Inductor component and method for manufacturing the same

Abstract

The present invention provides an inductor component capable of achieving miniaturization and a method for manufacturing the same. The inductor component comprises: an annular core; and a coil, which includes a plurality of pin members, adjacent pin members are connected so that the coil is wound around the core, adjacent first pin members and second pin members have a fusion portion formed by mutually fusion of the end of the first pin member and the end of the second pin member, and the end of the second pin member has a contraction portion with a narrowed width.

Description

Technical Field

[0001] The present invention relates to an inductive component and a method for manufacturing the same. Background Art

[0002] In the past, there was a structure described in Japanese Utility Model Gazette No. 50-20152 (Patent Document 1) as an inductor component. The inductor component includes a ring-shaped core and a coil wound around the core. The coil includes a first wire member in a "コ" shape and a second wire member in a straight line, and the end of the first wire member and the end of the second wire member are connected to form one turn of the coil.

[0003] Patent Document 1: Japanese Utility Model Patent Publication No. 50-20152

[0004] However, in the above-mentioned conventional inductor component, when the end of the first wire member and the end of the second wire member are to be welded to form a welded portion, the inventors of the present application have found that, as the inductor component is miniaturized, the gap between the welded portions of adjacent turns of the coil becomes a problem. Specifically, if the first and second wire members are laser welded to form a welded portion, there is a problem that the welded portion extends into the gap between adjacent turns of the coil. Therefore, it is not easy to reduce the gap between adjacent turns of the coil and reduce the size of the coil. Summary of the invention

[0005] Therefore, the present disclosure is to provide an inductor component capable of achieving miniaturization and a method for manufacturing the same.

[0006] In order to solve the above-mentioned problems, an inductor component according to one aspect of the present disclosure includes:

[0007] an annular core; and

[0008] A coil comprising a plurality of pin members, wherein adjacent pin members are connected so that the coil is wound around the core body, and adjacent first and second pin members have a welded portion formed by mutually welding an end portion of the first pin member and an end portion of the second pin member.

[0009] The second pin member has a narrowed portion at an end portion thereof.

[0010] Here, the width refers to the width in a direction perpendicular to a first plane including the center line of the end of the first pin member and the center line of the end of the second pin member. The ends of the first and second pin members are portions where welded portions are provided.

[0011] According to the above aspect, since the second pin member has a narrowed portion at the end thereof, the gap between adjacent turns of the coil can be reduced to reduce the size of the coil, thereby achieving miniaturization of the inductor component.

[0012] Preferably, in a technical solution of the inductor component,

[0013] The welded portion is formed by welding the end surface of the end portion of the first pin member and the peripheral surface of the end portion of the second pin member to each other.

[0014] The weld portion includes the constricted portion having a narrowed width when viewed from a direction along a center line of an end portion of the second pin member.

[0015] According to the above technical solution, the weld portion has a contraction portion, so it is possible to reduce the weld portion from protruding into the gap between adjacent turns of the coil. As a result, the gap between adjacent turns of the coil can be reduced, and the inductor component can be miniaturized.

[0016] Preferably, in one embodiment of the inductor component, the weld portion is not provided on the outer edge of the second pin member when viewed from a direction orthogonal to a first plane including a center line of an end of the first pin member and a center line of an end of the second pin member.

[0017] Here, the outer edge of the second pin member refers to an outer edge on the opposite side to the end (inner side) of the first pin member when viewed from a direction perpendicular to the first plane.

[0018] According to the above technical solution, the welding part is not provided on the outer edge of the second pin member. Therefore, the surface tension of the welding part toward the outer edge of the second pin member in the melted state can be suppressed, and it will not become a ball-shaped part that covers the outer edge. Therefore, the size of the welding part can be further reduced, the gap between adjacent turns of the coil can be further reduced, and the miniaturization of the inductor component can be achieved. In addition, the situation where the welding part protrudes outward from the outer edge of the second pin member can be reduced, and the outer shape of the coil can be reduced.

[0019] Preferably, in a technical solution of the inductor component, when viewed from the direction along the center line of the end of the above-mentioned second pin member, the above-mentioned welding portion is arranged on the inner side than the second plane, and the above-mentioned second plane includes the center line of the end of the above-mentioned second pin member and is orthogonal to the above-mentioned first plane.

[0020] Here, the inner side than the second plane means the end side of the first pin member than the second plane when viewed in the direction along the center line of the end portion of the second pin member.

[0021] According to the above aspect, the welded portion is provided inside the second plane, so that the size of the welded portion can be further reduced, the gap between adjacent turns of the coil can be further reduced, and the inductor component can be miniaturized.

[0022] Preferably, in one technical solution of the inductor component, when viewed from the direction along the center line of the end of the second pin member, the width of the portion of the first pin member excluding the weld portion is smaller than the width of the portion of the second pin member excluding the weld portion.

[0023] According to the above technical solution, the width of the portion of the first pin member excluding the welded portion is smaller than the width of the portion of the second pin member excluding the welded portion, so that the width of the welded portion can be prevented from becoming too large. As a result, a welded portion with a smaller width can be formed compared to a welded portion formed by the first pin member and the second pin member having the same diameter, so that the gap between adjacent turns of the coil can be reduced, and the inductor component can be miniaturized.

[0024] Preferably, in one aspect of the inductor component, a cross-sectional area of ​​a portion of the first pin member excluding the welded portion is equal to a cross-sectional area of ​​a portion of the second pin member excluding the welded portion.

[0025] Here, the cross-sectional areas of the first and second pin members refer to the average cross-sectional areas of planes perpendicular to the extending directions of the first and second pin members, respectively.

[0026] According to the above technical solution, the cross-sectional area of ​​the first pin member excluding the weld portion is equal to the cross-sectional area of ​​the second pin member excluding the weld portion. Therefore, even if the width of the first pin member excluding the weld portion becomes smaller, the increase in resistance of this part can be suppressed.

[0027] Preferably, in a technical solution of a method for manufacturing an inductor component, the inductor component comprises:

[0028] an annular core; and

[0029] The coil includes a plurality of pin members, and the adjacent pin members are connected so that the coil is wound around the core body.

[0030] The manufacturing method of the inductor component comprises:

[0031] A step of arranging the plurality of pin members on the core body in a state where, in the adjacent first and second pin members, the end surface of the end portion of the first pin member and the peripheral surface of the end portion of the second pin member are in contact with each other and the width of the end portion of the first pin member is smaller than the width of the end portion of the second pin member when viewed from a direction along the center line of the end portion of the second pin member; and

[0032] A step of applying heat to the first pin member and the second pin member to weld an end surface of an end portion of the first pin member and a peripheral surface of an end portion of the second pin member to each other to form a welded portion.

[0033] According to the above technical solution, when viewed from the direction along the center line of the end of the second pin member, in a state where the width of the end of the first pin member is smaller than the width of the end of the second pin member, a plurality of pin members are arranged on the core body, and the end surface of the end of the first pin member and the peripheral surface of the end of the second pin member are mutually welded to form a welded portion, so that when viewed from the direction along the center line of the end of the second pin member, the welded portion has a contraction portion with a narrowed width. Thus, the gap between adjacent turns of the coil where the welded portion protrudes can be reduced, the gap between adjacent turns of the coil can be reduced, and the inductor component can be miniaturized.

[0034] Preferably, in a technical solution of a method for manufacturing an inductor component, the inductor component comprises:

[0035] Ring-shaped core;

[0036] and a coil including a plurality of pin members, wherein adjacent pin members are connected so that the coil is wound around the core body,

[0037] The manufacturing method of the inductor component comprises:

[0038] A step of arranging the plurality of pin members on the core body in a state where, in the adjacent first and second pin members, an end face of an end portion of the first pin member and a peripheral face of an end portion of the second pin member are in contact with each other and a width of the end portion of the first pin member decreases toward the end face when viewed from a direction along a center line of the end portion of the second pin member; and

[0039] A step of applying heat to the first pin member and the second pin member to weld an end surface of an end portion of the first pin member and a peripheral surface of an end portion of the second pin member to each other to form a welded portion.

[0040] According to the above technical solution, when viewed from the direction along the center line of the end of the second pin member, in a state where the width of the end of the first pin member decreases toward the end face, a plurality of pin members are arranged on the core body, and the end face of the end of the first pin member and the peripheral surface of the end of the second pin member are welded to each other to form a welded portion, so that when viewed from the direction along the center line of the end of the second pin member, the welded portion has a contraction portion with a narrowed width. As a result, it is possible to reduce the situation where the welded portion protrudes into the gap between adjacent turns of the coil, reduce the gap between adjacent turns of the coil, and achieve miniaturization of the inductor component.

[0041] According to an aspect of the present disclosure, an inductor component and a method for manufacturing the same can be miniaturized. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1It is an upper perspective view showing the inductor component according to the first embodiment of the present invention.

[0043] Figure 2 This is a three-dimensional view of the bottom of the inductor component.

[0044] Figure 3 This is a bottom perspective view showing the interior of the inductor component.

[0045] Figure 4 This is an exploded perspective view of the inductor component.

[0046] Figure 5 is a cross-sectional view of the inductor component.

[0047] Fig. 6A yes Figure 3 An enlarged view of part A.

[0048] Figure 6B Yes means Fig. 6A A bottom view of the bending pin member and the second straight pin member as actually welded together as viewed from the Z direction.

[0049] Figure 6C is from Figure 6B Side view viewed in the Y direction.

[0050] Figure 7 It is a cross-sectional view showing a second embodiment of the pin member.

[0051] Fig. 8A The third embodiment of the method for manufacturing an inductor component is shown, and is a bottom view showing a state before welding.

[0052] Figure 8B The third embodiment of the method for manufacturing an inductor component is shown, and is a bottom view showing a state after welding.

[0053] Description of Reference Numerals

[0054] 1...inductor component; 2...housing; 21...bottom plate; 22...cover; 3...core; 301...first end surface; 302...second end surface; 303...inner peripheral surface; 304...outer peripheral surface; 41...first coil; 410...bent pin member (second pin member); 410a...conductor portion; 410b...film; 410c...center line; 410e...end portion; 410f...peripheral surface; 410h...width; 410i...outer edge; 410j...outermost end portion; 411...first straight pin member (first pin member); 412, 412A, 412B...second straight pin member (first pin member); 411a, 412a...conductor portion; 411c...mounting piece; 412c ...center line; 412e...end; 412f...end face; 412h...width; 412j...tapered surface; 42...second coil; 420...bending pin member (second pin member); 420a...conductor portion; 420b...membrane; 421...first straight pin member (first pin member); 422...second straight pin member (first pin member); 421a, 422a...conductor portion; 421c...mounting sheet; 51-54...first to fourth electrode terminals; 51a-54a...mounting portion; 60...insulating member; 70...adhesive member; 80...welding portion; 80a...first region; 80b...second region; 81...constricted portion; S1...first plane; S2...second plane. DETAILED DESCRIPTION

[0055] Hereinafter, an inductor component according to one aspect of the present disclosure will be described in detail based on the illustrated embodiments. Note that some of the drawings are schematic and may not reflect actual dimensions or ratios.

[0056] (First embodiment)

[0057] (Structure of inductor components)

[0058] Figure 1 It is a top perspective view showing an inductor component according to one embodiment of the present invention. Figure 2 This is a three-dimensional view of the bottom of the inductor component. Figure 3 This is a bottom perspective view showing the interior of the inductor component. Figure 4 This is an exploded perspective view of the inductor component.

[0059] like Figure 1 to Figure 4As shown, the inductor component 1 includes a housing 2, a ring-shaped core 3 housed in the housing 2, a first coil 41 and a second coil 42 wound around the core 3, and first to fourth electrode terminals 51 to 54 mounted on the housing 2 and connected to the first coil 41 and the second coil 42. The inductor component 1 is, for example, a common mode choke coil or the like.

[0060] The shell 2 has a bottom plate portion 21 and a box-shaped cover portion 22 covering the bottom plate portion 21. The shell 2 is made of a material having strength and heat resistance, preferably a flame retardant material. The shell 2 is made of resin or ceramic such as PPS (polyphenylene sulfide), LCP (liquid crystal polymer), PPA (polyphthalamide). A core 3 is provided on the bottom plate portion 21, and the central axis of the core 3 is orthogonal to the bottom plate portion 21. The central axis of the core 3 refers to the central axis of the inner diameter hole portion of the core 3. When viewed from the central axis direction of the core 3, the shape of the shell 2 (bottom plate portion 21 and cover portion 22) is rectangular. In this embodiment, the shape of the shell 2 is rectangular.

[0061] Here, the short side direction of the shell 2 observed from the central axis direction of the core 3 is set as the X direction, the long side direction of the shell 2 observed from the central axis direction of the core 3 is set as the Y direction, and the direction perpendicular to the X direction and the Y direction, that is, the height direction of the shell 2 is set as the Z direction. The bottom plate 21 and the cover 22 of the shell 2 are arranged face to face in the Z direction, the bottom plate 21 is on the lower side, and the cover 22 is on the upper side, the upper side is set as the positive direction of the Z direction, and the lower side is set as the negative direction of the Z direction. In addition, when the shape of the bottom plate 21 of the shell 2 is a square, the length of the shell 2 in the X direction is the same as the length of the shell 2 in the Y direction.

[0062] The first to fourth electrode terminals 51 to 54 are mounted on the bottom plate 21. The first electrode terminal 51 and the second electrode terminal 52 are located at two corners opposite to each other in the Y direction of the bottom plate 21, and the third electrode terminal 53 and the fourth electrode terminal 54 are located at two corners opposite to each other in the Y direction of the bottom plate 21. The first electrode terminal 51 and the third electrode terminal 53 are opposite to each other in the X direction, and the second electrode terminal 52 and the fourth electrode terminal 54 are opposite to each other in the X direction.

[0063] When viewed from the central axis, the core 3 is in an oblong shape (track shape). When viewed from the central axis, the core 3 includes: a pair of long side portions 31 extending along the major axis and facing each other in the minor axis direction; and a pair of short side portions 32 extending along the minor axis and facing each other in the major axis direction. In addition, when viewed from the central axis, the core 3 may be in a rectangular or elliptical shape.

[0064] The core 3 is composed of a magnetic core, and the magnetic core is made of, for example, a ceramic core such as ferrite or an iron-based powder molding or nanocrystalline foil. The core 3 has: a first end face 301 and a second end face 302 that are opposite to each other in the direction of the central axis; and an inner peripheral surface 303 and an outer peripheral surface 304. The first end face 301 is the lower end face of the core 3 and faces the inner surface of the bottom plate portion 21. The second end face 302 is the upper end face of the core 3 and faces the inner surface of the cover portion 22. The core 3 is housed in the shell 2 so that the long axis direction of the core 3 is consistent with the Y direction.

[0065] The cross section of the core 3 that is orthogonal to the circumferential direction is rectangular. The first end face 301 and the second end face 302 are arranged perpendicular to the central axis direction of the core 3. The inner peripheral surface 303 and the outer peripheral surface 304 are arranged parallel to the central axis direction of the core 3. In this specification, "vertical" is not limited to a completely vertical state, but also includes a substantially vertical state. In addition, "parallel" is not limited to a completely parallel state, but also includes a substantially parallel state.

[0066] The lower part of the core 3 is covered with an insulating member 60. The insulating member 60 is made of, for example, super engineering plastics such as LCP, PPA, and PPS, whereby the heat resistance, insulation, and processability of the insulating member 60 are improved.

[0067] The insulating member 60 is formed in an annular shape and has an annular recess 61 covering the lower portion of the core 3. Thus, the insulating member 60 can be mounted on the core 3 by fitting the annular recess 61 of the insulating member 60 into the lower portion of the core 3.

[0068] The core 3 has an embedding groove 35 in which the insulating member 60 is embedded. The embedding groove 35 opens at the first end surface 301, the inner peripheral surface 303, and the outer peripheral surface 304 of the core 3. In this way, by embedding the outer peripheral surface of the insulating member 60 into the embedding groove 35 of the core 3, the protrusion of the insulating member 60 from the outer surface of the core 3 can be reduced. In addition, the installation of the insulating member 60 becomes easy, and the misalignment of the insulating member 60 can be prevented.

[0069] The first coil 41 is wound around the core 3 and the insulating member 60 between the first electrode terminal 51 and the second electrode terminal 52. One end of the first coil 41 is connected to the first electrode terminal 51. The other end of the first coil 41 is connected to the second electrode terminal 52.

[0070] The second coil 42 is wound around the core 3 and the insulating member 60 between the third electrode terminal 53 and the fourth electrode terminal 54. One end of the second coil 42 is connected to the third electrode terminal 53. The other end of the second coil 42 is connected to the fourth electrode terminal 54.

[0071] The first coil 41 and the second coil 42 are wound along the long axis direction. In other words, the first coil 41 is wound around the long side portion 31 on one side of the core 3, and the second coil 42 is wound around the long side portion 31 on the other side of the core 3. The winding axis of the first coil 41 and the winding axis of the second coil 42 are parallel. The first coil 41 and the second coil 42 are symmetrical with respect to the long axis of the core 3.

[0072] The number of turns of the first coil 41 is the same as the number of turns of the second coil 42. The winding direction of the first coil 41 around the core 3 and the winding direction of the second coil 42 around the core 3 are opposite to each other. In other words, the winding direction of the first coil 41 from the first electrode terminal 51 to the second electrode terminal 52 and the winding direction of the second coil 42 from the third electrode terminal 53 to the fourth electrode terminal 54 are opposite to each other.

[0073] Furthermore, the first to fourth electrode terminals 51 to 54 are connected so that the common mode current flows from the first electrode terminal 51 toward the second electrode terminal 52 in the first coil 41 and flows from the third electrode terminal 53 toward the fourth electrode terminal 54 in the second coil 42. In other words, the common mode current flows in the same direction. If the common mode current flows to the first coil 41, a first magnetic flux based on the first coil 41 is generated in the core 3. If the common mode current flows to the second coil 42, a second magnetic flux is generated in the core 3, and the second magnetic flux is generated in the core 3 in a direction that reinforces the first magnetic flux. Therefore, the first coil 41 and the core 3 and the second coil 42 and the core 3 act as inductance components and remove noise from the common mode current.

[0074] The first coil 41 is formed by welding a plurality of pin members together by, for example, laser welding, spot welding, etc. Figure 3 It does not show the state where a plurality of pin members are actually welded, but shows the state where a plurality of pin members are assembled.

[0075] The plurality of pin members are not printed wiring or wires but rod-shaped members. The pin members are rigid and are less likely to be bent than wires used for connection between electronic component modules.

[0076] The plurality of pin members include a bent pin member 410 bent in a substantially U-shape, and linear pin members 411 and 412 extending substantially in a straight line (substantially in an I-shape). In this embodiment, the bent pin member 410 corresponds to the "second pin member" described in the claims, and the linear pin members 411 and 412 correspond to the "first pin member" described in the claims.

[0077] The first coil 41 includes, in order from one end to the other end, a first linear pin member 411 on one end side (one side), a plurality of sets of bent pin members 410 and second linear pin members 412, and a first linear pin member 411 on the other end side (the other side). The first linear pin member 411 and the second linear pin member 412 have different lengths. If the spring index of the bent pin member 410 is described, it is as follows: Figure 5 As shown in FIG. 1 , when the bending pin member 410 is wound around the second end face 302, the inner peripheral face 303 and the outer peripheral face 304 of the core body 3, the spring index Ks of the bending pin member 410 is less than 3.6 for the curvature radius R1 of the bending pin member 410 at the corner of the outer peripheral face 304 of the core body 3 and the curvature radius R2 of the bending pin member 410 at the corner of the inner peripheral face 303 of the core body 3. The spring index Ks is represented by the curvature radius R1, R2 of the bending pin member / the wire diameter r of the bending pin member. In this way, the bending pin member 410 is a member with high rigidity and is not easy to bend.

[0078] The bending pin member 410 and the second linear pin member 412 are alternately connected by a welding method such as laser welding or spot welding. One end of the second linear pin member 412 is connected to one end of the bending pin member 410, and the other end of the second linear pin member 412 is connected to one end of another bending pin member 410. By repeating this operation, a plurality of bending pin members 410 and second linear pin members 412 are connected, and the connected plurality of bending pin members 410 and second linear pin members 412 are spirally wound around the core 3. In other words, a unit element of one turn is formed by one set of the bending pin member 410 and the second linear pin member 412.

[0079] The bending pin member 410 is arranged parallel to the second end surface 302, the inner peripheral surface 303 and the outer peripheral surface 304 of the core body 3. The second linear pin member 412 is arranged parallel to the first end surface 301 of the core body 3. The first linear pin member 411 is arranged parallel to the first end surface 301 of the core body 3.

[0080] The adjacent bending pin members 410 are fixed by the bonding member 70. Thus, the mounting state of the plurality of bending pin members 410 to the core body 3 can be stabilized. Similarly, the adjacent first linear pin members 411 and second linear pin members 412 are fixed by the bonding member 70, and the adjacent second linear pin members 412 are fixed by the bonding member 70. Thus, the mounting state of the plurality of first linear pin members 411 and second linear pin members 412 to the core body 3 can be stabilized.

[0081] The first electrode terminal 51 is connected to one end of the first linear pin member 411 on one side, and the other end of the first linear pin member 411 on one side is connected to one end of the bent pin member 410 adjacent to the first linear pin member 411 on one side. One end of the first linear pin member 411 on one side has a mounting piece 411c. The first electrode terminal 51 has a mounting portion 51a that enters the housing 2. The mounting piece 411c of the first linear pin member 411 on one side is connected to the mounting portion 51a of the first electrode terminal 51.

[0082] The second electrode terminal 52 is connected to one end of the first linear pin member 411 on the other side, and the other end of the first linear pin member 411 on the other side is connected to one end of the second linear pin member 412 adjacent to the first linear pin member 411 on the other side. The mounting piece 411c at one end of the first linear pin member 411 on the other side is connected to the mounting portion 52a of the second electrode terminal 52.

[0083] The second coil 42 is composed of a plurality of pin members, similar to the first coil 41. In other words, the second coil 42 includes, in order from one end to the other end, a first linear pin member 421 on one end side (one side), a plurality of sets of bent pin members 420 and second linear pin members 422, and a first linear pin member 421 on the other end side (the other side). The bent pin members 420 and the second linear pin members 422 are alternately connected and wound around the core 3. In other words, a plurality of bent pin members 420 and the second linear pin members 422 are connected, and the connected plurality of bent pin members 420 and the second linear pin members 422 are wound around the core 3 in a spiral shape.

[0084] The third electrode terminal 53 is connected to one end of the first linear pin member 421, and the other end of the first linear pin member 421 is connected to one end of the bent pin member 420 adjacent to the first linear pin member 421. The mounting piece 421c at one end of the first linear pin member 421 is connected to the mounting portion 53a of the third electrode terminal 53.

[0085] The fourth electrode terminal 54 is connected to one end of the first linear pin member 421 on the other side, and the other end of the first linear pin member 421 on the other side is connected to one end of the second linear pin member 412 adjacent to the first linear pin member 421 on the other side. The mounting piece 421c at one end of the first linear pin member 421 on the other side is connected to the mounting portion 54a of the fourth electrode terminal 54.

[0086] like Figure 3 As shown, the first coil 41 and the second coil 42 (pin members 410 to 412, 420 to 422) each include a conductor and a coating covering the conductor. The conductor is, for example, a copper wire, and the coating is, for example, a polyamide-imide resin. The thickness of the coating is, for example, 0.02 to 0.04 mm.

[0087] The first linear pin members 411 and 421 are composed of conductor portions 411a and 421a without a coating. The second linear pin members 412 and 422 are composed of conductor portions 412a and 422a without a coating. The bent pin members 410 and 420 are composed of conductor portions 410a and 420a and coatings 410b and 420b.

[0088] The conductor parts 410a and 420a are exposed from the films 410b and 420b at one end and the other end of the bending pin members 410 and 420. In other words, the first linear pin members 411 and 421, the second linear pin members 412 and 422, and the bending pin members 410 and 420 are welded to each other at the exposed conductor parts 411a, 421a, 412a, 422a, 410a and 420a.

[0089] Fig. 6A yes Figure 3 It is an enlarged view of the A part and a bottom view viewed from the lower side in the Z direction. Fig. 6A This does not represent the actual welding state of the bending pin member 410 and the second linear pin member 412, but represents the assembled state of the bending pin member 410 and the second linear pin member 412. Fig. 6A As shown, the end surface 412f of the end portion 412e of the second linear pin member 412 and the peripheral surface 410f of the end portion 410e of the bent pin member 410 are in contact with each other.

[0090] The bending pin member 410 and the second linear pin member 412 are both cylindrical in shape. In other words, the cross-sectional shapes of the bending pin member 410 and the second linear pin member 412 are both circular. The cross section of the bending pin member 410 is a cross section at a plane perpendicular to the direction in which the bending pin member 410 extends, and the cross section of the second linear pin member 412 is a cross section at a plane perpendicular to the direction in which the second linear pin member 412 extends.

[0091] The end 410e of the bending pin member 410 and the end 412e of the second linear pin member 412 are welded to each other. The end surface 412f of the end 412e of the second linear pin member 412 is a concave surface having a shape corresponding to the peripheral surface 410f of the end 410e of the bending pin member 410.

[0092] When viewed from the direction along the center line 410c of the end 410e of the bending pin member 410 (hereinafter referred to as the Z direction), the width 412h of the second linear pin member 412 is smaller than the width 410h of the bending pin member 410. Here, the width refers to the width in the direction orthogonal to the first plane S1 including the center line 412c of the end 412e of the second linear pin member 412 and the center line 410c of the end 410e of the bending pin member 410. In this embodiment, the diameter of the second linear pin member 412 is smaller than the diameter of the bending pin member 410.

[0093] The center line 410c of the end 410e of the bending pin member 410 refers to the center line 410c of the portion including the end 410e of the bending pin member 410. In other words, the bending pin member 410 is substantially U-shaped, and the center line of the bending pin member 410 extends in different directions depending on the position, and thus, it becomes the center line 410c of the end 410e of the bending pin member 410. Similarly, the center line 412c of the end 412e of the second linear pin member 412 refers to the center line 412c of the portion including the end 412e of the second linear pin member 412.

[0094] Figure 6B express Fig. 6A The bending pin member 410 and the second straight pin member 412 are actually welded. Figure 6B As shown in the figure, the adjacent second linear pin member 412 and the bending pin member 410 have a welded portion 80 formed by welding the end 412e of the second linear pin member 412 and the end 410e of the bending pin member 410. Specifically, the welded portion 80 is formed by welding the end face 412f of the end 412e of the second linear pin member 412 and the peripheral surface 410f of the end 410e of the bending pin member 410. For convenience, the welded portion 80 is indicated by a hatching. By forming the welded portion 80, the end face 412f of the second linear pin member 412 and the peripheral surface 410f of the bending pin member 410 do not have their respective boundary surfaces and are formed integrally. For convenience, the end face 412f and the peripheral surface 410f before welding are indicated by imaginary lines.

[0095] The weld 80 is a structure in which the metal temporarily becomes liquid and solidifies, so the metal crystals of the weld 80 have no directionality due to the mixing of the liquid metal. On the other hand, for the portion other than the weld 80 of the pin members 410 and 412, the metal is not melted, so the metal crystals of this portion have directionality. Therefore, the difference between the weld 80 and the portion other than the weld 80 of the pin members 410 and 412 can be confirmed by visual observation or cross-sectional grinding.

[0096] The end 410e of the bending pin member 410 has a narrowed contraction portion 81. Specifically, when viewed from the Z direction, the welded portion 80 has a narrowed contraction portion 81. When viewed from the Z direction, the contraction portion 81 is provided at a position where the end surface 412f of the second linear pin member 412 and the peripheral surface 410f of the bending pin member 410 intersect. Specifically, the contraction portion 81 is provided at the center of the welded portion 80 in the X direction and at positions on both sides of the welded portion 80 in the Y direction.

[0097] According to this, the welded portion 80 has the contracted portion 81, so that the welded portion 80 can be reduced from protruding to the first coil 41 (see Figure 3 ). As a result, the gaps between adjacent turns of the first coil 41 can be reduced, and the inductor component 1 can be miniaturized. In particular, since the core 3 is an oblong (track shape), even if the welded portions 80 of adjacent turns are arranged along the long axis (Y direction), the distance between the welded portions 80 of adjacent turns can be ensured.

[0098] In addition, as shown in the first embodiment, when the second linear pin member 412 with a narrow width and the bending pin member 410 with a normal width (diameter) are welded, if the width of the welding portion 80 is not greater than the diameter of the bending pin member 410, even if the welding portion 80 does not have a contraction portion 81, the distance between the adjacent turns of the second linear pin members 412, 412 can be close.

[0099] The same is true for the welded portion formed between the adjacent first linear pin member 411 and the bent pin member 410. The same is true for the second coil 42, in other words, the same is true for the welded portion formed between the adjacent first linear pin member 421 and the bent pin member 420 and the welded portion formed between the adjacent second linear pin member 422 and the bent pin member 420. The same also applies to the following description.

[0100] Figure 6C is from Figure 6B The figure is observed in the Y direction. Figure 6B and Figure 6C As shown, when viewed from a direction perpendicular to the first plane S1 (hereinafter referred to as the Y direction), the welded portion 80 is not provided on the outer edge 410 i of the bending pin member 410 .

[0101] Here, the outer edge 410i of the bending pin member 410 refers to the outer edge of the second linear pin member 412 on the opposite side to the end 412e (inner side) when viewed from the Y direction. The bending pin member 410 is a cylinder, and therefore, the outer edge 410i of the bending pin member 410 is equivalent to a line. In addition, when the bending pin member 410 is a prism, the outer edge 410i of the bending pin member 410 is equivalent to a surface.

[0102] According to this, the welding part 80 is not provided at the outer edge 410i of the bending pin member 410, so that the surface tension of the welding part 80 toward the outer edge 410i of the bending pin member 410 can be suppressed, and it will not become a spherical shape that covers the outer edge 410i. Therefore, the size of the welding part 80 can be further reduced, and the gap between adjacent turns of the first coil 41 can be further reduced, and the inductor component 1 can be miniaturized. In addition, the welding part 80 can be reduced from protruding outward from the outer edge 410i of the bending pin member 410, and the outer shape of the first coil 41 can be reduced.

[0103] When viewed from the Z direction, the welded portion 80 is provided on the inner side of the second plane S2 which includes the center line 410c of the end portion 410e of the bent pin member 410 and is orthogonal to the first plane S1. Here, when viewed from the Z direction, on the inner side of the second plane S2 means on the end portion 412e side of the second linear pin member 412 on the inner side of the second plane S2.

[0104] According to this, the weld portion 80 is provided inside the second plane S2 , so that the size of the weld portion 80 can be further reduced, and the gap between adjacent turns of the first coil 41 can be further reduced, so that the inductor component 1 can be miniaturized.

[0105] When viewed from the Z direction, the width 412h of the second linear pin member 412 excluding the welded portion 80 is smaller than the width 410h of the bent pin member 410 excluding the welded portion 80. The welded portion 80 is formed by fusing the end portion 412e of the second linear pin member 412 and the end portion 410e of the bent pin member 410, and therefore, the maximum width of the welded portion 80 may be larger than the width 412h of the second linear pin member 412 excluding the welded portion 80 or the width 410h of the bent pin member 410 excluding the welded portion 80.

[0106] According to this, the width 412h of the second linear pin member 412 excluding the welded portion 80 is smaller than the width 410h of the bent pin member 410 excluding the welded portion 80, so that the width of the welded portion 80 can be prevented from becoming too large. In this way, the welded portion 80 can be formed to be smaller than the welded portion 80 formed by the second linear pin member 412 and the bent pin member 410 having the same diameter, so that the gap between adjacent turns of the first coil 41 can be reduced, and the inductor component 1 can be miniaturized.

[0107] like Figure 6C As shown, when viewed from the Y direction, the welded portion 80 is formed in a triangular shape. Here, the triangle is not limited to an ideal triangle, but also includes a substantial triangle whose corners and sides are curved. Specifically, when viewed from the Y direction, one side of the triangle is located in the negative Z direction, and one corner of the triangle is located in the positive Z direction. Preferably, the welded portion 80 is in a conical shape.

[0108] Thus, since the weld portion 80 is formed in a triangular shape, the weld portion 80 does not become a spherical shape, and the size of the weld portion 80 can be further reduced. The gap between adjacent turns of the first coil 41 can be further reduced, and the inductor component 1 can be miniaturized.

[0109] When viewed from the Y direction, the region of the welded portion 80 at the end 412e of the second straight pin member 412 (hereinafter referred to as the first region 80a) is larger than the region of the welded portion 80 at the end 410e of the bent pin member 410 (hereinafter referred to as the second region 80b). The boundary between the first region 80a and the second region 80b is the boundary between the end surface 412f and the peripheral surface 410f before welding, which is indicated by an imaginary line.

[0110] According to this, since the first region 80a is larger than the second region 80b, the amount of the welded portion 80 provided at the end portion 410e of the bending pin member 410 can be reduced. Therefore, the number of welded portions 80 provided on the outer edge 410i side of the bending pin member 410 can be reduced, so that the size of the welded portion 80 can be further reduced, and the gap between adjacent turns of the first coil 41 can be further reduced, and the inductor component 1 can be miniaturized. In addition, the welded portion 80 can be made larger on the side of the second linear pin member 412 having a smaller width, so that the welded portion 80 can be prevented from becoming larger on the side of the bending pin member 410 having a larger width.

[0111] The welded portion 80 is provided over the circumference of the end portion 412e of the second linear pin member 412. Therefore, the end portion 412e of the second linear pin member 412 and the end portion 410e of the bent pin member 410 can be securely connected.

[0112] like Figure 4As shown in FIG. 1 , the inductor component 1 preferably further includes an outer covering member 90 that covers a portion of the first coil 41 and the second coil 42 (shown by an imaginary line). Specifically, the outer covering member 90 covers the conductor portions 411a, 412a, 410a of the first coil 41 exposed from the film 410b and the conductor portions 421a, 422a, 420a of the second coil 42 exposed from the film 420b. In other words, the outer covering member 90 covers the first and second linear pin members 411, 412, 421, 422 (equivalent to the first pin member) and also covers the welded portion 80. As a material of the outer covering member 90, for example, a thermosetting epoxy resin can be used.

[0113] Thus, by providing the outer covering member 90, the first coil 41 and the second coil 42 can be prevented from being misaligned. In addition, the outer covering member 90 covers the linear pin members 411, 412, 421, 422, so that the linear pin members 411, 412, 421, 422 can be insulated. In addition, the linear pin members 411, 412, 421, 422 have a small width, so that bubbles generated when the outer covering member 90 is applied to the linear pin members 411, 412, 421, 422 easily pass through the gaps between the linear pin members 411, 412, 421, 422 of adjacent turns, and it is possible to suppress the bubbles from remaining in the outer covering member 90.

[0114] (Method for manufacturing inductor component)

[0115] Next, a method for manufacturing the inductor component 1 will be described.

[0116] like Figure 3 As shown in the figure, the first coil 41 and the second coil 42 are wound on the core 3 embedded in the insulating member 60, and their winding axes are parallel to each other. Specifically, the exposed conductor parts 411a, 412a, 410a of the first coil 41 and the exposed conductor parts 421a, 422a, 420a of the second coil 42 are arranged on the first end face 301 side of the core 3. Then, the pin members of the first coil 41 and the pin members of the second coil 42 are welded while keeping the first end face 301 of the core 3 facing upward.

[0117] Afterwards, if Figure 4 As shown, the core 3 and the coils 41 and 42 are mounted on the bottom plate 21 , and then the cover 22 is closed and housed in the case 2 , thereby manufacturing the inductor component 1 .

[0118] By using such a manufacturing method, the number of steps for manufacturing the inductor component 1 can be reduced, and the inductor component 1 can be manufactured more easily.

[0119] Next, a method of winding the first coil 41 and the second coil 42 around the core 3 will be described in more detail.

[0120] like Fig. 6A As shown, in the adjacent second linear pin member 412 and bending pin member 410, the end face 412f of the end 412e of the second linear pin member 412 and the peripheral face 410f of the end 410e of the bending pin member 410 are brought into contact with each other. At this time, when viewed from the Z direction, the second linear pin member 412 and the bending pin member 410 are arranged on the core body 3 in a state where the width 412h of the end 412e of the second linear pin member 412 is smaller than the width 410h of the end 410e of the bending pin member 410.

[0121] like Figure 6B and Figure 6C As shown, heat is applied to the second linear pin member 412 and the bent pin member 410, so that the end surface 412f of the end 412e of the second linear pin member 412 and the peripheral surface 410f of the end 410e of the bent pin member 410 are welded to each other to form the welded portion 80. Laser welding is used for welding, but electron beam welding, TIG welding, friction welding, etc. may also be used.

[0122] When a fiber laser is used for welding, for example, when the wire diameter of the pin member is 1.5 mm, the spot diameter of the laser is 0.1 mm, the fundamental wave of the laser is 1064 nm, and the laser output is 800 W×100 ms=80 J.

[0123] Accordingly, when viewed from the Z direction, the second linear pin member 412 and the bent pin member 410 are arranged on the core 3 in a state where the width 412h of the end 412e of the second linear pin member 412 is smaller than the width 410h of the end 410e of the bent pin member 410, and the end 412e of the second linear pin member 412 and the end 410e of the bent pin member 410 are welded to form the welded portion 80. Therefore, when viewed from the Z direction, the welded portion 80 has a narrowed contraction portion 81. Therefore, it is possible to reduce the possibility that the welded portion 80 protrudes into the gap between adjacent turns of the first coil 41, and the gap between adjacent turns of the first coil 41 can be reduced, thereby achieving miniaturization of the inductor component 1.

[0124] Preferably, during welding, the heat applied to the end 412e of the second linear pin member is greater than that to the end 410e of the bending pin member 410. By doing so, the welded portion 80 can be prevented from being provided at the outer edge 410i of the bending pin member 410 when viewed from the Y direction.

[0125] Thus, the surface tension of the welded portion 80 toward the outer edge 410i of the bending pin member 410 in the melted state can be suppressed, and the welded portion 80 will not become a spherical shape that covers the outer edge 410i. Therefore, the size of the welded portion 80 can be further reduced, and the gap between adjacent turns of the first coil 41 can be further reduced, and the inductor component 1 can be miniaturized. In addition, the welded portion 80 can be prevented from protruding outward from the outer edge 410i of the bending pin member 410, and the outer shape of the first coil 41 can be reduced.

[0126] Specifically, in the bending pin member 410, the molten metal has a surface tension force that makes it want to form a spherical structure in the direction perpendicular to the surface of the unmelted metal. Therefore, in a state where the outer edge 410i is not melted, the molten metal gathers in the direction perpendicular to the melted surface due to the surface tension, and the molten metal moves inward from the outer edge 410i. As a result, the welded portion 80 is not provided at the outer edge 410i of the bending pin member 410.

[0127] On the other hand, when the outer edge 410 i melts, the molten metal gathers in a state of protruding outward from the outer edge 410 i. As a result, a welded portion is provided at the outer edge 410 i of the bending pin member 410.

[0128] When viewed from the Y direction, the outer edge 410i of the bending pin member 410 has an outermost end 410j on the end surface side of the end 410e of the bending pin member 410. The outermost end 410j is a portion where the outer edge 410i intersects the end surface of the end 410e. Preferably, the weld 80 is not provided at the outermost end 410j of the outer edge 410i of the bending pin member 410.

[0129] According to this, the surface tension of the welded portion 80 in the molten state toward the outermost end portion 410j of the outer edge 410i of the bending pin member 410 can be suppressed, and the welded portion 80 will not become a spherical shape that covers the outer edge 410i. Specifically, when heat is applied to the end surface of the end portion 410e of the bending pin member 410 to melt the metal, if the outermost end portion 410j of the outer edge 410i is not melted, the melting of the metal will not spread to the outer edge 410i.

[0130] (Second embodiment)

[0131] Figure 7 2 is a cross-sectional view showing a second embodiment of the pin member. The second embodiment differs from the first embodiment in the shape of the end of the pin member. The following describes the different structure. The other structures are the same as those of the first embodiment, and are marked with the same reference numerals as those of the first embodiment and their descriptions are omitted.

[0132] like Figure 7As shown, the cross-sectional area of ​​the second linear pin member 412A except the welded portion 80 is equal to the cross-sectional area of ​​the bent pin member 410 except the welded portion 80. The cross-sectional area of ​​the bent pin member 410 is the cross-sectional area of ​​the plane perpendicular to the direction (center line 410c) in which the bent pin member 410 extends, and the cross-sectional area of ​​the second linear pin member 412A is the average cross-sectional area of ​​the plane perpendicular to the direction (center line 412c) in which the second linear pin member 412A extends. The width 412h of the second linear pin member 412A except the welded portion 80 is smaller than the width 410h of the bent pin member 410 except the welded portion 80, and the cross section of the second linear pin member 412A is an oblong shape that is long in the Z direction. The second linear pin member 412A can be formed in an oblong shape in cross section by, for example, pressing a pin member having a circular cross section from both sides.

[0133] Thus, the cross-sectional area of ​​the second linear pin member 412A is equal to the cross-sectional area of ​​the bent pin member 410 , and therefore, even if the width 412h of the portion of the second linear pin member 412A excluding the welded portion 80 is reduced, an increase in the electrical resistance of the portion can be suppressed.

[0134] Furthermore, before the pin members are welded, the entire second linear pin member 412A may be formed into an oblong cross-sectional shape, or only the end portion of the second linear pin member 412A may be formed into an oblong cross-sectional shape.

[0135] The first linear pin member 411 is also the same as described above, and the second coil 42 (pin members 420 , 421 , 422 ) is also the same as described above.

[0136] (Third embodiment)

[0137] Fig. 8A 1 is a bottom view showing a third embodiment of a method for manufacturing an inductor component. The third embodiment differs from the first embodiment in the shape of the pin member. The following describes the different structure. The other structures are the same as those of the first embodiment, and are marked with the same reference numerals as those of the first embodiment and their descriptions are omitted.

[0138] like Fig. 8AAs shown, in the adjacent second linear pin member 412B and the bending pin member 410, the end face 412f of the end 412e of the second linear pin member 412B and the peripheral face 410f of the end 410e of the bending pin member 410 are brought into contact with each other. At this time, when viewed from the Z direction, the second linear pin member 412B and the bending pin member 410 are arranged on the core body 3 in a state where the width of the end 412e of the second linear pin member 412B decreases toward the end face 412f. Specifically, the end 412e of the second linear pin member 412B has tapered surfaces 412j on both sides in the Y direction. At this time, when viewed from the Z direction, the width 412h of the portion of the second linear pin member 412B excluding the tapered surface 412j is the same as the width 410h of the end 410e of the bending pin member 410.

[0139] At this time, the tapered surface 412j of the end 412e of the second linear pin member 412B can be formed in a shape of an oblong cross section by, for example, pressing a pin member having a circular cross section from both sides. Accordingly, the cross-sectional area of ​​the end 412e of the second linear pin member 412B is equal to the cross-sectional area of ​​the second linear pin member 412B excluding the end 412e, and therefore, an increase in the electrical resistance of the end 412e of the second linear pin member 412B can be suppressed.

[0140] Afterwards, if Figure 8B As shown, heat is applied to the second linear pin member 412B and the bent pin member 410 so that the end surface 412f of the end 412e of the second linear pin member 412B and the peripheral surface 410f of the end 410e of the bent pin member 410 are welded to each other to form the welded portion 80.

[0141] The welded portion 80 is formed in this way, and therefore, when viewed from the Z direction, the welded portion 80 has a narrowed contraction portion 81. This can reduce the possibility that the welded portion 80 protrudes into the gap between adjacent turns of the first coil 41, and can reduce the gap between adjacent turns of the first coil 41, thereby miniaturizing the inductor component 1.

[0142] The first linear pin member 411 and the bent pin member 410 are the same as described above, and the second coil 42 (pin members 420 , 421 , 422 ) are the same as described above.

[0143] In addition, the present disclosure is not limited to the above-mentioned embodiment, and design changes can be made within the scope that does not deviate from the gist of the present disclosure. For example, each characteristic point of the first to third embodiments can be combined in various forms.

[0144] In the first to third embodiments, the weld has a constriction, but the constriction may be provided at a portion other than the weld at the end of the bending pin member. This can reduce the gap between adjacent turns of the coil and reduce the size of the coil, thereby miniaturizing the inductor component.

[0145] In the first to third embodiments, the welded portion is not provided on the outer edge of the bending pin member when viewed from the Y direction, but the welded portion may be provided on the outer edge of the bending pin member when viewed from the Y direction.

[0146] In the first to third embodiments, the welded portion is provided on the inner side than the second plane when viewed from the Z direction, but the welded portion may be provided on the outer side than the second plane when viewed from the Z direction.

[0147] In the first embodiment, in the process of arranging the plurality of pin members on the core body, the width of the end of the linear pin member is constant when viewed from the Z direction, but the width of the end of the linear pin member may decrease toward the end face as in the third embodiment. In this way, the welded portion having the contraction portion can be formed more easily.

[0148] In the first to third embodiments, a straight pin member is used as the first pin member, and a bent pin member is used as the second pin member, and the first pin member and the second pin member are integrated to form one turn of the coil, but the first pin member and the second pin member may each form one turn of the coil. In addition, a plurality of first pin members and second pin members may be integrated to form one turn of the coil. In this way, the shapes of the first pin member and the second pin member are not limited to I-shaped or U-shaped, and may be a shape that forms one turn or a shape that divides one turn into a plurality of parts.

Claims

1. An inductor component, characterized in that: have: an annular core; and The coil includes a plurality of pin members, and the adjacent pin members are connected and wound around the core to form the coil. The adjacent first pin member and the second pin member have a welded portion where an end portion of the first pin member and an end portion of the second pin member are welded to each other. The second pin member has a narrowed portion at its end. The welded portion is formed by welding the end surface of the end portion of the first pin member and the peripheral surface of the end portion of the second pin member to each other. The weld portion includes the constricted portion having a narrowed width when viewed from a direction along a center line of an end portion of the second pin member.

2. The inductor component according to claim 1, characterized in that: The weld portion is not provided on an outer edge of the second pin member when viewed from a direction perpendicular to a first plane including a center line of an end portion of the first pin member and a center line of an end portion of the second pin member.

3. The inductor component according to claim 2, characterized in that: The weld portion is provided inside a second plane when viewed from a direction along a center line of an end portion of the second pin member. The second plane includes the center line of the end portion of the second pin member and is orthogonal to the first plane.

4. The inductor component according to any one of claims 1 to 3, characterized in that: When viewed in a direction along a center line of an end portion of the second pin member, a width of a portion of the first pin member excluding the weld portion is smaller than a width of a portion of the second pin member excluding the weld portion.

5. The inductor component according to claim 4, characterized in that: A cross-sectional area of ​​a portion of the first pin member excluding the welded portion is equal to a cross-sectional area of ​​a portion of the second pin member excluding the welded portion.

6. A method for manufacturing an inductor component, which is a method for manufacturing an inductor component, wherein the inductor component comprises: an annular core; and The coil includes a plurality of pin members, and the adjacent pin members are connected and wound around the core to form the coil. The above-mentioned method for manufacturing an inductor component is characterized by comprising: A step of arranging the plurality of pin members on the core body in a state where an end surface of an end portion of the first pin member and a peripheral surface of an end portion of the second pin member are in contact with each other and a width of the end portion of the first pin member decreases toward the end surface when viewed from a direction along a center line of the end portion of the second pin member; and A step of applying heat to the first pin member and the second pin member to weld an end surface of an end portion of the first pin member and a peripheral surface of an end portion of the second pin member to each other to form a welded portion.

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