JP4925807B2 - Manufacturing method of sealing coil component and antenna coil component - Google Patents

Description

The present invention relates to a sealing coil component formed of a resin member so as to surround a coil component formed by winding a winding coil around a magnetic core, and a method for manufacturing an antenna coil component. . More specifically, the present invention relates to a method for manufacturing a sealing coil component and an antenna coil component suitable for application to a keyless entry system mounted on an automobile.

  Conventionally, as a coil component, one using a winding coil in which a conductive wire is wound around a magnetic core has been generally used. In recent years, there is an increasing demand for so-called sealed coil components in which part or all of the coil components are sealed with a resin member. The sealing coil component is a component formed for the purpose of maintaining high reliability even under various usage environments such as vibration, impact, temperature, humidity, dust, and dust. Such a sealing coil component has been often used for automobiles having a particularly severe use environment.

  Patent Document 1 discloses a bar antenna and a manufacturing method thereof. The bar antenna disclosed in Patent Document 1 includes a single core portion made of a thin rod-shaped ferromagnetic material, a bobbin that holds a winding conductor wound in an insulated state around the core portion and wraps around the core portion, A case in which the core part and the bobbin are accommodated, and a potting material (mainly urethane rubber or silicon rubber) in which the core part and the bobbin are sealed in the case are provided. And it is insulated from deterioration factors, such as temperature, humidity, and vibration, to the core portion of the bar antenna.

Patent Document 2 discloses an antenna coil. The antenna coil disclosed in Patent Document 2 includes a rod-shaped core, a flat concave insulating bobbin with one side open, and an insulating outer case with a concave cross section opened on one side larger than the bobbin. I have. The core of the antenna coil is housed in the recess of the bobbin, the coil (lead) in which the winding is formed in the winding groove formed on the bobbin, and the coil is housed in the recess of the exterior case, and is a highly flexible resin Made of adhesive (mainly made of urethane).
JP 2001-358522 A JP 2005-295473 A

  By the way, both the bar antenna disclosed in Patent Document 1 and the antenna coil disclosed in Patent Document 2 are housed in a case in which a coil is wound with an insulating bobbin interposed in a magnetic core. is doing. Then, the exterior case is filled with an adhesive (hereinafter collectively referred to as urethane resin or silicon resin) used for the material in any one or a combination of urethane rubber and silicon rubber, and bonded. The agent is cured.

  Here, in the process of filling the urethane resin or silicon resin, it is necessary to perform a vacuum filling process (also referred to as a vacuum impregnation process) in order to suppress unnecessary bubbles and holes as much as possible. In order to cure the filled resin, a step of putting in a heating atmosphere, an ultraviolet irradiation step, a curing reaction step by leaving in the atmosphere for a long time, or the like is required. As a result, there have been problems that the manufacturing process and manufacturing time of the bar antenna and the antenna coil are increased and the cost is increased.

  In addition, even if vacuum impregnation treatment is performed, if there are bubbles or voids that cannot be removed between the wires of the winding coil or between the magnetic core and the bobbin, the quality that can be used as a product is improved. It cannot be maintained. Further, the electrical characteristics of the product may change or the quality may change due to the stress generated by repeatedly applying thermal shock to the resin-molded bar antenna or antenna coil.

  The present invention has been made in view of such a situation, and an object of the present invention is to provide a sealing coil component and a manufacturing method of the sealing coil component that can relieve unnecessary stress generated during resin molding. And

The present invention relates to a coil component comprising at least a magnetic core, a winding coil wound around the magnetic core, and a base on which a flange for fixing the magnetic core around which the winding coil is wound is formed. The softening temperature and the melting temperature are higher than the resin from which the stress relaxation member is molded so as to surround the stress relaxation member and the stress relaxation member that relaxes the stress applied to the coil component by injection molding of the resin. When the thermoplastic resin having a high molding pressure is sealed and formed by injection molding, the base comes into contact with the convex portion formed on the inner wall surface of the mold member that seals and forms the exterior resin member. A sealed coil component including an exterior resin member in which a resin is sealed in a space generated between the inner wall surface of the member and the stress relaxation member, and a groove is formed on the surface where the convex portion and the flange are in contact with each other. It is.

The present invention also includes a step of manufacturing a coil component comprising a base having a flange formed by winding a winding coil around a magnetic core and fixing the magnetic core around which the winding coil is wound; A step of forming a stress relaxation member that relieves stress applied to the coil component by injection molding of the resin, and a softening temperature and a melting temperature of the stress relaxation member so as to surround the stress relaxation member. The flange is in contact with the convex portion formed on the inner wall surface of the mold member in which the base seals and forms the exterior resin member by forming the thermoplastic resin having a high molding pressure by injection molding. A resin is sealed in a space formed between the inner wall surface of the mold member and the stress relaxation member, and an exterior resin member is formed by injection molding in which a groove is formed on the surface where the convex portion and the flange come into contact. It is obtained by the manufacturing method of the antenna coil part and a step of forming.

  According to the present invention, since the stress relaxation member that relaxes the stress generated by the injection molding pressure of the resin during the injection molding of the exterior resin member is formed around the coil component, the coil component can be influenced by the injection molding pressure. There is no effect.

  Hereinafter, a first embodiment of the present invention will be described with reference to FIGS. In this embodiment, a detailed description will be given as an example applied to a sealed antenna coil component 1 suitable for use in a keyless entry system mounted on an automobile. The sealed antenna coil component is a name when the sealed coil component is used in a keyless entry system for automobiles.

  First, a configuration example of the sealed antenna coil component 1 of this example will be described with reference to the perspective view of FIG. 1A to 1D show a case where an elastic resin member is used as the stress relaxation member 9 that relieves stress generated during injection molding of the exterior resin member 2 that becomes the exterior of the sealed antenna coil component 1. A configuration example is shown.

  FIG. 1A shows an external configuration example of the sealed antenna coil component 1. A resinous exterior resin member 2 is formed on the exterior of the sealed antenna coil component 1. The exterior resin member 2 includes a rectangular parallelepiped-shaped coil component inner portion 8 that encloses a coil component (see FIG. 1C) 10 that generates a magnetic field by applying an electric current therein, and both longitudinal sides of the coil component inner portion 8 It is comprised from the vehicle body fixing | fixed part 4 formed in this. The vehicle body fixing portion 4 is formed with a hole portion 3 for bolting the sealed antenna coil component 1 to the vehicle body. At one end of the sealed antenna coil component 1, two conductive lead harnesses 5 extended from the included coil component 10 are exposed. The two lead harnesses 5 are connected to an external connection connector 6 for connecting to an electronic device. The sealed antenna coil component 1 is easily connected to an electronic device (not shown) by the external connection connector 6.

  The exterior resin member 2 is made of ABS (Acrylonitrile butadiene styrene), PBT (Poly Butylene Terephthalete), PPS (Poly Phenylene Sulfide), and PPS (Poly Phenylene Sulfide). ) It is encapsulated with resin or a mixture thereof. The coil component 10 can weaken the influence of vibrations and shocks from the external environment, temperature and humidity, dust, dust, and the like by the exterior resin member 2.

  Two grooves 7 are formed on the upper surface of the exterior resin member 2. The two groove portions 7 are traces supported in the mold cavity when the exterior resin member 2 and a stress relaxation member 9 described later are sealed.

  FIG. 1B shows a configuration example when the exterior resin member 2 is removed from the sealed antenna coil component 1. Inside the exterior resin member 2, a rectangular parallelepiped stress relaxation member 9 having elasticity is formed. The stress relieving member 9 has a function of relieving stress applied to the coil component 10 included when the exterior resin member 2 is injection molded.

  A first flanged resin base 11a and a second flanged resin base 11b having flange portions are disposed at both ends of the stress relaxation member 9 in the longitudinal direction. Detailed configuration examples of the first flanged resin base 11a and the second flanged resin base 11b will be described later.

  Of the coil component 10, the magnetic core 12, the winding coil 13, the portions of the first flanged resin base 11 a and the second flanged resin base 11 b except for the flanges and end surfaces, and a part of the lead harness 5. The elastic resin member is sealed so as to enclose, and the stress relaxation member 9 is formed.

  As the material of the stress relaxation member 9, an elastic resin member such as PA (Poly Amide) resin is used. There are the following four reasons for using the PA resin as the material of the stress relaxation member 9.

  As the first point, when performing injection molding of the stress relaxation member 9, the softening temperature and melting temperature of the PA resin are determined from the softening temperature and melting temperature of the ABS resin, PBT resin, PPS resin, etc. employed in the exterior resin member 2. Is also low. For this reason, the thermal influence given to the coil component 10 can be reduced.

  A second point is that the melt viscosity when the PA resin is melted is lower than the melt viscosity of the exterior resin member 2. For this reason, the stress relaxation member 9 can be sealed and molded with the injection molding pressure set low. That is, the stress relaxation member 9 can be formed without applying excessive stress to the coil component 10.

  The third point is that the physical property of the PA resin is a thermoplastic resin having elasticity in a cured state after the injection molding, that is, after the polymerization reaction. For this reason, it becomes possible to efficiently absorb and relax the molding pressure when the stress relaxation member 9 is sealed by the exterior resin member 2.

  As a fourth point, urethane resin, silicon resin, and the like are listed as those having elasticity as a physical property after the polymerization reaction, but the PA resin employed in this example has a higher polymerization reaction rate than these resins. For this reason, the time of the process of injection-molding the stress relaxation member 9 can be shortened.

  As described above, by using the PA resin as the material of the stress relaxation member 9, a wide variety of actions and effects can be obtained.

  FIG. 1C shows a configuration example when the exterior resin member 2 and the stress relaxation member 9 are removed from the sealed antenna coil component 1.

  The coil component 10 is included in the stress relaxation member 9. The coil component 10 is formed with a winding coil 13 having a rod-shaped magnetic core 12 made of sinterable ferrite as a core. The conductive wire wound around the magnetic core 12 is generally a conductive metal wire covered with an insulating film. Then, the conducting wire is wound on the magnetic core 12 with the number of windings appropriately set to ensure the desired electrical characteristics.

  On the upper surface of the first flanged resin base 11a, a triangular wire guide 14 for guiding the end of the winding coil 13 is formed. Both ends of the conducting wire wound around the winding coil 13 are guided to the upper surface of the first flanged resin base 11a. Then, both end portions of the winding coil 13 guided along the wire guide 14 are connected to the lead harness 5.

  1D shows an example in which the winding coil 13 is removed from the state of FIG. 1C and the first flanged resin base 11a, the second flanged resin base 11b, and the magnetic core 12 are disassembled. Indicates.

  The first flanged resin base 11 a is formed with a fitting portion 15 for fitting and fixing one end portion of the magnetic core 12. The magnetic core 12 is fitted into the fitting portion 15 and fixed with an adhesive or the like. The first flanged resin base 11 a supports the end portion of the lead harness 5. On the other hand, the second flanged resin base 11b has the same structure as the first flanged resin base 11a except that the lead harness 5 and the wire guide are not provided.

  As the material of the first flanged resin base 11a and the second flanged resin base 11b, as with the exterior resin member 2, ABS resin, PBT resin, PPS resin, or a mixture thereof is preferably used.

  Since the sealed antenna coil component 1 of this example has a flange on the resin base, the coil component 10 including the magnetic core 12 and the winding coil 13 and a part of the lead harness 5 are on the inner wall of the mold cavity. They can be placed without contact. As a result, the stress relieving member 9 is formed using an elastic resin member so as to surround the entire periphery.

  Moreover, since the stress relaxation member 9 is formed around the coil component 10, it is possible to effectively relieve the stress applied when the exterior resin member 2 in the subsequent process is encapsulated. At this time, the flange is not limited to the shape shown in FIG. 1, and for example, a shape in which a protruding member is provided on the constituent surface of the resin base is conceivable. That is, as long as the coil component 10 including the magnetic core 12 and the winding coil 13 and a part of the lead harness 5 can be arranged without contacting the inner wall of the mold cavity, various modifications are adopted. Good.

  Next, an example of the manufacturing method of the sealed antenna coil component 1 of this example will be described for each step with reference to the flowchart of FIG.

  First, a conductive wire is wound around a rod-shaped magnetic core 12 made of sinterable ferrite to produce a coil component 10 (step S1). When the magnetic core 12 is made of a Mn ferrite core, a metal magnetic core, or an amorphous magnetic core having a low insulation resistance value, a bobbin or insulating tape formed of an insulating resin or the like is wound around the magnetic core 12. It interposes between the coils 13. By interposing such a bobbin, an insulating tape, etc., high insulation can be secured between the magnetic core 12 and the winding coil 13. Further, as the material of the magnetic core 12, a metal magnetic material, an amorphous magnetic material, or the like may be adopted according to the design specifications. The shape of the magnetic core 12 is not limited to a rod shape, and can be variously changed.

  Next, the stress relaxation member 9 is formed using an elastic resin member so as to surround the entire periphery of the coil component 10 (step S2). As the stress relaxation member 9, an elastic resin member having higher elasticity than the exterior resin member 2 as a physical property after being cured is used. The stress relieving member 9 is used as a member that has the same functions and effects as the exterior resin member 2 although the structure and material are different. That is, the stress relieving member 9 has an effect of relieving stress generated during the sealing molding process (see step S3 in FIG. 2) of the exterior resin member 2 described later.

  At this time, the stress relieving member 9 has an effect of absorbing and relieving the injection molding pressure affecting the coil component 10 by its elasticity when the exterior resin member 2 is encapsulated. Further, there is an effect that the stress applied to the magnetic core 12 and the coil component 10 does not vary or become uneven. As a result, problems such as external influence on the sealed antenna coil component 1, deterioration of the electrical characteristics of the coil component 10, and breakage of the magnetic core 12 and the coil component 10 can be suppressed.

  Next, the exterior resin member 2 is formed so as to surround the entire periphery of the stress relaxation member 9 (step S3). As the material of the exterior resin member 2, ABS resin, PBT resin, PPS resin, which are excellent in heat resistance, moisture resistance, acid resistance, alkali resistance, etc. and excellent in moldability so as to be able to withstand various usage environments, or a mixture thereof Resin is used. The exterior resin member 2 is sealed and molded by injecting heat-melted resin into a mold cavity installed in a state where the stress relaxation member 9 is formed on the coil component 10.

  Since the physical properties of the resin used for the exterior resin member have a relatively high melt viscosity, it is necessary to set the injection molding pressure higher. Furthermore, since the shrinkage behavior when this resin is cured after injection molding is large, the stress generated tends to increase. Therefore, the reason why the stress relaxation member 9 having elasticity is formed in step S2 of FIG. 2 is mainly to relieve stress generated in the molding of the exterior resin member 2 in a later step.

  After going through the above steps, appearance inspection, evaluation of electrical characteristics, etc. are performed, and the sealed antenna coil component 1 is completed.

  Here, the state of injection molding of the elastic resin member in the step of forming the stress relaxation member 9 will be described with reference to FIG. FIG. 3 shows a state of the step S2 of FIG. 2: the process of forming the stress relaxation member 9. 3 shows a stress relaxation member forming mold 20 used for sealing and molding the elastic resin member around the coil component 10 and the coil component 10 along the line BB ′ of FIG. FIG.

  The stress relaxation member forming mold 20 includes an upper mold 22 and a lower mold 23 which are divided into two. The coil component 10 is installed in a mold cavity 21 formed in the lower mold 23 with the top and bottom reversed with respect to the state shown in FIG.

  In FIG. 3, the flange portions of the first flanged resin base 11 a and the second flanged resin base 11 b are arranged in contact with the inner wall portion of the mold cavity 21. For this reason, the coil component 10 including the magnetic core 12 and the winding coil 13 and a part of the lead harness 5 can be arranged without contacting the inner wall of the mold cavity 21. Then, at the time of injection molding of the exterior resin member 2, it is possible to perform injection molding by changing the thickness of the elastic resin member to a portion where it is desired to relieve unnecessary stress applied to the coil component 10.

  The upper mold 22 is formed with a resin injection hole 24 for injecting a molten elastic resin member into the mold cavity 31. The elastic resin member injected from the resin injection hole 24 and formed by injection has elasticity as a physical property after the polymerization reaction. For this reason, the stress relaxation member 9 has a function of relieving stress.

  Next, the state of injection molding of ABS resin, PBT resin, PPS resin, or a mixture thereof in the forming process of the exterior resin member 2 will be described with reference to FIG. FIG. 4 shows a state of the step S3 of FIG. 2: a process of forming the exterior resin member 2. 4 shows an exterior resin member forming mold 30 used for sealing and molding the resin member around the coil component 10 and the coil component 10 in which the stress relaxation member 9 is sealingly molded. This is an example of a cross-sectional view taken along the line AA ′ of a).

  The exterior resin member forming mold 30 includes an upper mold 32 and a lower mold 33 which are divided into two. The coil component 10 on which the stress relaxation member 9 is formed is installed in the mold cavity 31 formed in the lower mold 33 with the top and bottom reversed with respect to the state shown in FIG. is there.

  In FIG. 4, the flange portions of the first flanged resin base 11 a and the second flanged resin base 11 b are arranged in contact with the inner wall portion of the mold cavity 31. For this reason, the coil component 10 in which the stress relaxation member 9 is formed and a part of the lead harness 5 can be arranged without contacting the inner wall of the mold cavity 31.

  A resin injection hole 34 for injecting a molten resin member into the mold cavity 31 is formed in the upper mold 32. The ABS resin, PBT resin, PPS resin, or a mixture thereof injected and injected from the resin injection hole 34 is cured after the polymerization reaction, so that the impact resistance of the sealed antenna coil component 1 is increased. And since the 1st flanged resin base 11a and the 2nd flanged resin base 11b are the same as the material of the exterior resin member 2, they are excellent in adhesiveness. Therefore, sealing molding of the coil component 10 by the exterior resin member 2 is reliably performed, and the sealed antenna coil component 1 having high structural reliability is obtained.

  In the first embodiment described above, an elastic resin member such as PA resin is used as the material of the stress relaxation member 9. For this reason, in the formation process in which the exterior resin member 2 is injection molded, even if the injection molding pressure of the exterior resin member 2 is increased and stress is generated, the stress relaxation member 9 relaxes this stress. For this reason, there is an effect that the coil component 10 included in the stress relaxation member 9 is not affected by deformation or the like.

  Next, a sealed antenna coil component 40 according to a second embodiment of the present invention will be described with reference to FIGS. Also in the present embodiment, a detailed description will be given as an example applied to a sealed antenna coil component 40 suitable for use in a keyless entry system mounted on an automobile. However, in FIG. 5 and FIG. 6, the parts corresponding to FIG.

  First, a configuration example of the sealed antenna coil component 40 of this example will be described with reference to a perspective view of FIG. 5A to 5D show a case where a plate-like member is used as the stress relaxation member 49 that relieves the stress generated during the injection molding of the exterior resin member 2 ′ that is the exterior of the sealed antenna coil component 40. This is an example.

  FIG. 5A shows an external configuration example of the sealed antenna coil component 40. The appearance configuration itself is the same as that of the sealed antenna coil component 1 in the first embodiment already described. The sealed antenna coil component 40 is encapsulated with an exterior resin member 2 ′ that exhibits the same functions and effects as those of the exterior resin member 2 in the first embodiment. As the material of the exterior resin member 2 ', ABS resin, PBT resin, PPS resin, or a mixed resin thereof is used.

  FIG. 5B shows a configuration example when the exterior resin member 2 ′ is removed from the sealed antenna coil component 40. On the lower surface of the coil component 10, a plate-like member is disposed as a stress relaxation member 49 having a hardness similar to or higher than the hardness after the exterior resin member 2 ′ is cured. The stress relaxation member 49 has a function of evenly adjusting the amount of resin adhered and relaxing the stress applied to the coil component 10 when the exterior resin member 2 ′ is formed around the coil component 10.

  FIG. 5C shows a configuration example when the exterior resin member 2 ′ and the stress relaxation member 49 are disassembled from the sealed antenna coil component 40. It can be seen that the stress relaxation member 49 is disposed on the bottom surface of the coil component 10.

  5D shows an example in which the winding coil 13 is removed from the state of FIG. 5C and the first flanged resin base 11a, the second flanged resin base 11b, and the magnetic core 12 are disassembled. Indicates. This configuration is also the same as that of the sealed antenna coil component 1 in the first embodiment.

  As shown in FIG. 5, the sealed antenna coil component 40 of this example is characterized in that a plate-like member is disposed as a stress relaxation member 49 on the lower surface of the coil component 10.

  In addition, about the manufacturing method of the sealing antenna coil component 40, except the formation step of a stress relaxation member (a plate-shaped member is arrange | positioned in the lower surface of the coil component 10 in this example), the sealing antenna coil already demonstrated. Since it is the same as the example of the manufacturing method of the component 1 (see FIG. 2), detailed description is omitted.

  Next, the state of injection molding of ABS resin, PBT resin, PPS resin, or a mixture thereof in the forming process of the exterior resin member 2 ′ will be described with reference to FIG. FIG. 6 shows an exterior resin member forming mold 50 used for sealing and molding a resin member around the coil component 10 and a sealed antenna coil component 40 on which a plate-like member is arranged. ) Is a cross-sectional view taken along the line CC ′.

  The exterior resin member forming mold 50 includes an upper mold 52 and a lower mold 53 which are divided into two. The coil component 10 on which the stress relaxation member 49 is formed is installed in the mold cavity 51 formed in the lower mold 53 with the top and bottom reversed with respect to the state shown in FIG. is there.

  The flange portions of the first flanged resin base 11 a and the second flanged resin base 11 b are arranged so as to contact the inner wall portion of the mold cavity 51. For this reason, the coil component 10 composed of the magnetic core 12 and the winding coil 13 and a part of the lead harness 5 can be arranged without contacting the inner wall of the mold cavity 51.

  A resin injection hole 54 for injecting a molten resin member into the mold cavity 51 is formed in the upper mold 52. The ABS resin, PBT resin, PPS resin, or a mixture thereof injected and injection-molded from the resin injection hole 54 is cured as a physical property after the polymerization reaction, so that the impact resistance of the sealed antenna coil component 40 is increased. It becomes. The first flanged resin base 11a and the second flanged resin base 11b are excellent in adhesion because they are the same as the material of the exterior resin member 2 '. Therefore, sealing molding of the coil component 10 by the exterior resin member 2 ′ is performed reliably, and the sealed antenna coil component 40 having a structurally high reliability is obtained.

  In the second embodiment described above, a plate-like member having a hardness equal to or higher than that of the exterior resin member 2 ′ is disposed on the lower surface of the coil component 10 as the stress relaxation member 49. As shown in FIG. 6, the plate-like member is disposed on the side where the molten resin is injected when the exterior resin member 2 'is injection-molded. For this reason, since the injected molten resin does not directly collide with the coil component 10, an unnecessary impact is not given to the coil component 10.

  The stress relaxation member 49 is formed as a plate-like member, and is disposed in order to equalize the amount of resin adhered to the exterior resin member 2 ′ formed around the coil component 10. The degree of the resin shrinkage stress or the like generated when the exterior resin member 2 ′, which is injection-molded so as to surround the entire periphery of the coil component 10 due to the arrangement of the plate-like member, undergoes a polymerization reaction with respect to the entire periphery of the coil component 10 Can be equalized. For this reason, the plate-like member has an effect that the stress applied to the magnetic core 12 and the coil component 10 does not cause variation or bias. Further, since the stress relaxation member 49 is formed in a plate shape, the stress relaxation member 49 has an effect of relaxing stress generated during the sealing molding process of the exterior resin member 2 ′. As a result, it is possible to suppress problems such as deterioration of the electrical characteristics of the coil component 10 and breakage of the magnetic core 12 and the coil component 10.

  Further, in the sealed antenna coil component 40 of the present example, the exterior resin member 2 ′ corresponding to the part attached to the car body of the automobile has a base-like thickness. For this reason, in the state which has not arrange | positioned the plate-shaped member, the amount of resin which forms exterior resin member 2 'which seals the coil components 10 will vary. In the sealed antenna coil component 40, the plate-like member is arranged so that the amount of adhesion when the exterior resin member 2 ′ is injected around the coil component 10 is evenly adjusted. For this reason, there exists an effect that the applied condition of the stress caused by the expansion behavior or the contraction behavior when the injected molten resin causes a curing reaction is made uniform. For this reason, there is an effect that the magnetic core 12 and the stress applied to the coil component 10 that are generated by applying non-uniform stress to the coil component 10 do not cause variation or bias.

  Further, the material of the plate-like member is ABS resin, PBT resin, PPS resin or a mixture thereof as in the case of the exterior resin member 2 '. For this reason, a plate-shaped member does not bend or deform | transform by the expansion behavior and shrinkage | contraction behavior at the time of the injection-molded molten resin causing a curing reaction. Therefore, there is an effect that it is possible to more effectively suppress the application of uneven stress to the coil component 10.

  The sealed antenna coil component 40 of this example has been described as an example in which a plate-like member is formed using the same material as that of the exterior resin member 2 '. For example, the material having a hardness higher than that of the exterior resin member 2'. Even if a ceramic plate, metal plate, other reinforced plastic plate, or the like is employed, the same function and effect as the stress relaxation member 49 of this example can be obtained.

  Further, if conditions such as the size, volume, and arrangement position of the plate-like member are set so that the amount of the exterior resin member 2 'adhering to the periphery of the coil component 10 is made uniform, the above-described second embodiment example The same effect can be expected without being limited thereto.

  In the sealed antenna coil component in the first and second exemplary embodiments described above, the example in which the elastic resin member and the plate-like member are employed as the stress relaxation member has been described. Since the sealed antenna coil component includes an elastic resin member or a plate-like member as a stress relaxation member, the stress generated by the injection molding pressure of the resin during the injection molding of the exterior resin member can be relaxed. For this reason, non-uniform stress is not applied to the coil component 10 and the magnetic core 12.

  Further, the sealed antenna coil component can be formed by a manufacturing process that can realize time reduction easily. For this reason, there exists an effect that sealing molding of resin can be performed in the state which maintained the quality of the coil components 10 and the magnetic body core 12. FIG. Also, by arranging the stress relaxation member, the exterior resin can be molded at high pressure without applying stress to the coil components, etc., so that a high quality exterior resin member with excellent durability against the external environment is formed. As a result, a highly reliable sealed antenna coil component can be obtained.

  Further, the coil component contained in the sealed antenna coil component is protected by the stress relaxation member and the exterior resin member. For this reason, there exists an effect that it is not given to the coil component which includes the influence of the impact etc. from the outside concerning a sealing antenna coil component.

  Furthermore, the sealed antenna coil component according to the present invention having the stress relaxation member is also used for the expansion / contraction behavior of the exterior resin member generated by the thermal stress repeatedly applied when used as a product. High reliability can be maintained by the stress relaxation effect.

  In the first and second exemplary embodiments described above, it has been described that the elastic resin member or the plate-like member has a function of relieving unnecessary stress when employed alone. Furthermore, you may make it use combining an elastic resin member and a plate-shaped member. In this case, it goes without saying that a further stress relaxation effect can be obtained for the coil component sealed by the exterior resin member.

  Moreover, although the case where the sealed antenna coil component in the first and second embodiments described above is adopted in a keyless entry system mounted on an automobile has been described, the same functions and effects can be obtained even in other applications. Needless to say you can get

It is the block diagram which showed the example of the sealing antenna coil component in the 1st Example of this invention. It is the flowchart which showed the example of the manufacturing process of the sealing antenna coil components in the 1st Example of this invention. It is explanatory drawing which showed the cross-sectional example of the sealing antenna coil components in alignment with the BB 'line | wire of FIG. 1 among the processes which form the stress relaxation member in the 1st Example of this invention. It is explanatory drawing which showed the cross-sectional example of the sealing antenna coil components in alignment with the AA 'line of FIG. 1 among the processes which form the exterior resin member in the 1st Example of this invention. It is the block diagram which showed the example of the sealing antenna coil components in the 2nd Example of this invention. It is explanatory drawing which showed the cross-sectional example of the sealing antenna coil components in alignment with the CC 'line | wire of FIG. 5 among the processes which form the exterior resin member in the 2nd Example of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Sealing antenna coil component, 2 ... Exterior resin member, 3 ... Bolt fastening hole part, 4 ... Car body fixing | fixed part, 5 ... Lead harness, 6 ... External connector, 7 ... Groove part, 9 ... Stress relaxation member, DESCRIPTION OF SYMBOLS 10 ... Coil components, 11a ... 1st flanged resin base, 11b ... 2nd flanged resin base, 12 ... Magnetic body core, 13 ... Winding coil, 14 ... Wire guide, 15 ... Insertion part, 20 ... Stress Relief member forming mold, 30 ... Exterior resin member forming mold, 40 ... Sealed antenna coil component, 49 ... Stress relieving member, 50 ... Exterior resin member forming die

Claims (3)

A coil component comprising a magnetic core, a winding coil wound around the magnetic core, and a base on which a flange for fixing the magnetic core around which the winding coil is wound is formed;
A stress relieving member that relieves stress applied to the coil component by resin injection molding;
So as to surround the stress relaxation member, said stress softening temperature and melting temperature than the resin used in the molding of relaxation member is high, the thermoplastic resin shall be subject to high molding pressure is sealing formed by injection molding Thus, when the flange comes into contact with the convex portion formed on the inner wall surface of the mold member that seals and forms the exterior resin member, the base between the inner wall surface of the mold member and the stress relaxation member A sealing coil component comprising: an exterior resin member in which the resin is sealed in a generated space and a groove is formed on a surface at a position where the convex portion and the flange are in contact with each other. The sealed coil component according to claim 1,
As the stress relaxation member,
Sealing coil component, characterized by employing the elastic resin member that physical properties after curing has a higher elasticity than the exterior resin member. Wind the winding coil around the magnetic core,
Producing a coil component comprising the magnetic core, the winding coil, and a base on which a flange for fixing the magnetic core around which the winding coil is wound is formed;
Forming a stress relieving member that relieves stress applied to the coil component by injection molding of the resin;
So as to surround the stress relaxation member, said stress softening temperature and melting temperature than the resin used in the molding of relaxation member is high, the thermoplastic resin shall be subject to high molding pressure by sealing formed by injection molding The base is formed between the inner wall surface of the mold member and the stress relieving member by contacting the flange with a convex portion formed on the inner wall surface of the mold member that seals and forms the exterior resin member. And a step of forming an exterior resin member formed by injection molding in which the resin is sealed in the open space and a groove is formed on the surface where the convex portion and the flange are in contact with each other. .

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