is possible to suppress short-circuiting between the endmost straight pin member 411, the adjacent straight pin member 412, and the second electrode terminal 52. Specifically, as shown in FIG. 9, which will be described later, even if the endmost straight pin member 411 and the straight pin member 412 are slightly inclined in the Y direction and extend in the X direction, the maximum length L2 is By making the length shorter than the maximum length L1, a distance between the wide portion 52W and the adjacent linear pin members 412 can be secured. As a result, short-circuiting between the wide portion 52W and the adjacent straight pin members 412 can be suppressed.
  • the maximum width W1 of the narrow portion 52N in the X direction is, for example, 0.65 mm.
  • the maximum length L1 of the narrow portion 52N in the Y direction is, for example, 0.85 mm.
  • the maximum width W2 of the wide portion 52W in the X direction is, for example, 0.85 mm.
  • the maximum length L2 of the wide portion 52W in the Y direction is, for example, 0.65 mm. That is, the difference L3 between the maximum length L1 of the narrow portion 52N in the Y direction and the maximum length L2 of the wide portion 52W in the Y direction is, for example, 0.2 mm.
  • the distance L4 between the narrow portion 52N and the wide portion 52W is, for example, 0.5 mm.
  • the mounting portion 522 has a flat plate shape parallel to the XY plane.
  • the mounting part 522 is embedded in the bottom part 210 of the bottom plate part 21 and fixed to the bottom plate part 21.
  • the mounting portion 522 is exposed from the bottom surface of the bottom plate portion 21 and becomes a portion to be mounted on a mounting board.
  • the mounting portion 522 is connected to the mounting board by, for example, reflow soldering.
  • the mounting portion 522 is plated with Sn to ensure solder wettability.
  • the coil connecting portion 521 and the mounting portion 522 do not exist on the same plane and do not overlap when viewed from the direction (Z direction) orthogonal to the first main surface 52s1.
  • the coil connecting portion 521 is located above the mounting portion 522 in the Z direction.
  • the coil connecting portion 521 and the mounting portion 522 do not overlap when viewed from the direction orthogonal to the first main surface 52s1.
  • the relay section 523 has a flat plate shape and is arranged at an angle with respect to the XY plane. One end of the relay section 523 in the Y direction is connected to the coil connection section 521, and the other end of the relay section 523 in the Y direction is connected to the mounting section 522.
  • the coil connecting portion 521, the mounting portion 522, and the relay portion 523 are shaped like a flat plate bent twice.
  • the shape of the relay portion 523 is not particularly limited, and may be a shape other than a flat plate shape.
  • the relay part 523 and the coil connecting part 521 are easily bent with the mounting part 522 as a fulcrum, the springiness in the direction perpendicular to the first main surface 52s1 of the coil connecting part 521 is reduced to the second electrode terminal. 52.
  • the coil connecting portion 521 and the first end of the first coil 41 can be brought into contact with each other more reliably.
  • the connection stability between the first coil 41 and the second electrode terminal 52 can be improved.
  • the stress applied to the first connection member 81 can be reduced due to the springiness of the second electrode terminal 52, and the reliability of the coil component 1 can be improved.
  • the fillet portion 524 extends upward in the Z direction from the end of the mounting portion 522 on the opposite side to the side to which the relay portion 523 is connected.
  • the fillet portion 524 is exposed to the outside of the coil component 1.
  • the fillet portion 524 becomes a portion where the solder gets wet. Therefore, when the coil component 1 is mounted on the mounting board via solder, the solder wets the fillet portion 524, making it possible to visually check the solder mounting and improving the solder connection strength.
  • fillet portion 524 is plated with Sn to ensure solder wettability.
  • FIG. 9 is a schematic plan view partially showing the connecting portion between the second electrode terminal 52 and the first coil 41.
  • FIG. 10 is a XX sectional view of FIG. 9. Note that, in FIG. 9, the bending pin member 410 connected to one end of the straight pin member 412 is omitted. Further, in FIG. 10, cross-sectional hatching of the resin member 90 is omitted for ease of viewing.
  • the first connecting member 81 connects the circumferential surface 411ps of the first end 41e1 of the first coil 41 and the coil connecting portion 521 of the second electrode terminal 52.
  • the first connecting member 81 is a welded portion formed by laser welding the first end portion 41e1 and the coil connecting portion 521, for example, or solder.
  • the first connecting member 81 is preferably a weld. Thereby, the connection strength between the first coil 41 and the second electrode terminal 52 can be increased. Furthermore, the electrical resistance between the first coil 41 and the second electrode terminal 52 can be reduced. Thereby, the electrical resistance of the coil component 1 can be lowered.
  • the first connecting member 81 is a welded portion formed by laser welding the first end portion 41e1 and the coil connecting portion 521. Further, in this embodiment, the first end portion 41e1 is the entirety of the endmost straight pin member 411. In addition, in FIG. 9, for convenience, the inner surface of the first recess C1 that existed before welding is shown by a virtual line (two-dot chain line).
  • the first end portion 41e1 is disposed only on the first main surface 52s1 side of the coil connecting portion 521, faces the first main surface 52s1, and is the first recess C1 when viewed from a direction orthogonal to the first main surface 52s1. are arranged so that they overlap.
  • the circumferential surface 411ps of the first end 41e1 has two flat surfaces 411fs facing each other in the Y direction and two flat surfaces 411fs facing each other in the Z direction. and a curved surface connecting each flat surface 411fs. That is, the cross-sectional shape of the first end portion 41e1 is approximately rectangular with rounded corners.
  • the flat surface 411fs can be formed, for example, by crushing the peripheral surface of a pin member having a circular cross section.
  • the flat surface 411fs is arranged to face the first main surface 52s1 and overlap the first recess C1 when viewed from a direction perpendicular to the first main surface 52s1. Note that the peripheral surface of the first end portion 41e1 does not need to have the flat surface 411fs.
  • the cross-sectional shape of the first end portion 41e1 may be circular.
  • At least a portion of the first connecting member 81 is located within the first recess C1 and is in contact with the inner surface C1f of the first recess C1. Specifically, a portion of the first connecting member 81 is located within the first recess C1. In other words, a part of the first connection member 81 is located in a region inside the coil connection part 521 from the opening of the side surface 52s3 of the coil connection part 521. A portion of the first connecting member 81 is in contact with the inner surface C1f of the first recess C1.
  • the second end of the first coil 41 is disposed only on the first main surface side of the coil connection part of the first electrode terminal 51, facing the first main surface, and perpendicular to the first main surface.
  • a part of the first connecting member 81 is located within the first recess C1 and is in contact with the inner surface C1f of the first recess C1.
  • the first end of the second coil 42 is disposed only on the first main surface side of the coil connection part of the fourth electrode terminal 54, faces the first main surface, and is perpendicular to the first main surface.
  • the first connecting member 81 When viewed from the direction, the first connecting member 81 is arranged to overlap with the first recess C1, and a part of the first connecting member 81 is located within the first recess C1 and is in contact with the inner surface C1f of the first recess C1. Further, the second end portion of the second coil 42 is disposed only on the first main surface side of the coil connection portion of the third electrode terminal 53, faces the first main surface, and is perpendicular to the first main surface. When viewed from the direction, the first connecting member 81 is arranged to overlap with the first recess C1, and a part of the first connecting member 81 is located within the first recess C1 and is in contact with the inner surface C1f of the first recess C1.
  • the first and second ends of the coils 41 and 42 and the first to fourth electrode terminals 51 to 54 are different from each other. Since the coils 41 and 42 are arranged only on the first main surface side of the coil connection portions 54 and connected to face the first main surface, the coils 41 and 42 are connected to the first to fourth electrode terminals 51 to 54. connection is not established.
  • "tying" means winding the coils 41 and 42 around the first to fourth electrode terminals 51 to 54.
  • the thick coils 41 and 42 can be connected to the thin first to fourth electrode terminals 51 to 54, and the first to fourth electrode terminals 51 to 54 can be easily bent, and the coil 41 can handle large currents. , 42 can be used.
  • the coils 41 and 42 are not wound around the first to fourth electrode terminals 51 to 54, bending and bulges do not occur in the coils 41 and 42, and thereby the coils 41 and 42 and the first to fourth electrode terminals A gap is less likely to occur between 51 and 54, making it possible to achieve connection stability and miniaturization.
  • the coil connecting portion of the first to fourth electrode terminals 51 to 54 is The first connecting member 81 can be observed from the second main surface side (the bottom plate portion 21 side of the case 2). Thereby, the state of connection between the coils 41 and 42 and the first to fourth electrode terminals 51 to 54 can be easily visually inspected.
  • the circumferential surfaces of the endmost straight pin members 411, 421 face the first main surfaces of the coil connection portions of the first to fourth electrode terminals 51 to 54; When connecting the four electrode terminals 51 to 54 and the endmost straight pin members 411, 421, it is possible to easily align the endmost straight pin members 411, 421.
  • the flat surfaces of the ends of the coils 41 and 42 are connected to the first to fourth electrode terminals 51 to 54 via the first connecting member 81. Therefore, since the contact area between the ends of the coils 41, 42 and the first to fourth electrode terminals 51 to 54 can be increased, the contact area between the coils 41, 42 and the first to fourth electrode terminals 51 to 54 can be increased. can improve the mechanical strength of Furthermore, since the cross-sectional area of the electrical path between the coils 41, 42 and the first to fourth electrode terminals 51 to 54 becomes larger, the electrical resistance of the coil component 1 can be reduced.
  • the first coil 41 is attached to the core 3.
  • the first coil 41 can be wound close to the core 3.
  • the plurality of straight pin members 422 and the plurality of bent pin members 420 are connected alternately to form the spiral of the second coil 42, when the second coil 42 is wound around the core 3, In addition, the second coil 42 can be wound close to the core 3.
  • the first to fourth electrode terminals 51 to 54 are elastically deformable so that the coil connecting portion can swing in a direction perpendicular to the first main surface.
  • the coil connecting portion 521 is attached to the first main surface 52s1 using the mounting portion 522 as a fulcrum.
  • the second electrode terminal 52 is elastically deformable so that it can swing in orthogonal directions.
  • the connection stability between the coils 41 and 42 and the first to fourth electrode terminals 51 to 54 can be further improved. Further, even when an external impact is applied to the coil component 1, the stress applied to the first connecting member 81 can be further reduced, and the reliability of the coil component 1 can be further improved.
  • the first main surface of the coil connecting portion is located on the radially inner side of the coils 41 and 42 than the first main surface 210a of the bottom portion 210 of the bottom plate portion 21.
  • the position P2 of the first main surface 52s1 of the coil connecting portion 521 is closer to the first coil 41 than the position P1 of the first main surface 210a of the bottom part 210 of the bottom plate part 21.
  • the position P2 of the first main surface 52s1 is located above the position P1 of the first main surface 210a.
  • the thickness of the resin member 90 disposed on the second main surface 52s2 side of the coil connecting portion 521 is the thickness of the bottom portion 210 (that is, the thickness between the first main surface 210a and the second main surface 210b). distance).
  • the first connecting member 81 does not have a portion that protrudes outward from the side surface of the coil connecting portion when viewed from a direction perpendicular to the first main surface of the coil connecting portion. In other words, the first connecting member 81 does not have a portion that protrudes outward beyond the side opening of the coil connecting portion. According to this configuration, the coil component 1 can be downsized.
  • the method for manufacturing the coil component 1 includes arranging the ends of the coils 41 and 42 only on the first main surface side of the coil connecting parts 511 to 541 of the first to fourth electrode terminals 51 to 54, and and a step of arranging the coil connecting portions so as to face each other and to overlap with the first recesses C1 provided in the first to fourth electrode terminals 51 to 54 when viewed from the direction perpendicular to the first main surface;
  • the method includes a step of irradiating at least a portion of the inner surface C1f of the first recess C1 with a laser from the surface side to form the first connecting member 81.
  • the coils 41 and 42 can be connected to the first to fourth electrode terminals 51 to 54 without being entangled.
  • the coil component 1 can be downsized.
  • the first coil 41 and the second coil 42 are wound around the core 3 into which the core cover 60 is fitted so that their winding axes run parallel to each other. At least a portion of the exposed conductor portions 411a, 412a, 410a of the first coil 41 and at least a portion of the exposed conductor portions 421a, 422a, 420a of the second coil 42 are arranged on the first end surface 301 side of the core 3.
  • each pin member of the first coil 41 is welded, and each pin member of the second coil 42 is welded, with the first end surface 301 of the core 3 facing upward.
  • the core 3 and the coils 41, 42 are placed in the recess 215 of the bottom plate 21 so that the conductor portions of the coils 41, 42 exposed from the coating are located on the first main surface 210a side.
  • the circumferential surface of the first end 41e1 of the first coil 41 is It is arranged on the first main surface 52s1 side of the coil connecting portion 521 of the electrode terminal 52 to face the first main surface 52s1, and is provided on the second electrode terminal 52 when viewed from the direction orthogonal to the first main surface 52s1.
  • the first concave portion C1 is arranged so as to overlap with the first concave portion C1. Then, the first end portion 41e1 of the first coil 41 is pressed against the coil connecting portion 521 from the first main surface 52s1 side of the coil connecting portion 521 to bring the first end portion 41e1 into contact with the coil connecting portion 521.
  • the coil connecting portion 521, the mounting portion 522, and the relay portion 523 of the second electrode terminal 52 have the shape of a flat plate bent twice, so the first end portion 41e1 is
  • the coil connecting portion 521 allows reliable contact. Thereby, connection stability between the first end portion 41e1 and the coil connecting portion 521 can be ensured.
  • the electrode terminals 51, 53, 54 the circumferential surfaces of the first or second ends of the coils 41, 42 are brought into contact with the coil connecting portions of the electrode terminals 51, 53, 54.
  • the extreme straight pin members 411 and 421 may have height variations in the Z direction.
  • first to fourth electrode terminals 51 to 54 have spring properties in the direction (Z direction) perpendicular to the first main surface of the coil connection part, they absorb the above-mentioned height variations and ensure that all Electrode terminals 51 to 54 can be connected to the ends of coils 41 and 42.
  • the laser beam is applied to both the coil connecting portion 521 and the first end portion 41e1.
  • the laser spot diameter is small (for example, 0.05 mm)
  • the laser is scanned along the inner surface C1f of the first recess C1 within the area LI surrounded by the dashed line in FIG. 11A. As a result, as shown in FIG.
  • a first connecting member 81 is formed in which the first end portion 41e1 and the coil connecting portion 521 are melted and then solidified, and the first end portion 41e1 and the second electrode terminal 52 are connected. Connected. Similarly, the first ends or second ends of the coils 41, 42 are connected to the electrode terminals 51, 53, 54.
  • both the coil connection part and the first end of the coil are irradiated with laser, and the coil connection part and the first end of the coil can be melted and welded.
  • the first to fourth electrode terminals 51 to 54 do not have the first recess C1 and, for example, welding is performed by irradiating a laser to the center part of the second main surface of the coil connection part, the first to fourth electrode terminals 51 to 54 of the coil The laser is not irradiated on the edge, resulting in poor connection stability.
  • a liquid resin member 90 is filled into the recess 215 by, for example, a potting method. At this time, the liquid resin member 90 remains in the recess 215 and spreads over the conductor portions exposed from the coatings of the coils 41 and 42 and a portion of the core cover 60. Furthermore, the liquid resin member 90 is also filled in the opening 216 of the bottom plate portion 21 . Note that in order to prevent the liquid resin member 90 from leaking from the opening 216, a tape is attached to the second main surface 210b of the bottom portion 210 so as to close the opening 216.
  • thermosetting epoxy resin is used as the material for the resin member 90, and has an elastic modulus of 7 GPa, and is cured by heating at 120° C. for 30 minutes as a curing condition.
  • the coil component 1 is manufactured by covering the box part 22 and storing it in the case 2.
  • the number of steps in manufacturing the coil component 1 can be reduced, and the coil component 1 can be manufactured more easily.
  • FIG. 12 is a schematic cross-sectional view partially showing the coil component of the second embodiment.
  • FIG. 12 corresponds to FIG. 10, and the illustration of the side wall portion 211 side is omitted.
  • the second embodiment differs from the first embodiment in the configuration of the first connecting member. This difference will be explained below.
  • the other configurations are the same as those in the first embodiment, are given the same reference numerals as in the first embodiment, and the description thereof will be omitted.
  • the first connecting member 81A has a larger protrusion height from the first main surface 52s1 of the coil connecting portion 521 than the first connecting member 81 of the first embodiment.
  • a position P3 of a portion of the circumferential surface of the first end portion 41e1 that faces the first main surface 52s1 is located above a position P2 of the first main surface 52s1.
  • the first end portion 41e1 (that is, the endmost straight pin member 411) is located above the other straight pin members 412 in the Z direction.
  • the thickness of the resin member 90 disposed on the second main surface 52s2 side of the coil connecting portion 521 can be made thicker than the thickness of the bottom portion 210. Therefore, stress that may be generated in the first connecting member 81A due to external force such as vibration impact can be reduced.
  • the first principal surface 52s1 of the coil connecting portion 521 may be positioned above the position in advance where the portion of the circumferential surface of the linear pin member 412 facing the bottom portion 210 side is arranged. good.
  • the first coil 41 when the first coil 41 is assembled to the case 2, only the first end portion 41e1 (that is, the endmost straight pin member 411) is pushed up in the Z direction due to the spring property of the second electrode terminal 52.
  • the first end portion 41e1 may be located higher than the other linear pin members 412.
  • FIG. 13 is a schematic plan view partially showing the coil component of the third embodiment.
  • the third embodiment differs from the first embodiment mainly in the arrangement of the straight pin member and the bent pin member, the shape of the electrode terminal, and the provision of the second connection member. The main differences will be explained below.
  • the other configurations are the same as those in the first embodiment, are given the same reference numerals as in the first embodiment, and the description thereof will be omitted.
  • the extending direction of the endmost straight pin member 411 and the straight pin member 412 is parallel to the direction perpendicular to the axial direction (Y direction) of the first coil 41.
  • the bending pin member 410 extends in the X direction with an imaginary line connecting both ends in the extending direction slightly inclined in the Y direction.
  • the bending pin member 410 is arranged so that a plane including the center line of the bending pin member 410 is inclined with respect to a plane (XZ plane) orthogonal to the axial direction of the first coil 41.
  • the plurality of bending pin members 410 include adjacent bending pin members 410aj connected adjacently to the endmost straight pin member 411.
  • the end surface 411ef of the end of the end straight pin member 411 and the circumferential surface 410ps of the end of the adjacent bend pin member 410aj are connected to each other.
  • the first end portion 41e1 of the first coil 41 is the endmost straight pin member 411 and the adjacent bent pin member 410aj.
  • the coil connection and the relay part of the first electrode terminal 51 were arranged closer to the center part of the case 2 than the side wall part 211 of the case 2 in the X direction.
  • the coil connection and relay portion of the electrode terminal 51B are arranged closer to the side wall portion 211 of the case 2 than the center portion of the case 2 in the X direction.
  • the coil connection and the relay part of the third electrode terminal 53 were arranged closer to the center part of the case 2 than the side wall part 211 of the case 2 in the X direction, but in this embodiment, The coil connection and relay portion of the third electrode terminal 53B are arranged closer to the side wall portion 211 of the case 2 than the center portion of the case 2 in the X direction.
  • the coil connection and relay portion are arranged closer to the side wall portion 211 of the case 2 than the center portion of the case 2, similarly to the first embodiment. Since the coil connections and relay parts of all the first to fourth electrode terminals are arranged closer to the side wall part 211 of the case 2 than the center part of the case 2, for example, the first electrode terminal and the fourth electrode terminal can be connected in common. In this case, the second electrode terminal and the third electrode terminal can be made common. Therefore, according to the above configuration, the number of types of electrode terminals can be reduced more than in the first embodiment.
  • the coil connecting portion 511B of the first electrode terminal 51B has a first recess C1 that opens to a first main surface, a second main surface 51s2, and a side surface 51s3 (not shown), a wide portion 51W, and a narrow portion 51N. . That is, the coil connecting portion 511B has a shape that is bifurcated at the tip end side in the Y direction when viewed from a direction perpendicular to the first main surface. Furthermore, the coil connecting portion 511B has a second recess C2 that opens to the first main surface, the second main surface 51s2, and the side surface 51s3. The second recess C2 is provided at a corner of the coil connecting portion 511B, and is disposed adjacent to the wide portion 51W.
  • the maximum length of the wide portion 51W in the Y direction and the maximum length of the narrow portion 51N in the Y direction are the same.
  • the tip position of the wide portion 51W in the Y direction and the tip position of the narrow portion 51N in the Y direction can be aligned, so that the first electrode terminal 51B is connected to the straight pin member 412 adjacent to the endmost straight pin member 411.
  • Short circuit can be suppressed.
  • the wide portion 51W is arranged at the connection portion between the endmost straight pin member 411 and the adjacent bent pin member 410aj.
  • the narrow portion 51N is arranged closer to the end of the first end portion 41e1 of the first coil 41 than the wide portion 51W.
  • the coil component 1B includes a second connection member 82 that connects the first end 41e1 of the first coil 41 and the first electrode terminal 51B.
  • the second connecting member 82 is a welded portion, solder, or the like formed by laser welding the first end portion 41e1 and the coil connecting portion 511B, for example.
  • the second connecting member 82 is a welded portion formed by irradiating a laser along at least a portion of the inner surface of the second recess C2.
  • An end surface 410ef of the adjacent bent pin member 410aj on the side to which the endmost straight pin member 411 is connected faces the first main surface of the coil connecting portion 511B of the first electrode terminal 51B, and When viewed from the orthogonal direction, it overlaps with the inner surface C2f of the second recess C2. At least a portion of the second connecting member 82 is located within the second recess C2 and is in contact with the inner surface C2f of the second recess C2. Thereby, the second connecting member 82 connects the first electrode terminal 51B and the end surface 410ef of the adjacent bending pin member 410aj.
  • the second connecting member 82 since the second connecting member 82 is further provided, the mechanical strength between the first coil 41B and the first electrode terminal 51B can be further improved. Furthermore, since the cross-sectional area of the electrical path between the first coil 41B and the first electrode terminal 51B becomes larger, the electrical resistance of the coil component 1B can be further reduced.
  • the third electrode terminal 53B may also have the same configuration as the first electrode terminal 51B. That is, the third electrode terminal 53B has a second recess C2, and at least a portion of the second connecting member 82 is located within the second recess C2 and contacts the inner surface C2f of the second recess C2.
  • the second connecting member 82 may connect the third electrode terminal 53B to the end surface of an adjacent bent pin member adjacent to the endmost straight pin member.
  • FIG. 14 is a schematic plan view partially showing the coil component of the fourth embodiment.
  • the fourth embodiment differs from the third embodiment in that one electrode terminal has a plurality of parts each consisting of a coil connection part and a relay part. This difference will be explained below.
  • the other configurations are the same as those in the third embodiment, are given the same reference numerals as in the third embodiment, and the description thereof will be omitted.
  • a portion consisting of a coil connecting portion 511B and a relay portion 513 (hereinafter, this portion will be referred to as a “projection portion”) is adjacent to each other in the X direction.
  • the projecting pieces (the projecting piece located on the reverse X direction side) is the same as the coil connecting part 511B and the relay part 513 in the first electrode terminal 51B of the third embodiment.
  • the other protruding piece (the protruding piece located on the forward X direction side) has the same shape as the one protruding piece.
  • the coil connecting portion 511B of the other projecting piece is connected to the circumferential surface of the endmost straight pin member 411 via the first connecting member 81.
  • the plurality of first connecting members 81 connect the first end 41e1 of the first coil 41B and the first electrode terminal 51C, the first coil 41B and the first electrode terminal 51C The mechanical strength between them can be further improved. Furthermore, since the cross-sectional area of the electrical path between the first coil 41B and the first electrode terminal 51C becomes larger, the electrical resistance of the coil component 1B can be further reduced.
  • the third electrode terminal 53C may also have the same configuration as the first electrode terminal 51C. That is, the third electrode terminal 53C has two protruding pieces adjacent to each other in the X direction, and the coil connecting portion of one of the protruding pieces connects via the first connecting member 81 and the second connecting member 82.
  • the coil connecting portion of the other projecting piece is connected to the circumferential surface of the outermost straight pin member 421 and the end surface of the adjacent bent pin member, and the coil connecting portion of the other projecting piece is connected to the circumferential surface of the outermost straight pin member 421 via the first connecting member 81. It may be connected to the surface.
  • FIG. 15 is a schematic plan view partially showing the coil component of the fifth embodiment.
  • the fifth embodiment differs from the third embodiment in that the endmost straight pin member on one side of the coil in the axial direction is not provided. This difference will be explained below.
  • the other configurations are the same as those in the third embodiment, are given the same reference numerals as in the third embodiment, and the description thereof will be omitted.
  • the first end 41e1 of the first coil 41C is composed of a bent pin member 410 instead of a straight pin member.
  • the plurality of bending pin members 410 include an endmost bending pin member 4101 located at the farthest end of at least one side of the first coil 41C in the axial direction.
  • an end surface 4101ef opposite to the side to which the straight pin member 412 is connected faces the first main surface (not shown) of the coil connecting portion 511B of the first electrode terminal 51B, and , are arranged so as to overlap with the second recess C2 when viewed from the direction perpendicular to the first principal surface.
  • the second connecting member 82 connects the coil connecting portion 511B of the first electrode terminal 51B and the end surface 4101ef of the most bent pin member 4101.
  • the endmost straight pin member connected to the first electrode terminal is removed from the coil component 1B of the third embodiment.
  • the second recess C2 corresponds to the "first recess” in the claims
  • the second connection member 82 corresponds to the "first connection member" in the claims.
  • the endmost bending pin member 4101 and the first electrode terminal 51B are connected along the extending direction of the endmost bending pin member 4101, current can be smoothly applied to the first coil 41C. It can flow.
  • the pin member located at the extreme end on one side in the axial direction of the first coil 41C is the bent pin member 410, the number of straight pin members can be reduced.
  • the diameter of the bent pin member is typically larger than the diameter of the straight pin member. Therefore, when laser welding the end face of the bent pin member and the electrode terminal, for example, the laser can be irradiated over a wider range than when laser welding the peripheral face of the straight pin member and the electrode terminal, for example. As a result, the mechanical strength between the coil and the electrode terminal can be improved. Furthermore, since the cross-sectional area of the electrical path between the coil and the electrode terminal becomes larger, the electrical resistance of the coil component can be further reduced.
  • the endmost straight pin member connected to the third electrode terminal may be removed.
  • the sixth embodiment differs from the first embodiment mainly in that the first recess is not provided in the coil connection portion of the electrode terminal. The main differences will be explained below. The other configurations are the same as those in the first embodiment, and detailed description thereof will be omitted.
  • the electrode terminal includes a coil connecting part connected to the end of the coil, a mounting part mounted on the mounting board, and a relay part connecting the coil connecting part and the mounting part.
  • the coil connection portion includes a first main surface and a second main surface opposite to the first main surface.
  • the end portion of the coil is disposed only on the first main surface side of the coil connection portion and faces the first main surface.
  • the coil connecting portion and the mounting portion do not exist on the same plane and do not overlap when viewed from a direction perpendicular to the first principal surface.
  • the coil connection portion is not provided with the first recess.
  • the position where the first connection member is provided is not particularly limited, for example, the first connection member may be provided in an area including a part of the side surface of the coil connection portion when viewed from a direction perpendicular to the first main surface of the coil connection portion. It may be. Further, the first connecting member may be provided, for example, at the center of the second main surface of the coil connecting portion.
  • the end of the coil and the electrode terminal are connected such that the end of the coil is disposed only on the first main surface side of the coil connection part of the electrode terminal and faces the first main surface. Therefore, the coil is not connected to the electrode terminal. Therefore, it is possible to prevent deformation of the electrode terminal due to coil binding work or residual stress of the coil. Thereby, a thick coil can be connected to a thin electrode terminal, and an electrode terminal that can be easily bent and a coil that can handle a large current can be used. In addition, since the coil is not tied around the electrode terminal, no bending bulge occurs in the coil, which makes it difficult to create a gap between the coil and the electrode terminal, making it possible to achieve connection stability and miniaturization.
  • the relay part and the coil The connection part becomes easily bent. Thereby, it is possible to impart springiness to the electrode terminal in a direction perpendicular to the first main surface of the coil connecting portion.
  • the coil connecting portion and the end of the coil can be brought into contact more reliably, thereby improving the connection stability between the coil and the electrode terminal. I can do it.
  • the stress applied to the first connection member can be reduced due to the springiness of the electrode terminal, and the reliability of the coil component can be improved.
  • the present disclosure is not limited to the above-described embodiments, and design changes can be made without departing from the gist of the present disclosure.
  • the features of the first to sixth embodiments may be combined in various ways.
  • the shape of the case and the shape of the core are not limited to this embodiment, and can be changed in design.
  • the number of coils is not limited to this embodiment, and the design can be changed. Further, it is not necessary to provide a box portion of the case, and it is not necessary to provide a core cover.
  • the electrode terminal had a wide portion and a narrow portion, but the shape of the electrode terminal is not particularly limited as long as it has the first recess.
  • the wide portion and the narrow portion may have the same maximum width.
  • the first recess is shaped like a part of an ellipse, but the shape of the first recess is not particularly limited.
  • a part of the first connection member was located in the first recess and was in contact with the inner surface of the first recess, but the entire first connection member was located in the first recess. It may be located within the recess and may be in contact with the inner surface of the first recess.
  • a part of the second connection member was located in the second recess and was in contact with the inner surface of the second recess, but the entire second connection member was located in the second recess. It may be located within the recess and may be in contact with the inner surface of the second recess.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

La présente invention concerne un composant de bobine qui comprend une bobine, une borne d'électrode de type plaque, et un premier élément de connexion qui connecte une première section d'extrémité de la bobine et la borne d'électrode, la borne d'électrode comprenant une partie de connexion de bobine connectée à la première section d'extrémité de la bobine ; la partie de connexion de bobine comprend une première surface primaire, une seconde surface primaire faisant face à la première surface primaire, et une surface latérale qui relie la première surface primaire et la seconde surface primaire ; la partie de connexion de bobine présente une première section d'évidement ouverte dans la première surface primaire, la seconde surface primaire et la surface latérale ; la première section d'extrémité de la bobine est disposée uniquement sur le premier côté primaire de la partie de connexion de bobine pour faire face à la première surface primaire, et est disposée de façon à chevaucher la première section d'évidement lorsqu'elle est vue dans une direction perpendiculaire à la première surface primaire ; et au moins une partie du premier élément de connexion est positionnée à l'intérieur de la première section d'évidement et est en contact avec la surface interne de la première section d'évidement.
PCT/JP2023/009392 2022-03-18 2023-03-10 Composant de bobine et procédé permettant de fabriquer un composant de bobine WO2023176738A1 (fr)

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JP2022044129 2022-03-18
JP2022-044129 2022-03-18

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010005652A (ja) * 2008-06-26 2010-01-14 Tdk Corp 絶縁導線の被覆剥離方法
WO2017141838A1 (fr) * 2016-02-15 2017-08-24 株式会社村田製作所 Partie bobine et procédé de fabrication de partie bobine
WO2017169737A1 (fr) * 2016-04-01 2017-10-05 株式会社村田製作所 Composant de bobine et son procédé de fabrication
JP2018107306A (ja) * 2016-12-27 2018-07-05 太陽誘電株式会社 コモンモードフィルタ
KR102123630B1 (ko) * 2018-12-24 2020-06-17 아비코전자 주식회사 공통모드 필터 및 제작 방법
JP2020519031A (ja) * 2017-05-12 2020-06-25 モダ−イノチップス シーオー エルティディー チョークコイル

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010005652A (ja) * 2008-06-26 2010-01-14 Tdk Corp 絶縁導線の被覆剥離方法
WO2017141838A1 (fr) * 2016-02-15 2017-08-24 株式会社村田製作所 Partie bobine et procédé de fabrication de partie bobine
WO2017169737A1 (fr) * 2016-04-01 2017-10-05 株式会社村田製作所 Composant de bobine et son procédé de fabrication
JP2018107306A (ja) * 2016-12-27 2018-07-05 太陽誘電株式会社 コモンモードフィルタ
JP2020519031A (ja) * 2017-05-12 2020-06-25 モダ−イノチップス シーオー エルティディー チョークコイル
KR102123630B1 (ko) * 2018-12-24 2020-06-17 아비코전자 주식회사 공통모드 필터 및 제작 방법

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