JP6613454B2 - Coil parts - Google Patents

Description

  The present invention relates to a coil component used in various electronic devices and a manufacturing method thereof.

  In recent years, electronic control of automobile drive systems and control systems has been increasingly advanced, and many electronic devices have been installed in one automobile. Power supply circuits such as booster circuits and rectifier circuits for electronic devices Coil parts are used.

  With these coil parts, due to the increase in capacity of electronic equipment such as automobiles, thick conductors corresponding to large currents are used as the conductors used in the coil parts. For example, the diameter of the conductors is 0.8 to 2.0 mm. Such a thick lead wire is used, and the lead wire is used as a lead portion of a coil component that is drawn out and connected to an external electric circuit.

  And, for example, in an electronic device mounted on an automobile, such a coil component is fixed and attached to the housing of the electronic device with an adhesive or a fixing member, and the connection between the circuit board of the electronic device and the coil component is It is known to use a lead portion of a coil component by resistance welding to a relay bus bar fixed to an electronic device.

JP 2007-31614 A

  In recent years, with the diversification of electronic devices mounted on automobiles and the like, the interval between relay bus bars to which the lead portions of coil parts are connected has also increased, and the number of these types of bus bars has increased. In order to use a coil component for a general purpose with respect to the interval, it has been required to correct the position and shape of the lead part of the coil component in accordance with the interval between different bus bars.

  However, when the lead wire of the coil component becomes thick, when trying to correct the position and shape of the lead portion of the coil component, a large stress is applied to the main body of the coil component to apply a large stress to the lead portion of the coil component. There has been a problem in that there is a risk that the fixing of the coil will be lost or the coil parts may be damaged.

  An object of the present invention is to provide a highly versatile coil component that can easily correct the position and shape of the lead portion of the coil component in accordance with the interval between different bus bars of an electronic device.

  In order to solve the above-mentioned problems, the present invention provides a coil part in which a conducting wire having a circular cross section is wound, a body part incorporating the coil part, and a first lead part in which both ends of the coil part protrude from the body part And the second lead portion, and the first and second lead portions have a thickness direction smaller than the first and second lead portions in the radial section of the first and second lead portions, respectively, and the width direction is The first and second lead portions have a flat first flat portion and a second flat portion that are larger than the diameter of the first and second lead portions. The first flat portion has a thickness direction and a second flat portion, respectively. The first and second lead portions are extended in the same direction, and the thickness directions of the first flat portions of the first and second lead portions are the same direction. .

  With the above configuration, the first and second lead portions have a flat shape in which the thickness direction is smaller than the lead portion diameter dimension and the width direction is larger than the lead portion diameter dimension in the radial section of the first and second lead portions. Since the first flat part and the second flat part are formed, the first flat part and the second flat part are more easily bent than the thick lead part. It is possible to make the bending easier by reducing the stress when straightening.

  In addition, since the thickness direction of the first flat portion and the thickness direction of the second flat portion are arranged to be orthogonal, the direction in which the first flat portion is easily bent and the direction in which the second flat portion is easily bent are orthogonal, If the thickness direction of the first flat portion is arranged in the vertical direction, for example, the tips of the first and second lead portions can be easily corrected in the vertical direction. In this case, the thickness direction of the second flat portion is arranged in the horizontal direction. As a result, the tips of the first and second lead portions can be easily corrected in the horizontal direction. By bending both the first and second flat portions, the tips of the lead portions can be horizontally and vertically aligned. Both can be easily corrected.

  And since the 1st, 2nd lead part is extended in the same direction, and the thickness direction of the 1st flat part of each of the 1st, 2nd lead part is made the same direction, the 1st lead part and the 2nd lead part are Since the direction in which it is easy to bend during correction is the same, the first and second lead portions can be more easily corrected.

  From these results, the position and shape of the lead part of the coil component can be easily corrected in accordance with the interval between the different bus bars of the electronic device, and the versatility of the coil component can be improved.

The perspective view of the coil components in one embodiment of this invention Enlarged view of the lead part of the coil component of FIG. The perspective view which shows the example which connected the coil components and bus bar of FIG. The perspective view which shows another example of the coil components in one embodiment of this invention Enlarged view of the lead part of the coil component of FIG. The perspective view which shows the example which corrected the lead part of the coil components of FIG. The perspective view which shows another example of the coil components in one embodiment of this invention The figure explaining the manufacturing process of the coil components of one embodiment of this invention The figure explaining the manufacturing process of the coil components of one embodiment of this invention The figure explaining the manufacturing process of the coil components of one embodiment of this invention The figure explaining the manufacturing process of the coil components of one embodiment of this invention The figure explaining the manufacturing process of the coil components of one embodiment of this invention The figure explaining the manufacturing process of the coil components of one embodiment of this invention

  Hereinafter, a coil component according to an embodiment of the present invention will be described with reference to the drawings.

  FIG. 1 is a perspective view of a coil component according to an embodiment of the present invention.

  As shown in FIG. 1, a coil component according to an embodiment of the present invention includes a coil portion 21 in which a conducting wire having a circular cross section is wound, a body portion 22 incorporating the coil portion 21, and both end portions of the coil portion 21. And a lead portion 23 that protrudes from the body portion 22 and is connected to an external electric circuit.

  In FIG. 1, the inside of the body portion 22 is indicated by a broken line.

  The coil portion 21 is formed by spirally winding a conducting wire having a circular cross section with an insulating coating on the exterior. In order to cope with the large current of the electronic equipment, the conducting wire is a thick conducting wire made of copper and having a diameter of about 0.8 to 2.0 mm. In the present embodiment, the conducting wire having a diameter of φ1.0 mm is 5 .5 turns.

  The body portion 22 includes a coil portion 21 therein and constitutes a magnetic core of the coil component. The coil portion 21 is embedded in a composite material in which an iron-based metal magnetic powder and a thermosetting binder are mixed. After the pressure molding, the molded body obtained is heat treated to thermally cure the thermosetting binder. In the present embodiment, the outer dimension of the body portion 22 is 12.0 × 12. It is formed in a substantially quadrangular prism shape of 0.0 × 6.0 mm.

  The lead portion 23 is formed by extending the conductive wires at both ends of the coil portion 21 to protrude outside the body portion 22. The lead portion 23 extends from one end portion of the coil portion 21 and the other lead portion 23 a. The second lead portion 23b having an extended end portion is protruded in the same direction in parallel from one side surface of the body portion 22. In addition, the insulating film of the conductor of the part which comprises the lead part 23 is peeled.

  Further, the lead portion 23 includes a flat first flat portion 24 having a thickness direction smaller than the diameter size of the lead portion 23 and a width direction larger than the diameter size of the lead portion 23 in the radial section of the lead portion 23. A second flat portion 25 is formed.

  And when viewed in the cross-section in the thickness direction of each of the first flat part 24 and the second flat part 25 in the extending direction of the lead part 23, on both sides of each of the first flat part 24 and the second flat part 25, A coupling portion 26 is formed to connect the first flat portion 24 and the second flat portion 25 to the thickness portion of the lead portion 23 from the diameter portion.

  And the thickness direction of the 1st flat part 24 and the thickness direction of the 2nd flat part 25 are arrange | positioned so that it may mutually orthogonally cross.

  The first flat portion 24 and the second flat portion 25 are formed in the first lead portion 23a and the second lead portion 23b, respectively.

  The first flat part 24 and the second flat part 25 will be described in more detail with reference to FIG.

  FIG. 2 is an enlarged view of the lead portion of the coil component according to the embodiment of the present invention, and shows the body portion 22 side of the first lead portion 23a in an enlarged manner. In FIG. FIG. 2B is a view from the front side of the drawing in the direction 29 in FIG. 1, and FIG. 2C is a view from the lower side of the drawing in the direction 28 in FIG. FIG. 2 (d) shows a view from the back side of the drawing in the direction 29 in FIG.

  Here, although the first lead portion 23a is shown in FIG. 2, the same first flat portion 24 and second flat portion 25 are also formed in the second lead portion 23b.

  As shown in FIG. 2, the first flat portion 24 is formed on the body portion 22 side of the first lead portion 23 a, and the second flat portion 25 is formed on the opposite side of the body portion 22 via the first flat portion 24. ing.

  First, the first flat portion 24 will be described. The first flat portion 24 is provided with a plane parallel to the extending direction of the first lead portion 23a on the contact surface of a punch (not shown) of a press die. The punch is pushed into the first lead portion 23a and crushed. In the radial cross section of the first lead portion 23a, the thickness dimension Fft of the first flat portion 24 is smaller than the diameter dimension Ld of the first lead portion 23a. doing.

  Further, in the radial cross section of the first lead portion 23a, both sides of the first flat portion 24 in the direction orthogonal to the thickness direction of the first flat portion 24 are subjected to crushing processing so that copper of the conductive wire extends and the first lead portion 23a. A bulging portion 30 is formed that is bulged by being pushed to the outside of the diameter dimension Ld, and the width dimension Ffw of the first flat portion 24 is larger than the diameter dimension Ld of the first lead portion 23a.

  When viewed in a cross-section in the thickness direction of the first flat portion 24 in the extending direction of the first lead portion 23a, the first flat portion 24 has both sides from the portion of the diameter Ld of the first lead portion 23a. A coupling portion 26 that connects the portions of the flat portion 24 having the thickness dimension Fft is formed.

  When the first flat portion 24 is crushed by a punch of a press die, the coupling portion 26 is formed by changing the lead of the first lead portion 23a from a circular portion to a flat portion of the first flat portion 24. The thickness is reduced as it goes to.

  By doing so, the thickness dimension Fft of the first flat part 24 in the radial cross section of the first lead part 23a is made smaller than the diameter dimension Ld of the first lead part 23a. Can bend easily.

  Further, since the width dimension Ffw of the first flat part 24 is made larger than the diameter dimension Ld of the first lead part 23a, the reduction of the cross-sectional area of the first flat part 24 is reduced, and the loss increases with respect to a large current. Can be suppressed.

  Here, when the first lead portion 23a is to be easily bent, it is conceivable to make it easier to bend by making the cross-sectional shape of the contact surface of the punch into a semicircular shape or an V shape of the alphabet. Copper extends in the extending direction of the first lead portion 23a and the bulged portion 30 is hardly formed, and the cross-sectional area of the first flat portion 24 is greatly reduced.

  On the other hand, as in the present embodiment, a flat surface parallel to the extending direction of the first lead portion 23a is formed on the contact surface of the punch, and the punch is pushed into the first lead portion 23a to be crushed. Thus, as the punch is pushed into the first lead portion 23a, the copper of the conducting wire is extended to form the pushing side flat portion 31 on the side where the punch is pushed, and the receiving side gold portion is also formed on the opposite side of the pushing side flat portion 31. The copper of the conducting wire is deformed into a flat shape by the mold to form the receiving side flat portion 32, and the bulging portion 30 can be more easily formed by being extended by two planes with the conducting wire interposed therebetween.

  In this case, the length dimension of the pushing-side flat surface portion 31 in the extending direction of the first lead portion 23a, that is, the length dimension Ffl of the first flat portion 24 is 0.2 times the radial dimension Ld of the first lead portion 23a. It is preferably 2.0 times, and less than 0.2 times is not preferable because the amount of bending when the first flat portion 24 is bent is reduced. This is not preferable because the length becomes longer and the outer dimensions of the entire coil component increase. More preferably, it is preferably 0.5 to 1.5 times.

  Further, the thickness dimension Fft of the first flat part 24 is preferably 0.3 to 0.7 times the diameter dimension Ld of the first lead part 23a, and if it is smaller than 0.3 times, the strength of the first lead part 23a. Is not preferable because it becomes weak, and if it is larger than 0.7 times, the effect of easily bending the first lead portion 23a is reduced, which is not preferable. More preferably, it is preferably 0.4 to 0.6 times.

  Next, the second flat portion 25 will be described. The second flat portion 25 is provided with a plane parallel to the extending direction of the first lead portion 23a on the contact surface of a punch (not shown) of the press die. The punch pressing direction when the first flat portion 24 is formed is 90 ° shifted and the punch is pressed into the first lead portion 23a to be crushed.In the radial section of the first lead portion 23a, The thickness dimension Sft of the second flat part 25 is made smaller than the diameter dimension Ld of the first lead part 23a.

  Further, in the radial cross section of the first lead portion 23a, both sides of the second flat portion 25 in the direction orthogonal to the thickness direction of the second flat portion 25 extend the copper of the conductive wire by crushing and the first lead portion 23a. A bulging portion 30 is formed that is bulged by being pushed to the outside of the diameter dimension Ld, and the width dimension Sfw of the second flat portion 25 is larger than the diameter dimension Ld of the first lead portion 23a.

  When viewed in a cross-section in the thickness direction of the second flat portion 25 in the extending direction of the first lead portion 23a, both sides of the second flat portion 25 are spaced from the portion of the diameter Ld of the first lead portion 23a. A coupling portion 26 that connects the portions of the two flat portions 25 having the thickness dimension Sft is formed.

  When the second flat portion 25 is crushed by a punch of a press die, the coupling portion 26 is formed by changing the lead of the first lead portion 23a from a circular portion to a flat portion of the second flat portion 25. The thickness is reduced as it goes to.

  By doing in this way, since the thickness dimension Sft of the 2nd flat part 25 in the radial cross section of the 1st lead part 23a was made smaller than the diameter dimension Ld of the 1st lead part 23a, the 2nd flat part 25 was made into small stress. Can bend easily.

  Further, since the width dimension Sfw of the second flat part 25 is made larger than the diameter dimension Ld of the first lead part 23a, the reduction of the cross-sectional area of the second flat part 25 is reduced, and the loss increases with respect to a large current. Can be suppressed.

  Here, when the first lead portion 23a is to be easily bent, it is conceivable to make it easier to bend by making the cross-sectional shape of the contact surface of the punch a semicircular shape or an alphabet V shape. Copper extends in the extending direction of the first lead portion 23a and the bulged portion 30 is hardly formed, and the cross-sectional area of the second flat portion 25 is greatly reduced.

  On the other hand, as in the present embodiment, a flat surface parallel to the extending direction of the first lead portion 23a is formed on the contact surface of the punch, and the punch is pushed into the first lead portion 23a to be crushed. Thus, as the punch is pushed into the first lead portion 23a, the copper of the conducting wire is extended to form the pushing side flat portion 31 on the side where the punch is pushed, and the receiving side gold portion is also formed on the opposite side of the pushing side flat portion 31. The copper of the conducting wire is deformed into a flat shape by the mold to form the receiving side flat portion 32, and the bulging portion 30 can be more easily formed by being extended by two planes with the conducting wire interposed therebetween.

  In this case, the length dimension of the pushing side plane part 31 in the extending direction of the first lead part 23a, that is, the length dimension Sfl of the second flat part 25 is 0.2 to 2 times the diameter dimension Ld of the first lead part 23a. It is preferably 0.0 times, and if it is 0.2 times or less, the amount of bending when the second flat portion 25 is bent is reduced, which is not preferable. If it is more than 2.0 times, the length of the first lead portion 23a is not preferable. Becomes longer and the outer dimensions of the entire coil component become larger, which is not preferable. More preferably, it is preferably 0.5 to 1.5 times.

  Further, the thickness dimension Sft of the second flat part 25 is preferably 0.3 to 0.7 times the diameter dimension Ld of the first lead part 23a, and if it is smaller than 0.3 times, the strength of the first lead part 23a. Is not preferable because it becomes weak, and if it is larger than 0.7 times, the effect of easily bending the first lead portion 23a is reduced, which is not preferable. More preferably, it is preferably 0.4 to 0.6 times.

  The first flat portion 24 and the second flat portion 25 formed in this manner are arranged so that the thickness direction of the first flat portion 24 and the thickness direction of the second flat portion 25 are orthogonal to each other. Since the direction in which the one flat portion 24 is easily bent and the direction in which the second flat portion 25 is easily bent are orthogonal to each other, the first lead portion 24 is arranged in the vertical direction (direction 28 in FIG. 1). 23a can be easily corrected in the vertical direction. In this case, since the thickness direction of the second flat portion 25 is arranged in the horizontal direction (direction 29 in FIG. 1), the tip of the first lead portion 23a is It can be easily corrected in the horizontal direction, and by bending both the first flat portion 24 and the second flat portion 25, the tip of the first lead portion 23a can be easily corrected in both the horizontal direction and the vertical direction. Can

  Here, the arrangement between the thickness direction of the first flat portion 24 and the thickness direction of the second flat portion 25 is that the thickness direction of the first flat portion 24 and the thickness direction of the second flat portion 25 are arranged to be orthogonal to each other. Is not limited to 90 °, and it is only necessary to correct the tip of the first lead portion 23a in both the horizontal direction and the vertical direction by bending both the first flat portion 24 and the second flat portion 25. If the angle formed by the thickness direction of the first flat portion 24 and the thickness direction of the second flat portion 25 is in the range of 80 ° to 100 °, similar effects can be obtained.

  At this time, the distance between the first flat part 24 and the second flat part 25 is between the coupling part 26 between the coupling part 26 on the first flat part 24 side and the coupling part 26 on the second flat part 25 side. Is preferably 0.8 to 3.0 times the diameter Ld of the first lead portion 23a. If the distance Cl is smaller than 0.8 times, the first flat portion 24 and the second flat portion 25 have a small stress. Since the effect of facilitating bending becomes small, it is not preferable, and if it exceeds 3.0 times, the length of the first lead portion 23a becomes long and the overall size of the coil component becomes large.

  This is because when the punch is pushed into the first lead portion 23a and processed into a flat shape, the receiving-side flat portion 32 formed on the surface opposite to the pushed-in side may be an extension of the first lead portion 23a. The extending portion 32a of the receiving side plane portion 32 may extend to the outside of the coupling portion 26 up to about 0.5 times the diameter Ld of the first lead portion 23a.

  Since the extended portion 32 a of the receiving side flat portion 32 is work hardened when the conductor is crushed, the receiving portion of the receiving flat portion 32 of the first flat portion 24 and the receiving portion of the second flat portion 25 are received. If the extended portion 32a of the side plane portion 32 overlaps perpendicularly in the extending direction of the first lead portion 23a, it becomes difficult to deform the first flat portion 24 and the second flat portion 25 when bending the first flat portion 24 and the second flat portion 25. This is because a larger stress is required as compared with the case where they do not overlap, and the distance Cl between the coupling portion 26 and the coupling portion 26 on the second flat portion 25 side is equal to the radial dimension Ld of the first lead portion 23a. More preferably, it is 1.0 to 2.0 times.

  The thickness dimension Fft of the first flat part 24, the thickness dimension Sft of the second flat part 25, the width dimension Ffw of the first flat part 24, the width dimension Sfw of the second flat part 25, and the length of the first flat part 24. The length dimension Ffl and the length dimension Sfl of the second flat part 25 are preferably set so that each dimension of the first flat part 24 and each dimension of the second flat part 25 are the same. The balance of the bendability of the first flat part 24 and the second flat part 25 can be balanced, and the position and shape of the first lead part 23a can be easily corrected.

  Next, a usage example of the coil component of the above-described embodiment will be described with reference to FIG.

  FIG. 3 is a perspective view showing an example in which the coil component and the bus bar shown in FIG. 1 are connected. In FIG. 3, 33a and 33b are bus bars 33 made of a copper plate for relaying to a circuit board fixed to an electronic device. Yes, the bus bars 33a and 33b are arranged at the same height in the vertical direction, and the interval between the bus bar 33a and the bus bar 33b in the horizontal direction is wider than the interval between the first lead portion 23a and the second lead portion 23b of the coil component. .

  In the coil component, the body portion 22 is fixed to a housing of an electronic device (not shown) by an adhesive or a fixing member, and the second flat portion 25 of the first lead portion 23a is drawn in a direction 29 (horizontal direction in FIG. 3). The tip of the first lead portion 23a is bent on the back side, overlapped with the bus bar 33a, and connected by resistance welding at the welding portion 34.

  Then, the second flat portion 25 of the second lead portion 23b is bent toward the front side of the drawing in the direction 29, and the distal end portion of the second lead portion 23b is overlapped with the bus bar 33b and connected by resistance welding at the welding portion 34. It is what is done.

  Thus, the coil component of the present embodiment can easily correct the position and shape of the lead part 23 of the coil component in accordance with the interval between the different bus bars 33 of the electronic device.

  In addition, the first and second lead portions 23a and 23b are extended in the same direction, and the thickness directions of the first flat portions 24 of the first and second lead portions 23a and 23b are the same direction. Since the direction in which the second lead portions 23a and 23b are easily bent becomes the same, the first and second lead portions 23a and 23b can be more easily corrected, and the versatility of the coil component is improved. It is something that can be done.

  In particular, when the lead part 23 is resistance-welded to the bus bar 33, the welded part 34 is crushed by the welding electrode to cause a stress that is pushed back to the body part 22 side. The flat part 24 and the second flat part 25 can be relaxed by bending, and it can be suppressed that the attachment strength of the coil component to the housing and the connection strength of the welded part 34 are impaired.

  In the example of use shown in FIG. 3 described above, the example in which only the second flat portion 25 is bent has been described. However, when the bus bars 33a and 33b are bar-shaped bus bars having different heights, the second flat portion 25 is used. In addition, the first flat portion 24 may be bent in the direction 28 (vertical direction in FIG. 1), and the position and shape of the lead portion 23 can be corrected not only in the horizontal direction but also in the vertical direction.

  However, when the first flat portion 24 is bent, the lead portion 23 is corrected so as to extend obliquely upward or obliquely downward. Therefore, when the bus bar is a bar-shaped bus bar having a different height, the lead portion 23 is overlapped. However, when the bus bar is a plate-shaped bus bar having a different height, the extending direction of the lead portion 23 and the surface of the plate-shaped bus bar cannot be connected in parallel.

  Next, another example of the coil component of the present embodiment that enables connection with such a plate-like bus bar having different heights will be described with reference to FIG.

  FIG. 4 is a perspective view showing another example of the coil component according to the embodiment of the present invention. In FIG. 4, the inside of the body portion 22 is indicated by a broken line.

  The difference between the coil component shown in FIG. 4 and the coil component shown in FIG. 1 is that a third flat portion 35 is formed in the lead portion 23 in addition to the first flat portion 24 and the second flat portion 25. The same reference numerals are given to the same components as those of the coil component shown in FIG. 1, and detailed description thereof will be omitted.

  The lead portion 23 is formed with a flat third flat portion 35 having a thickness direction smaller than the diameter size of the lead portion 23 and a width direction larger than the diameter size of the lead portion 23 in the radial section of the lead portion 23. ing.

  Further, when viewed in a cross-section in the thickness direction of the third flat portion 35 in the extending direction of the lead portion 23, on both sides of the third flat portion 35, the radial portion of the third flat portion 35 extends from the portion having the radial dimension of the lead portion 23. A coupling portion 26 is formed to connect portions of thickness dimensions.

  The third flat portion 35 is disposed on the opposite side of the first flat portion 24 via the second flat portion 25, and the thickness direction of the third flat portion 35 is the same as the thickness direction of the first flat portion 24. It is arranged in the direction.

  The third flat portion 35 is formed in each of the first lead portion 23a and the second lead portion 23b.

  The third flat portion 35 will be described in more detail with reference to FIG.

  FIG. 5 is an enlarged view of the lead portion of the coil component according to the embodiment of the present invention, and shows the body portion 22 side of the first lead portion 23a in an enlarged manner. In FIG. 4 is a view from the top of the drawing in the direction 28 in FIG. 4, FIG. 5B is a view from the front of the drawing in the direction 29 in FIG. 4, and FIG. 5C is a view from the bottom in the drawing in the direction 28 in FIG. FIG. 5 (d) shows a view from the back side of the drawing in the direction 29 in FIG.

  Here, although the first lead portion 23a is illustrated in FIG. 5, a similar third flat portion 35 is also formed in the second lead portion 23b.

  The third flat portion 35 is provided with a flat surface parallel to the extending direction of the first lead portion 23a on the contact surface of the punch (not shown) of the press die, thereby forming the first flat portion 24. The punch is pushed into the first lead portion 23a from the same direction as the pushing direction and crushed. In the radial cross section of the first lead portion 23a, the thickness dimension Tft of the third flat portion 35 is set to the first lead portion 23a. Is smaller than the diameter Ld.

  Further, in the radial cross section of the first lead portion 23a, both sides of the third flat portion 35 in the direction orthogonal to the thickness direction of the third flat portion 35 are subjected to crushing processing so that copper of the conductive wire extends and the first lead portion 23a. A bulging portion 30 is formed that is bulged by being pushed outside the diameter dimension Ld, and the width dimension Tfw of the third flat portion 35 is made larger than the diameter dimension Ld of the first lead portion 23a.

  When viewed in a cross-section in the thickness direction of the third flat portion 35 in the extending direction of the first lead portion 23a, both sides of the third flat portion 35 are arranged from the portion of the diameter Ld of the first lead portion 23a. A coupling portion 26 that connects the portions of the three flat portions 35 having the thickness dimension Tft is formed.

  When the coupled portion 26 is formed by crushing the third flat portion 35 with a punch of a press die, the lead of the first lead portion 23a is changed from a circular portion to a flat portion of the third flat portion 35. The thickness is reduced as it goes to.

  By doing so, the thickness dimension Tft of the third flat part 35 in the radial cross section of the first lead part 23a is made smaller than the diameter dimension Ld of the first lead part 23a. Can bend easily.

  Further, since the width dimension Tfw of the third flat part 35 is made larger than the diameter dimension Ld of the first lead part 23a, the reduction of the cross-sectional area of the third flat part 35 is reduced, and the loss increases with respect to a large current. Can be suppressed.

  Here, when the first lead portion 23a is to be easily bent, it is conceivable to make it easier to bend by making the cross-sectional shape of the contact surface of the punch into a semicircular shape or an V shape of the alphabet. Copper extends in the extending direction of the first lead portion 23a and the bulged portion 30 is hardly formed, and the cross-sectional area of the third flat portion 35 is greatly reduced.

  On the other hand, as in the present embodiment, a flat surface parallel to the extending direction of the first lead portion 23a is formed on the contact surface of the punch, and the punch is pushed into the first lead portion 23a to be crushed. Thus, as the punch is pushed into the first lead portion 23a, the copper of the conducting wire is extended to form the pushing side flat portion 31 on the side where the punch is pushed, and the receiving side gold portion is also formed on the opposite side of the pushing side flat portion 31. The copper of the conducting wire is deformed into a flat shape by the mold to form the receiving side flat portion 32, and the bulging portion 30 can be more easily formed by being extended by two planes with the conducting wire interposed therebetween.

  In this case, the length dimension of the pushing side plane part 31 in the extending direction of the first lead part 23a, that is, the length dimension Tfl of the third flat part 35 is 0.2 to 2 times the diameter dimension Ld of the first lead part 23a. It is preferable to make it 0.0 times, and if it is 0.2 times or less, the amount of bending when the third flat portion 35 is bent is reduced, which is not preferable. If it is more than 2.0 times, the length of the first lead portion 23a Becomes longer and the outer dimensions of the entire coil component become larger, which is not preferable. More preferably, it is preferably 0.5 to 1.5 times.

  Further, the thickness dimension Tft of the third flat part 35 is preferably 0.3 to 0.7 times the diameter dimension Ld of the first lead part 23a, and if it is smaller than 0.3 times, the strength of the first lead part 23a. Is not preferable because it becomes weak, and if it is larger than 0.7 times, the effect of easily bending the first lead portion 23a is reduced, which is not preferable. More preferably, it is preferably 0.4 to 0.6 times.

  Further, since the thickness direction of the third flat portion 35 is arranged in the same direction as the thickness direction of the first flat portion 24, the third flat portion 35 is bent in the direction opposite to the direction in which the first flat portion 24 is bent. The extending direction of the first lead portion 23a on the body portion 22 side from the first flat portion 24 and the extending direction of the first lead portion 23a on the distal end side from the third flat portion 35 can be shifted in parallel. When the thickness directions of the one flat portion 24 and the third flat portion 35 are arranged in the vertical direction (direction 28 in FIG. 5), the first lead portion 23a on the distal end side is shifted from the third flat portion 35 in parallel in the vertical direction. can do.

  And since the 3rd flat part 35 is arrange | positioned on the opposite side to the 1st flat part 24 via the 2nd flat part 25, since the distance of the 3rd flat part 35 and the 1st flat part 24 is separated, The amount by which the first lead portion 23a is displaced in parallel in the vertical direction can be increased.

  Furthermore, in this case, since the first flat portion 24 and the second flat portion 25 and the second flat portion 25 and the third flat portion 35 are arranged so that the thickness directions thereof are orthogonal to each other, the second flat portion 25 is easily bent. The direction becomes the horizontal direction (direction 29 in FIG. 5), and the tip of the first lead portion 23a can be corrected in the horizontal direction by bending the second flat portion 25.

  Here, arranging the first flat portion 24 and the second flat portion 25 and the second flat portion 25 and the third flat portion 35 so that the thickness directions thereof are orthogonal to each other means that the thickness direction of the first flat portion 24 and the second flat portion 25 are the same. The angle formed by the thickness direction of the flat portion 25 and the angle formed by the thickness direction of the second flat portion 25 and the thickness direction of the third flat portion 35 are not limited to 90 °, and the first flat portion 24, It is only necessary to correct the tip of the first lead portion 23a in both the horizontal direction and the vertical direction by bending the second flat portion 25 and the third flat portion 35. The thickness direction of the first flat portion 24 and the second flat portion 25 are sufficient. The same effect can be obtained if the angle between the thickness direction of the second flat portion 25 and the angle between the thickness direction of the third flat portion 35 and the thickness direction of the third flat portion 35 is in the range of 80 ° to 100 °. .

  At this time, the interval between the third flat portion 35 and the second flat portion 25 is the same as the interval between the first flat portion 24 and the second flat portion 25, and the coupling portion 26 on the third flat portion 35 side and the second flat portion 25 side. The distance Cl between the coupling portion 26 and the coupling portion 26 on the flat portion 25 side is preferably 0.8 to 3.0 times the diameter Ld of the first lead portion 23a, more preferably 0.8 times. If it is small, the effect that the third flat portion 35 and the second flat portion 25 are easily bent by a small stress is reduced, which is not preferable. If it is larger than 3.0 times, the length of the first lead portion 23a is increased, and the entire coil component is increased. This is not preferable because the size becomes large.

This is because when the punch is pushed into the first lead portion 23a and processed into a flat shape, the receiving side flat portion 32 formed on the surface opposite to the pushed-in side may be an extension of the first lead portion 23a. The extending portion 32a of the receiving side plane portion 32 may extend to the outside of the coupling portion 26 up to about 0.5 times the diameter Ld of the first lead portion 23a.

  Since the extended portion 32a of the receiving side flat portion 32 is work hardened when the conductive wire is crushed, the receiving portion of the receiving flat portion 32a of the third flat portion 35 and the receiving portion of the second flat portion 25 are received. If the extended portion 32a of the side plane portion 32 overlaps perpendicularly in the extending direction of the first lead portion 23a, the third flat portion 35 and the second flat portion 25 are less likely to be deformed when attempting to bend. This is because a larger stress is required than in the case where they do not overlap, and the distance Cl between the coupling portion 26 between the coupling portion 26 on the third flat portion 35 side and the coupling portion 26 on the second flat portion 25 side. Is more preferably 1.0 to 2.0 times the diameter Ld of the first lead portion 23a.

  The thickness dimension Tft of the third flat part 35 and the thickness dimensions Fft and Sft of the first and second flat parts 24 and 25, and the width dimension Tfw of the third flat part 35 and the first and second flat parts 24 and 25. The width dimensions Ffw and Sfw of the third flat portion 35 and the length dimensions Tfl of the first and second flat portions 24 and 25 are the length dimensions Ffl and Sfl of the first and second flat portions 24 and 25, respectively. It is preferable that the dimensions of the second flat parts 24 and 25 are the same, and by making the same dimensions the balance of the bendability of the first flat part 24, the second flat part 25 and the third flat part 35. It is possible to easily correct the position and shape of the first lead portion 23a.

  Next, an example in which the first flat portion 24 and the third flat portion 35 of the coil component shown in FIG. 4 are bent in opposite directions and corrected will be described with reference to FIG.

  As shown in FIG. 6, the first flat portion 24 of the first lead portion 23a is directed upward in the direction 28 (vertical direction in FIG. 6), and the third flat portion 35 of the first lead portion 23a is directed in the direction 28. Bending downward, the position of the leading end side of the first lead portion 23a is moved in parallel to the upper side of the drawing in the direction 28.

  In addition, the first flat portion 24 of the second lead portion 23b is bent downward in the direction 28 in the drawing, and the third flat portion 35 of the first lead portion 23a is bent in the upward direction of the drawing in the direction 28, so that the second lead portion 23b is bent. The position of the front end side of is moved in parallel to the lower side of the drawing in the direction 28.

  In this way, when the front end side of the lead portion 23 is viewed from the direction 29, it can be corrected to a vertically parallel position in the direction 28, and is superimposed on plate-like bus bars (not shown) having different heights. Resistance welding can be done.

  At this time, by bending the second flat portion 25, the tip of the lead portion 23 can be moved in the horizontal direction (direction 29 in FIG. 6), and resistance welding is performed by overlapping the bus bars with different heights and intervals. It is something that can be done.

  And adjustment to the different height and space | interval of a bus-bar can be performed by adjusting the bending amount of the 1st, 2nd, 3rd flat part 24, 25, 35 suitably.

  1 and 4, the first flat portion 24 is formed outside the body portion 22. However, as shown in FIG. 7, the lead portion 23 protrudes from the body portion 22. The coil portion 21 may be formed in a composite material in which the body portion 22 is mixed with a ferrous metal magnetic powder and a thermosetting binder as in the present embodiment. When embedding and molding, the first flat portion 24 having a smaller thickness than the thick lead portion 23 can prevent the composite magnetic material from leaking from the molding die, and stress applied to the lead portion 23 can be reduced. The transmission to the portion 22 can be reduced and the occurrence of cracks in the body portion 22 can be suppressed.

  Next, a method for manufacturing a coil component according to an embodiment of the present invention configured as described above will be described with reference to the drawings. 8-11 is a figure explaining the manufacturing process of the coil components of this Embodiment shown in FIG.

  First, as shown in FIG. 8, a conductor with an insulating coating having a circular cross section is wound to form an air-core coil portion 21, and the first lead portion 23 a and the second lead portion 23 b at both ends of the coil portion 21 are formed. Pull out.

  The first lead portion 23a and the second lead portion 23b are each drawn out in the same direction perpendicular to the winding axis direction of the coil portion 21, and the insulating film is peeled off at the portion protruding to the outside of the body portion 22. .

  Next, as shown in FIG. 9, the first and second lead portions 23a and 23b are crushed by pressing, and the first and second lead portions 23a and 23b are flattened with the first flat portion 24 and the first flat portion 24, respectively. Two flat portions 25 are formed.

  First, the process of forming the 1st flat part 24 is formed by pressing the 1st, 2nd lead parts 23a and 23b with the 1st press metal mold | die 36 shown to Fig.10 (a).

  FIG. 10A shows a side view showing a state in which the coil portion 21, the first and second lead portions 23a, 23b are attached to the first press die 36. It has a lower die 36a for placing the first and second lead portions 23a, 23b and a vertical punch 36b movable in the vertical direction. The lower die 36a is a lower fixed plate of the first press die 36. The vertical punch 36b is fixed to the lower surface of the upper movable plate 36d that can move up and down of the first press die 36.

  The lower fixing plate 36c is provided with a coil positioning projection 36e. By placing the coil portion 21 so that the air core portion of the coil portion 21 is fitted to the coil positioning projection 36e, the first and second lead portions 23a and 23b are lowered. The first and second lead portions 23a and 23b are positioned by a plurality of lead positioning pins 36f placed on the upper surface of the mold 36a and provided on the upper surface of the lower mold 36a.

  The vertical punch 36b is provided in advance on the upper movable plate 36d corresponding to the position where the first flat portion 24 is formed, and the first flat is previously formed on the lower surface of the vertical punch 36b that contacts the first and second lead portions 23a and 23b. A plane parallel to the extending direction of the first and second lead portions 23a and 23b corresponding to the width dimension Ffw of the portion 24 and the length dimension Ffl of the first flat portion 24 is formed.

  The first and second lead portions 23a and 23b are positioned on the lower die 36a of the first press die 36, and the upper movable plate 36d is moved.

  FIG. 10B shows a state in which the upper movable plate 36d is moved. The upper movable plate 36d is moved downward in the vertical direction (downward direction in FIG. 10B), and the first and first By pushing the vertical punch 36b into the two lead portions 23a and 23b with the thickness dimension Fft of the first flat portion 24 as the bottom dead center, the thickness direction in the radial cross section of the first and second lead portions 23a and 23b 2 is smaller than the diameter dimension of the first and second lead parts 23a and 23b and the width direction is larger than the diameter dimension of the first and second lead parts 23a and 23b. Form.

  In this way, the first flat portion is formed by pushing the vertical punch 36b from the vertical direction into the first and second lead portions 23a and 23b drawn in the same direction, thereby forming the first and second portions 23a and 23b. One flat portion 24 can be formed simultaneously with the same thickness direction, compared to the case where the first flat portions 24 of the first and second lead portions 23a and 23b are formed in a separate process. The number of steps can be reduced, and the first flat portions 24 of the first and second lead portions 23a and 23b can be prevented from being displaced in the thickness direction.

  The upper movable plate 36d is preferably provided with a lead pressing rubber 36g having elasticity such as rubber on both sides of the vertical punch 36b. By doing so, the lead pressing rubber 36g is first, It is possible to suppress the warping of the first and second lead portions 23a and 23b by pressing the second lead portions 23a and 23b.

  Next, the process of forming the 2nd flat part 25 is formed by pressing the 1st, 2nd lead parts 23a and 23b with the 2nd press metal mold | die 37 shown to Fig.11 (a).

  FIG. 11A shows a top view showing a state in which the coil part 21, the first and second lead parts 23a, 23b are attached to the second press die 37. An intermediate mold 37a that is sandwiched between the first and second lead portions 23a and 23b and maintains the distance between the first and second lead portions 23a and 23b, and the intermediate mold on both sides of the intermediate mold 37a. A horizontal punch 37b that can move in the horizontal direction toward 37a is provided. The intermediate die 37a is fixed to the upper surface of the lower fixed plate 37c of the second press die 37.

  The horizontal punch 37b is fixed to the intermediate mold 37a side of a horizontal movable plate 37d that is movable in the horizontal direction toward the intermediate mold 37a, and the horizontal punch 37b and the horizontal movable plate 37d are disposed on both sides of the intermediate mold 37a. Have.

  The lower fixing plate 37c is provided with a coil positioning projection 37e, and the first and second lead portions 23a and 23b are arranged by placing the coil portion 21 so that the air core portion of the coil portion 21 is fitted to the coil positioning projection 37e. The coil part 21 is positioned at a position sandwiching the intermediate mold 37a, and the first and second lead parts 23a, 23b are positioned by a plurality of lead positioning pins 37f provided on both side surfaces of the intermediate mold 37a. Yes.

  The horizontal punch 37b is provided in advance on the horizontal movable plate 37d corresponding to the position where the second flat portion 25 is formed, and the width dimension Sfw of the second flat portion 25 and the length of the second flat portion 25 are previously provided on the lower surface of the horizontal punch 37b. A plane parallel to the extending direction of the first and second lead portions 23a and 23b corresponding to the length dimension Sfl is formed.

  The first and second lead portions 23a and 23b are positioned on the intermediate die 37a of the second press die 37, and the horizontal movable plate 37d is moved.

  FIG. 11B shows a state in which the horizontal movable plate 37d is moved. The horizontal movable plate 37d is moved toward the intermediate mold 37a, and the second and second lead portions 23a and 23b are moved to the second. By pushing the horizontal punch 37b with the thickness dimension Sft of the flat part 25 as the bottom dead center, the thickness direction is the first, second lead part 23a, The flat second flat portion 25 shown in FIG. 2 is formed which is smaller than the diameter size of 23b and whose width direction is larger than the diameter size of the first and second lead portions 23a and 23b.

  In this way, the first flat portion 25 is formed by pushing the horizontal punch 37b horizontally into the first and second lead portions 23a and 23b drawn in the same direction from both sides of the intermediate die 37a. The second flat portions 25 of the second portions 23a and 23b can be simultaneously formed with the same thickness direction, and the second flat portions 25 of the first and second lead portions 23a and 23b can be formed separately. The number of steps can be reduced as compared with the case where the steps are formed, and it is possible to eliminate the occurrence of deviation in the thickness direction of the second flat portion 25 of the first and second lead portions 23a and 23b.

  Then, by pressing the second flat portion 25 in the horizontal direction with respect to the first flat portion 24 formed by pressing in the vertical direction, the thickness direction of the first flat portion 24 and the second flat portion 25 are It can be formed so that the thickness direction is orthogonal.

  The upper movable plate 37d is preferably provided with a rubber and other elastic lead pressing rubber 37g on both sides of the horizontal punch 37b. By doing so, the lead pressing rubber 37g is first, It is possible to suppress the warping of the first and second lead portions 23a and 23b by pressing the second lead portions 23a and 23b.

  In the above description, the first flat portion 24 and the second flat portion 25 are formed in this order. However, the second flat portion 25 and the first flat portion 24 may be formed in this order. .

  Next, as shown in FIG. 12, the coil portion 21 is built in the body portion 22, and the body portion 22 in which the first and second lead portions 23 a and 23 b protrude from the body portion 22 in the same direction is formed.

  The body portion 22 is formed by pressure molding a composite material in which an iron-based metal magnetic powder and a thermosetting binder are mixed, and a molding mold ( (Not shown), the first and second lead portions 23a and 23b are released, the composite material in the cavity is pressure-molded, and the resulting molded body is heat treated at a temperature of 180 ° C. Then, the body portion 22 is formed by thermosetting the thermosetting binder.

  Finally, the coil parts shown in FIG. 1 can be obtained by cutting the leading ends of the first and second lead portions 23a and 23b to a predetermined length.

  Further, in the coil component manufacturing method shown in FIG. 4, which is another example of the coil component according to the present embodiment, in addition to the description of the manufacturing method, the first and second lead portions 23a and 23b are further formed by pressing. In the radial cross section of the first and second lead portions 23a and 23b, the thickness direction is smaller than the first and second lead portions 23a and 23b, and the width direction is the first and second lead portions. The method further includes a step of forming a flat third flat portion 35 having a diameter larger than the diameters 23a and 23b.

  The step of forming the third flat portion 35 is formed by pressing the first and second lead portions 23a and 23b with the first press die 36 shown in FIG.

  FIG. 13A shows a side view showing a state in which the coil part 21, the first and second lead parts 23a, 23b are attached to the first press die 36, and the first part shown in FIG. The difference between the one press die 36 and the first press die 36 shown in FIG. 10A corresponds to the first flat portion 24 via the position corresponding to the second flat portion 25 on the upper movable plate 36d. A vertical punch 36b corresponding to the third flat portion 35 is further provided on the side opposite to the vertical punch 36a, and both the first flat portion 24 and the vertical punch 36b corresponding to the third flat portion 35 are provided.

  The vertical punch 36b corresponding to the third flat portion 35 is provided on the upper movable plate 36d corresponding to the position where the third flat portion 35 is formed, and is in contact with the first and second lead portions 23a and 23b. A plane parallel to the extending direction of the first and second lead portions 23a and 23b corresponding to the width dimension Tfw of the third flat portion 35 and the length dimension Tfl of the third flat portion 35 is formed on the lower surface of the first flat portion 35.

  FIG. 13B shows a state in which the upper movable plate 36d is moved. The upper movable plate 36d is moved downward in the vertical direction (downward direction in FIG. 13B). By pushing the vertical punch 36b corresponding to the first flat portion 24 and the third flat portion 35 into the second lead portions 23a and 23b, the flat shape shown in FIG. 5 is applied to the first and second lead portions 23a and 23b. The first flat part 24 and the third flat part 35 are formed simultaneously.

  By doing in this way, the 3rd flat part 35 is arrange | positioned in the 1st, 2nd lead parts 23a and 23b on the opposite side to the 1st flat part 24 via the 2nd flat part 25, respectively, and a 3rd flat part is carried out. The thickness direction of the portion 35 can be formed in the same direction as the thickness direction of the first flat portion 24, and the coil component shown in FIG. 4 can be obtained.

  Moreover, since the 3rd flat part 35 and the 1st flat part 24 can be formed simultaneously, compared with the case where the 3rd flat part 35 and the 1st flat part 24 are formed in another process, the number of processes is reduced. In addition, the third flat portion 35 and the first flat portion 24 can be prevented from being displaced in the thickness direction.

  The coil component according to the present invention is industrially useful because it facilitates the correction of the position and shape of the lead portion of the coil component in accordance with the interval between different bus bars of the electronic device, and can increase the versatility of the coil component. .

DESCRIPTION OF SYMBOLS 21 Coil part 22 Body part 23 Lead part 23a 1st lead part 23b 2nd lead part 24 1st flat part 25 2nd flat part 26 Coupling part 27 direction 28 direction 29 direction 30 bulging part 31 push side plane part 32 receiving Side plane portion 32a Extending portion of receiving side plane portion 33 Bus bar 33a Bus bar 33b Bus bar 34 Welded portion 35 Third flat portion 36 First press die 36a Lower die 36b of first press die 36b Vertical of first press die Punch 36c Lower fixed plate of the first press die 36d Upper movable plate of the first press die 36e Coil positioning protrusion of the first press die 36f Lead positioning pin of the first press die 36g Lead of the first press die Holding rubber 37 Second press die 37a Intermediate die of second press die 37b Horizontal press die of second press die Inch 37c Lower fixed plate of the second press die 37d Horizontal movable plate of the second press die 37e Coil positioning protrusion of the second press die 37f Lead positioning pin of the second press die 37g Lead of the second press die Presser rubber

Claims (2)

A coil portion in cross-section is wound is circular conductor,
A body part in which the coil part is incorporated;
And a first lead and the second lead portion at both ends of the coil portion protruding from said body portion,
The first and second lead portions are
Wherein each first, in the radial cross section of the second lead portion, wherein the thickness direction first, smaller than the diameter of the second lead portion, wherein the first width direction, have greater than the diameter of the second lead portion a flat of the first flat portion and a second flat portion,
On both sides of each of the first and second flat portions, there is a coupling portion that connects the diameter portion of the first and second lead portions and the thickness portion of the first and second flat portions. Have
The first flat part and the second flat part are:
Between the coupling part on the first flat part side and the coupling part on the second flat part side, an interval of 0.8 to 3.0 times the radial dimension of the first and second lead parts Have
Are arranged such that the thickness direction of the front SL and the second flat portion thickness direction of the first flat portion is perpendicular,
Wherein the first lead portion and the second lead portion, is stretched in the same direction, the first, the thickness direction of the second lead portion each of said first flat portion is arranged in the same direction, the coil component. The first and second lead portions are
Wherein each first, in the radial cross section of the second lead portion, wherein the thickness direction first, smaller than the diameter of the second lead portion, wherein the first width direction, have greater than the diameter of the second lead portion It further has a flat third flat part,
On both sides of the third flat part, there is a coupling part that connects a part of the diameter of the first and second lead parts and a part of the thickness of the third flat part,
The second flat part and the third flat part are:
Between the coupling part on the second flat part side and the coupling part on the third flat part side, an interval of 0.8 to 3.0 times the radial dimension of the first and second lead parts Have
It said third thickness direction of the flat portion is arranged in the same direction as the thickness direction of the first flat portion, the coil component according to claim 1, wherein.

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