Coil device

Abstract

The present invention provides a coil device with high reliability. The inductor (1) has: a coil (2) made of flat wire, a first terminal (4a) having a first receiving recess (421a) having a first lead (3a) for receiving the coil (2) formed thereon, and a second terminal (4b) having a second receiving recess (421b) having a second lead (3b) for receiving the coil (2) formed thereon, wherein the first receiving recess (421a) and the second receiving recess (421b) are offset along the winding axis direction of the coil (2).

Description

Technical Field

[0001] The present invention relates to coil devices, for example, used as inductors. Background Technology

[0002] As a coil device used as an inductor, a coil device is known that has a base, a coil embedded in the base, and a terminal portion for connecting the lead-out portion of the coil disposed in the base (Patent Document 1). In the coil device described in Patent Document 1, the lead-out portion of the coil can be connected to the terminal portion by riveting the terminal portion to the lead-out portion of the coil.

[0003] In the coil device described in Patent Document 1, the coil is formed by a wire, so no adverse conditions will occur, and the leads of the coil can be riveted with terminals. However, in the case where the coil is formed by a flat wire, it is difficult to rivet the leads of the coil with terminals, and there is room for improvement.

[0004] Existing technical documents

[0005] Patent Literature

[0006] Patent Document 1: Japanese Utility Model Application Publication No. 3-51807 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] The present invention was developed in view of this actual situation, and its purpose is to provide a coil device that allows easy connection between the lead-out portion of the coil and the terminal.

[0009] Technical solutions for solving the problem

[0010] To achieve the above objectives, a first aspect of the present invention provides a coil device comprising:

[0011] A coil, which is made of flat wire;

[0012] The first terminal has a first wiring portion having a first receiving recess that receives a first lead-out portion of the coil;

[0013] The second terminal has a second wiring portion having a second receiving recess that accommodates the second lead of the coil.

[0014] The first receiving recess and the second receiving recess are misaligned along the winding axis of the coil.

[0015] In the coil device of the first aspect of the present invention, a first receiving recess for receiving a first lead-out portion of the coil is formed at the first wiring portion, and a second receiving recess for receiving a second lead-out portion of the coil is formed at the second wiring portion. Therefore, by receiving the first lead-out portion in the first receiving recess, the first lead-out portion can be connected to the first wiring portion. When connecting the first lead-out portion to the first wiring portion, it is not necessary to rivet a first terminal to the first lead-out portion, and the first lead-out portion and the first terminal can be easily connected. Similarly, by receiving the second lead-out portion in the second receiving recess, the second lead-out portion can be connected to the second wiring portion. When connecting the second lead-out portion to the second wiring portion, it is not necessary to rivet a second terminal to the second lead-out portion, and the second lead-out portion and the second terminal can be easily connected.

[0016] In particular, in the coil device of the present invention, the first receiving recess and the second receiving recess are misaligned along the winding axis direction of the coil. Therefore, even if the first lead-out position of the first lead-out portion and the second lead-out position of the second lead-out portion are misaligned along the winding axis direction of the coil, the first lead-out portion or the second lead-out portion will not be unnecessarily bent, and the first lead-out portion and the second lead-out portion can be led out to the first terminal and the second terminal respectively. Therefore, in this respect, the first lead-out portion can be easily connected to the first terminal, and the second lead-out portion can be easily connected to the second terminal.

[0017] Preferably, the first and second wiring portions extend along the winding axis at different positions, with the length of the first wiring portion along the winding axis being longer than the length of the second wiring portion along the winding axis. By configuring it in this way, the first and second receiving recesses can be staggered along the winding axis of the coil by a distance corresponding to the difference between the lengths of the first and second wiring portions along the winding axis, achieving the aforementioned effect with a simple structure.

[0018] Preferably, the first terminal has a first base that raises the first wiring portion along the winding axis direction, and the second terminal has a second base that raises the second wiring portion along the winding axis direction. The second lead of the coil, which is housed in the second receiving recess, is connected to the second base. With this structure, the second lead is supported by the second base, so even if an external force is applied to the second lead, it is less likely to become misaligned in the winding axis direction. Therefore, the position of the second lead can be positioned at a predetermined location, preventing uneven inductance characteristics and other properties in each product due to uneven positioning of the second lead.

[0019] Preferably, the first lead-out portion of the coil housed in the first receiving recess is located above the bottom of the first receiving recess. With this structure, even if the first lead-out position of the first lead-out portion deviates in the winding axis direction due to manufacturing errors, the first lead-out portion will not be bent when housed in the first receiving recess, and the first lead-out portion can be connected to the first terminal while being led out in a straight line.

[0020] Furthermore, in the case of the aforementioned structure, a gap (allowance) is formed between the bottom of the first lead-out portion and the first receiving recess. However, by forming this allowance in this way, the depth of the first receiving recess is made relatively deep in advance, preventing the coil from tilting and ensuring that the first lead-out portion can be reliably received in the first receiving recess. Additionally, even if, for example, due to design changes, the first lead-out position of the first lead-out portion is positioned differently along the winding axis than usual, the first lead-out portion can still be reliably received in the first receiving recess.

[0021] Preferably, the first receiving recess is formed by a first cut in the first wiring portion along the winding axis direction, and the second receiving recess is formed by a second cut in the second wiring portion along the winding axis direction. With this structure, for example, by inserting the first lead-out portion into the first receiving recess from the top of the first wiring portion along the winding axis direction, the first lead-out portion can be easily received in the first receiving recess. Similarly, the second lead-out portion can be easily received in the second receiving recess, for example, by inserting the second lead-out portion into the second receiving recess from the top of the second wiring portion along the winding axis direction.

[0022] Preferably, in the first wiring portion, a pair of first protrusions are formed by sandwiching the first receiving recess, and in the second wiring portion, a pair of second protrusions are formed by sandwiching the second receiving recess. The pair of first protrusions are connected by a joint, and the pair of second protrusions are also connected by a joint. By configuring the first lead-out portion sandwiched between each of the pair of first protrusions, the first lead-out portion can be stably received in the first receiving recess. Furthermore, by engaging each of the pair of first protrusions with a joint in this state, the first lead-out portion can be effectively prevented from detaching from the first receiving recess. Similarly, by configuring the second lead-out portion sandwiched between each of the pair of second protrusions, the second lead-out portion can be stably received in the second receiving recess. Furthermore, by engaging each of the pair of second protrusions with a joint in this state, the second lead-out portion can be effectively prevented from detaching from the second receiving recess.

[0023] Preferably, when viewed from the front, the first and second wiring portions are positioned further inward than the outer periphery of the coil in a direction orthogonal to the winding axis. In this configuration, the distance between the first and second receiving recesses is narrower than the distance between the first lead-out position of the first lead and the second lead-out position of the second lead, with the first and second receiving recesses positioned between the first and second lead-out positions. To receive the first lead-out in the first receiving recess in this manner, the first lead-out needs to be bent inward from the first lead-out position towards the first receiving recess. This generates an elastic force in the first lead-out, allowing it to be secured with sufficient strength within the first receiving recess when received. Similarly, the second lead-out is also secured with sufficient strength within the second receiving recess.

[0024] Preferably, the first lead-out portion and the second lead-out portion extend in approximately the same direction, and the first wiring portion and the second wiring portion are disposed on one side of the coil from which the first lead-out portion and the second lead-out portion extend. With this structure, when performing, for example, laser welding on the first wiring portion and the second wiring portion, the laser can be irradiated on each wiring portion from approximately the same direction, thus facilitating laser welding and simplifying manufacturing.

[0025] To achieve the above objectives, a second aspect of the present invention provides a coil device comprising:

[0026] Matrix;

[0027] A coil, which is composed of flat wire and is embedded inside the substrate;

[0028] The first terminal has a first wiring portion that connects to the first lead-out portion of the coil, and the first wiring portion is disposed inside the base;

[0029] The second terminal has a second wiring portion that connects to the second lead of the coil, and the second wiring portion is disposed inside the base.

[0030] A first receiving recess is formed at the first wiring portion to receive the first lead-out portion.

[0031] A second receiving recess is formed in the second wiring portion to receive the second lead-out portion.

[0032] In the coil device of the second aspect of the present invention, similar to the coil device of the first aspect, the first lead-out portion can be connected to the first wiring portion by accommodating the first receiving recess. When connecting the first lead-out portion to the first wiring portion, it is not necessary to rivet the first terminal to the first lead-out portion, and the first lead-out portion and the first terminal can be easily connected. Similarly, by accommodating the second lead-out portion to the second receiving recess, the second lead-out portion can be connected to the second wiring portion. When connecting the second lead-out portion to the second wiring portion, it is not necessary to rivet the second terminal to the second lead-out portion, and the second lead-out portion and the second terminal can be easily connected.

[0033] Furthermore, in the coil device of the present invention, a first wiring portion having a first receiving recess and a second wiring portion having a second receiving recess are disposed inside the base. In addition, the coil is made of flat wire. Therefore, it is possible to easily manufacture a surface-mount type coil device that allows easy connection between each lead and each terminal and can carry a large current. Attached Figure Description

[0034] Figure 1 This is a perspective view of a coil device according to an embodiment of the present invention.

[0035] Figure 2 It means Figure 1 A three-dimensional view of the internal structure of the coil device shown.

[0036] Figure 3 It indicates formation Figure 1 The diagram shows a three-dimensional view of the structure of the first core used in the base of the coil device.

[0037] Figure 4 It indicates formation Figure 1 The diagram shows a perspective view of the structure of the second core used in the base of the coil device.

[0038] Figure 5 It means Figure 2 The diagram shows a three-dimensional view of the coil structure.

[0039] Figure 6 It means Figure 2 A perspective view of the structure of a pair of terminals shown.

[0040] Figure 7A It means in Figure 6 A side view showing the state of a pair of terminals with coils mounted on their respective bases.

[0041] Figure 7B It means to observe from another perspective. Figure 7A A three-dimensional view showing the state of a pair of terminals and a coil.

[0042] Figure 8 It means Figure 2 A top view of the structure of the coil device shown.

[0043] Figure 9A It means Figure 1 A diagram illustrating the manufacturing method of the coil device.

[0044] Figure 9B It means Figure 9A The diagram shows the subsequent processes.

[0045] Figure 9C It means Figure 9B The diagram shows the subsequent processes.

[0046] Figure 9D It means Figure 9C The diagram shows the subsequent processes.

[0047] Figure 9E It means Figure 9D The diagram shows the subsequent processes.

[0048] Figure 9F It means Figure 9E The diagram shows the subsequent processes. Detailed Implementation

[0049] The present invention will now be described based on the embodiments shown in the accompanying drawings.

[0050] like Figure 1 As shown, the inductor 1 of one embodiment of the present invention is a surface-mount inductor having a generally cuboid shape. Figure 1 In this inductor 1, the surface on the negative Z-axis direction is called the mounting surface 8a, which is disposed opposite to the circuit board or the like. Hereinafter, the surface on the opposite side of the mounting surface in the inductor 1 will be referred to as the reverse mounting surface 8b.

[0051] like Figure 2 As shown, inductor 1 has a coil 2, a pair of terminals 4a and 4b, and a core (base) 8. Furthermore, in Figure 2 In China, for Figure 1 The inductor 1 shown is represented by a state where its direction is rotated 180° along the XZ plane, and the illustration shows the mounting surface 8a of the inductor 1 positioned above the paper, and the reverse mounting surface 8b of the inductor 1 positioned below the paper. Hereinafter, for ease of understanding, the inductor 1 will be described with "above the paper" as "above the paper" and "below the paper" as "below the paper".

[0052] The dimensions of inductor 1 are not particularly limited, but its width in the X-axis direction is preferably 2 to 20 mm, its width in the Y-axis direction is preferably 2 to 20 mm, and its width in the Z-axis direction is preferably 1 to 10 mm.

[0053] Core 8 is composed of a mixture containing magnetic powder and binder resin, which is combined... Figure 3 The first core 5 shown is Figure 4 The second core 6 shown is formed by compressing and molding the pre-formed first core 5 and the second core 6 inside the mold, thus integrating them. Furthermore, at the joint of the first core 5 and the second core 6, their boundary is not discernible; they become a single, integral unit. The structure of the first core 5 and the second core 6 will be described below.

[0054] like Figure 3 As shown, the first core 5 has a core base bottom 50 and a columnar portion 51 formed on the surface (upper surface) of the core base bottom 50. The first core 5 mainly forms Figure 2 A portion of the reverse mounting surface 8b side of the core 8 shown.

[0055] The first core 5 is composed of a synthetic resin in which ferrite particles or metallic magnetic particles are dispersed. However, the material constituting the first core 5 is not limited to this, and it may also be composed of a synthetic resin that does not contain these particles. Examples of ferrite particles include Ni-Zn ferrite, Mn-Zn ferrite, etc. Examples of metallic magnetic particles are not particularly limited, and examples include Fe-Ni alloy powder, Fe-Si alloy powder, Fe-Si-Cr alloy powder, Fe-Co alloy powder, Fe-Si-Al alloy powder, amorphous iron, etc.

[0056] The synthetic resin contained in the first core 5 is not particularly limited, but preferred examples include epoxy resin, phenolic resin, polyester resin, polyurethane resin, polyimide resin, silicone resin, etc.

[0057] The core base 50 is composed of a roughly rectangular parallelepiped shape (roughly flat shape), where the first core 5 and the second core 6 are connected. Figure 4 In the combined state, the lower surface of the core base bottom 50 forms Figure 1 and Figure 2 The core 8 shown has a reverse mounting surface 8b. Two stepped portions 500 and a stepped upper portion 501 located between the stepped portions 500 are formed on the surface (upper surface) of the core base bottom 50. The stepped upper portion 501 forms the upper surface of the step relative to the stepped portions 500, and a columnar portion 51 is formed on the stepped upper portion 501. The width of the stepped upper portion 501 in the Y-axis direction is the same as the width of the core base bottom 50 in the Y-axis direction, and the stepped portion 501 extends from one end of the core base bottom 50 in the Y-axis direction to the other end. The ratio of the width of the stepped upper portion 501 in the X-axis direction to the width of the core base bottom 50 in the X-axis direction is preferably 1 / 4 to 1 / 2.

[0058] A stepped portion 500 is formed on the negative X-axis side of the core base bottom 50, sandwiching a columnar portion 51. Another stepped portion 500 is formed on the positive X-axis side of the core base bottom 50, sandwiching a columnar portion 51. Viewed from the Z-axis direction, each stepped portion 500 has the same shape and is approximately rectangular in shape with a predetermined length in both the X-axis and Y-axis directions.

[0059] The width of each stepped portion 500 in the Y-axis direction is the same as the width of the core base bottom 50 in the Y-axis direction, and each stepped portion 500 extends from one end of the core base bottom 50 in the Y-axis direction to the other end. The width of one stepped portion 500 in the X-axis direction is approximately equal to the distance from the end of the columnar portion 51 on the negative X-axis side to the end of the core base bottom 50 on the negative X-axis side, and one stepped portion 500 extends from the end of the columnar portion 51 on the negative X-axis side to the end of the core base bottom 50 on the X-axis direction. The width of another stepped portion 500 in the X-axis direction is approximately equal to the distance from the end of the columnar portion 51 on the positive X-axis side to the end of the core base bottom 50 on the positive X-axis side, and another stepped portion 500 extends from the end of the columnar portion 51 on the positive X-axis side to the end of the core base bottom 50 on the positive X-axis side.

[0060] When manufacturing inductor 1, it is arranged at each step portion 500. Figure 6 The bases 41a and 41b of the terminals 4a and 4b shown can be positioned relative to the bases 41a and 41b at the positions of the steps 500. In addition, by arranging the bases 41a and 41b of the terminals 4a and 4b at the steps 500, misalignment of the terminals 4a and 4b can be prevented.

[0061] From the viewpoint of effectively performing this positioning, the depth D1 of the step portion 500 along the Z-axis direction is based on the thickness T1 of the base portions 41a and 41b. Figure 6 It is determined that the ratio of the depth D1 to the thickness T1, D1 / T1, is preferably 1 / 8 ≤ D1 / T1 ≤ 2, and more preferably 1 / 4 ≤ D1 / T1 ≤ 1. It is particularly preferred that the depth D1 of the step portion 500 along the Z-axis is approximately equal to the thickness T1 of the bases 41a and 41b, so that when the bases 41a and 41b are arranged in each step portion 500, the surfaces (upper surfaces) of the bases 41a and 41b are flush with the surface of the upper part 501 of the step.

[0062] A first recess 52 is formed on each side of the core base bottom 50 in the X-axis direction. Each first recess 52 is configured with... Figure 6 The connecting portions 43a and 43b of the terminals 4a and 4b shown. The depth of the first recess 52 along the X-axis direction is not particularly limited, and... Figure 6The thickness of the connecting portions 43a and 43b shown is the same as or greater than that of the connecting portions 43a and 43b. The depth of each first recess 52 along the X-axis is preferably such that, when the connecting portions 43a and 43b are arranged in each first recess 52, the surfaces of the connecting portions 43a and 43b are not exposed from each first recess 52. The width of the first recess 52 in the Y-axis direction is preferably 1 / 3 to 3 / 4 of the width of the core base bottom 50 in the Y-axis direction, preferably equal to... Figure 6 The Y-axis widths of the connecting parts 43a and 43b shown are approximately equal.

[0063] The columnar portion 51 is integrally formed with approximately the center of the core base bottom 50 and extends along the Z-axis direction. More specifically, the position (axis center) of the columnar portion 51 is offset from the center of the core base bottom 50 in the negative Y-axis direction by a predetermined distance.

[0064] The columnar portion 51 is configured (inserted or wound). Figure 5 The coil (air-core coil) 2 shown. Therefore, the diameter of the columnar portion 51 is smaller than the inner diameter of the coil 2. In addition, as mentioned above, the position of the columnar portion 51 is offset relative to the center of the core base bottom 50 in the negative Y-axis direction. Therefore, when the first core 5 and the second core 6 ( Figure 4 In the combined state, the center of coil 2 (winding shaft) is relative to... Figure 2 The center of core 8 shown is misaligned towards the negative Y-axis direction.

[0065] The columnar portion 51 is cylindrical in shape, and its height is preferably greater than that of the coil 2. By having the columnar portion 51 in the first core 5, the effective permeability of the first core 5 in the inner region of the coil 2 can be sufficiently ensured, and the inductance characteristics of the inductor 1 can be made good.

[0066] like Figure 4 As shown, the second core 6 is composed of a roughly four-cornered ring shape and is placed on Figure 3 The first core 5 is shown on its surface (upper surface) and is combined with the first core 5 in the state of assembling coil 2. The second core 6 can be made of the same kind of material as the first core 5, or it can be made of a different kind of material. The second core 6 has: a main body 60; a receiving hole 61; terminal receiving grooves 62a, 62b; connecting grooves 63a, 63b; a second recess 64; a third recess 65. Figure 9C ); Bottom 66. The second core 6 mainly forms Figure 2 A portion of the mounting surface 8a side of the core 8 shown.

[0067] The main body 60 is constructed of a bottomed cylindrical shape, and its overall shape is approximately rectangular. The thickness of the main body 60 in the Z-axis direction is greater than that of the bottomed cylindrical shape. Figure 3The thickness of the core base bottom 50 in the Z-axis direction increases. The width of the main body 60 in the X-axis direction is approximately the same as the width of the core base bottom 50 in the X-axis direction, and the width of the main body 60 in the Y-axis direction is approximately the same as the width of the core base bottom 50 in the Y-axis direction. When the first core 5 and the second core 6 are combined, the upper surface of the main body 60 (the surface opposite to the bottom 66) is connected to the surface (upper surface) of the core base bottom 50 of the first core 5.

[0068] A receiving hole 61 is formed approximately at the center of the main body 60, extending from one side (upper surface) to the other side (bottom 66) along the Z-axis direction of the main body 60. The opening of the receiving hole 61 is approximately circular in shape, similar to... Figure 5 The outer circumference shape of the coil 2 shown is roughly the same. The end of the receiving hole 61 opposite to the opening is closed by the bottom 66. The columnar portion 51 of the first core 5, in which the coil 2 is assembled, is received in the receiving hole 61. Figure 3 ).

[0069] The bottom 66 forms the lower surface of the main body 60. With the columnar portion 51 housed inside the receiving hole 61 (i.e., the second core 6 and the first core 5 are combined), the bottom 66 forms... Figure 1 and Figure 2 The mounting surface 8a of the core 8 shown. That is, in Figure 4 In the middle, mounting parts 44a and 44b of terminals 4a and 4b are arranged on the Z-axis negative direction side of the bottom 66.

[0070] Second recesses 64 are formed on each side of the main body 60 in the X-axis direction. Each second recess 64 is provided with... Figure 6 The connecting portions 43a and 43b of terminals 4a and 4b are shown. The depth of the second recess 64 along the X-axis direction is... Figure 3 The depth of the first recess 52 along the X-axis is the same. Furthermore, the width of the second recess 64 along the Y-axis is the same as the width of the first recess 52 along the Y-axis. With the second core 6 assembled with the first core 5, the second recess 64 connects to the first recess 52 along the Z-axis. Thus, as... Figure 1 As shown, on each side of the core 8 in the X-axis direction, the side recess 80 is formed to extend from one end to the other in the Z-axis direction.

[0071] like Figure 9C As shown, a third recess 65 is formed on the surface (outer surface) of the bottom 66. Two third recesses 65 are formed on the bottom 66, each third recess 65 being formed continuously relative to each second recess 64 formed on each side of the main body 60 in the X-axis direction. The third recesses 65 and the second recesses 64 intersect orthogonally at the corners of the main body 60, and the third recess 65 extends from the end of the second recess 64 in the Z-axis direction toward the center of the bottom 66.

[0072] like Figure 4 As shown, terminal receiving grooves 62a and 62b are formed at the corners of the main body 60. Terminal receiving groove 62a is formed at the corner where the surface formed on the positive Y-axis side of the main body 60 intersects the surface formed on the positive X-axis side, and terminal receiving groove 62b is formed at the corner where the surface formed on the positive Y-axis side of the main body 60 intersects the surface formed on the negative X-axis side.

[0073] Terminal receiving slots 62a and 62b extend from one side (upper surface) to the other side (bottom 66) of the main body 60 along the Z-axis direction. The openings of the terminal receiving slots 62a and 62b are approximately rectangular in shape. Figure 3 When the first core 5 is combined with the second core 6, it can be accommodated inside the terminal receiving slot 62a. Figure 2 The terminal 4a shown has a wiring portion 42a. The wiring portion 42a, in which the lead-out portion 3a of the wire 3 is connected by the molten material 9, is housed in the terminal receiving groove 62a. A space of a size that can accommodate the molten material 9 is formed inside the terminal receiving groove 62a.

[0074] In addition, in the case of Figure 3 When the first core 5 is combined with the second core 6, it can be accommodated inside the terminal receiving slot 62b. Figure 2 The terminal 4b shown has a wiring portion 42b. The wiring portion 42b, in which the lead-out portion 3b of the wire 3 is connected by the molten material 9, is housed in the terminal receiving groove 62b. A space of a size that can accommodate the molten material 9 is formed inside the terminal receiving groove 62b.

[0075] The X-axis width ratio of terminal receiving slots 62a and 62b Figure 2 The width of the wiring portions 42a and 42b in the X-axis direction increases. The width of the terminal receiving grooves 62a and 62b in the Y-axis direction is greater than that attached to... Figure 2 The width of the molten material 9 in the Y-axis direction of the terminal receiving grooves 42a and 42b shown increases. The depth of the terminal receiving grooves 62a and 62b along the Z-axis direction becomes the overall depth of the terminal receiving grooves 42a and 42b that can accommodate terminals 4a and 4b, and is at least greater than the length of the terminal receiving grooves 42a and 42b in the Z-axis direction. Figure 2 As shown, the length of the wiring portion 42a along the Z-axis direction may be longer than the length of the wiring portion 42b along the Z-axis direction, and in a manner corresponding to this case, the length of the terminal receiving groove 62a along the Z-axis direction may be extended than the length of the terminal receiving groove 62b along the Z-axis direction.

[0076] Connecting grooves 63a and 63b extend from one side (upper surface) to the other side (bottom 66) of the main body 60 in the Z-axis direction. Additionally, connecting grooves 63a and 63b extend along the Y-axis direction, connecting the receiving hole 61 and the terminal receiving grooves 62a and 62b. Connecting groove 63a connects to the end of the receiving hole 62 in the positive X-axis direction, and connecting groove 63b connects to the end of the receiving hole 62 in the negative X-axis direction.

[0077] In the Figure 3 As shown, the first core 5 is combined with the second core 6, and is housed inside the connecting groove 63a. Figure 2 The lead-out portion 3a of the wire 3 shown is received by the lead-out portion 3b of the wire 3 in the connecting groove 63b. The width of the connecting groove 63a in the X-axis direction is larger than the width of the lead-out portion 3a in the X-axis direction, and the width of the connecting groove 63b in the X-axis direction is larger than the width of the lead-out portion 3b in the X-axis direction. The depth of the connecting grooves 63a and 63b along the Z-axis direction is the total depth that can accommodate the lead-out portions 3a and 3b. Figure 2 As shown, the length of the lead-out portion 3a in the Z-axis direction may be greater than the length of the lead-out portion 3b in the Z-axis direction, and in a manner corresponding to this case, the length of the connecting groove 63a along the Z-axis direction may be extended than the length of the connecting groove 63b along the Z-axis direction.

[0078] like Figure 5 As shown, coil 2 is composed of a flat-wound coil. Coil 2 is formed by winding a conductor 3, which is made of flat wire, in an α-shape, and is constructed in two layers along the Z-axis direction. The winding axis direction of coil 2 corresponds to the Z-axis direction. The conductor 3 is wound such that the two relatively wider sides of the four sides constituting the outer surface of the flat wire face the inner and outer circumferences of coil 2. Alternatively, it can be wound such that the two relatively narrow sides of the four sides constituting the outer surface of the flat wire face the inner and outer circumferences of coil 2, thus forming coil 2 composed of a flat-wound coil.

[0079] Coil 2 is composed of an air-core coil. During the manufacturing of inductor 1, coil 2 is mounted on the first core 5. Figure 3 The cylindrical portion 51 of the first core 5 shown is inserted into the interior of the coil 2. When the second core 6 is assembled into the first core 5 and they are compressed, as shown... Figure 2 As shown, coil 2 is embedded inside core 8.

[0080] Examples of materials constituting conductor 3 include copper and copper alloys, silver, nickel, and other good conductors; however, there are no particular limitations on the type of conductor. Conductor 3 is composed of an insulated conductor, with an insulating coating applied to its surface. The resin constituting the insulating coating is not particularly limited; for example, polyamide-imide resin or polyurethane resin can be used. Alternatively, a self-fusing conductor with a fusion-bonded coating on the outside of the insulating coating can also be used as conductor 3. The resin constituting the fusion-bonded coating is not particularly limited; for example, polyamide resin or epoxy resin can be used.

[0081] like Figure 5 As shown, the lead-out portion 3a of the wire 3 is in the second layer (second stage) of the coil 2, extending outward from the first lead-out position 2c of the coil 2 and linearly along the Y-axis. The lead-out portion 3b of the wire 3 is in the first layer (first stage) of the coil 2, extending outward from the second lead-out position 2d of the coil 2 and linearly along the Y-axis. The leads-out portions 3a and 3b are not twisted and extend in the same direction (Y-axis direction). The first lead-out position 2c and the second lead-out position 2d are staggered along the Z-axis, and the leads-out portions 3a and 3b are also staggered along the Z-axis.

[0082] The leads 3a and 3b of wire 3 and Figure 2 The terminals 4a and 4b shown are connected to the wiring portions 42a and 42b. Furthermore, in Figure 5 In the state shown, the leads 3a and 3b extend along the Y-axis direction, but when connected to the wiring parts 42a and 42b, they extend in a direction that is inclined inward relative to the Y-axis direction.

[0083] like Figure 6 As shown, terminal 4a has: a base 41a, a wiring portion 42a, a connecting portion 43a, and a mounting portion 44a. Terminal 4b has: a base 41b, a wiring portion 42b, a connecting portion 43b, and a mounting portion 44b. Terminals 4a and 4b are formed by machining, for example, a conductive sheet material such as metal, but the method of forming terminals 4a and 4b is not limited to this.

[0084] The bases 41a and 41b have a flat plate shape extending in a direction substantially orthogonal to the winding axis of the coil 2 (i.e., the X-axis and Y-axis directions). The bases 41a and 41b have: inner square edges 41a1 and 41b1; side edges 41a2 and 41b2; and outer square edges 41a3 and 41b3. The inner square edges 41a1 and 41b1 are the inner edges of the bases 41a and 41b in the X-axis direction and extend linearly along the Y-axis direction. The inner square edges 41a1 and 41b1 are arranged facing each other.

[0085] Side edges 41a2 and 41b2 are edges of the bases 41a and 41b in the Y-axis direction, located on the opposite side to the wiring portions 42a and 42b along the Y-axis direction. Side edges 41a2 and 41b2 extend linearly along the X-axis direction. Side edges 41a2 and 41b2 are located on the outer side of the Y-axis direction, compared to the ends of the connecting portions 43a and 43b on the negative Y-axis direction side.

[0086] The outer square edges 41a3 and 41b3 are the outer edges of the bases 41a and 41b in the X-axis direction, facing the side of the core 8. The outer square edges 41a3 and 41b3 extend approximately parallel to the inner square edges 41a1 and 41b1.

[0087] The bases 41a and 41b are arranged in Figure 2 The interior of core 8 is shown. Viewed from the Z-axis direction, the bases 41a and 41b have a generally rectangular shape. During the manufacture of inductor 1, the bases 41a and 41b are mounted at specified intervals along the X-axis direction. Figure 3 The first core 5 shown has each stepped portion 500 of the core base bottom 50. The interval between the base bottom 41a and the base bottom 41b corresponds to the distance between each stepped portion 500 along the X-axis direction, that is, the width of the upper part 501 of the step in the X-axis direction.

[0088] The bases 41a and 41b are disposed on the surface of the stepped portion 500, therefore, when the first core 5 is assembled... Figure 4 The second core 6 shown is in a state where (i.e., it is formed) Figure 2 As shown in the state of core 8), the bases 41a and 41b are positioned such that the thickness of the stepped portion 500 is separated from the reverse mounting surface 8b of core 8 in the Z-axis direction.

[0089] The ratio H / T2 of the height H of the bases 41a, 41b of the reverse mounting surface 8b of the core 8 in the Z-axis direction to the thickness T2 of the core 8 in the Z-axis direction is preferably 1 / 15 to 1 / 2, and more preferably 1 / 8 to 1 / 3. By setting the value of H / T2 to this range, the portion of the core 8 located between the bases 41a, 41b and the reverse mounting surface 8b of the core 8 has an appropriate thickness, which can prevent defects such as cracks from occurring in this portion.

[0090] like Figure 2As shown, a coil 2 is mounted on the upper surface of the bases 41a and 41b. More specifically, a second end 2b of the coil 2 in the winding axis direction is provided on the upper surface of the bases 41a and 41b, and the second end 2b contacts the bases 41a and 41b. When the reverse mounting surface 8b is set as a reference, the position of the second end 2b of the coil 2 in the Z-axis direction is above the position of the bottom surface of the bases 41a and 41b in the Z-axis direction by the amount of the thickness of the bases 41a and 41b, and a step is formed between the second end 2b of the coil 2 and the bottom surface of the bases 41a and 41b.

[0091] like Figure 8 As shown, with the second end 2b of the coil 2 provided at the bases 41a and 41b, the inner square edges 41a1 and 41b1 of the bases 41a and 41b are located between the outer and inner circumferential surfaces of the coil 2. This structure allows the second end 2b of the coil 2 to be stably positioned at the bases 41a and 41b. Furthermore, since the inner square edges 41a1 and 41b1 of the bases 41a and 41b are not positioned on the magnetic flux path through the inner circumference of the coil 2, an inductor 1 that effectively ensures the magnetic flux path and possesses good inductance characteristics can be achieved.

[0092] In order to enable the above configuration, the relationship between the distance L1 in the X-axis direction between the base 41a and the base 41b, the inner diameter R1 of the coil 2, and the outer diameter R2 of the coil 2 is preferably R1≦L1<R2.

[0093] As shown in the figure, when the distance L1 in the X-axis direction between the base 41a and the base 41b is approximately equal to the inner diameter R1 of the coil 2, the contact area between the second end 2b of the coil 2 and the bases 41a and 41b can be sufficiently ensured, and the coil 2 can be placed on the bases 41a and 41b in a more stable state.

[0094] Furthermore, from the viewpoint of placing the coil 2 stably on the bases 41a and 41b, the width L2 in the X-axis direction of the bases 41a and 41b is preferably L2 ≥ (R2 - R1) / 4, more preferably L2 ≥ (R2 - R1) / 2, particularly preferably L2 ≥ (R2 - R1) / 2, and R1 ≤ L1 < R2. In this case, when the coil 2 is placed on the bases 41a and 41b, the outer peripheral surface of the coil 2 can be prevented from being exposed outside the outer edges 41a3 and 41b3 or the side edges 41a2 and 41b2 of the bases 41a and 41b, and the second end 2b of the coil 2 can be supported by the bases 41a and 41b with sufficient supporting force.

[0095] With the coil 2 mounted on the bases 41a and 41b, the outer peripheral surface of the coil 2 is positioned inside the virtual line VL1 in the Y-axis direction, which connects the side edge 41a2 of the base 41a and the side edge 41b2 of the base 41b in the X-axis direction. By mounting the coil 2 on the bases 41a and 41b without positioning the outer peripheral surface of the coil 2 outside the virtual line VL1 in the Y-axis direction, the outer peripheral surface of the coil 2 can be positioned at a position that is sufficiently separated from the side surface of the core 8 in the negative Y-axis direction. This ensures sufficient thickness of the core 8 between the outer peripheral surface of the coil 2 (the end of the coil 2 in the negative Y-axis direction) and the side surface of the core 8 in the negative Y-axis direction, thus preventing cracks from forming on the side surface of the core 8 in the negative Y-axis direction. Furthermore, the ratio of the length L4 between the side edges 41a2, 41b2 and the side surface of the core 8 in the negative Y-axis direction to the width L5 in the Y-axis direction of the core 8, L4 / L5, is preferably 1 / 32 to 1 / 6, and more preferably 1 / 20 to 1 / 10.

[0096] Furthermore, from the viewpoint of placing the coil 2 in a stable state on the bases 41a and 41b, the length L3 of the bases 41a and 41b along the Y-axis direction is preferably L3 ≥ R2 / 2, and more preferably L3 ≥ R2. Additionally, the length L3 of the bases 41a and 41b along the Y-axis direction is preferably larger than the length of the connecting portions 43a and 43b along the Y-axis direction.

[0097] When L3≧R2 is set, especially in the Y-axis direction, it is possible to prevent the outer peripheral surface of coil 2 from being exposed on the side edges 41a2, 41b2 of the bases 41a, 41b or on the outside of the wiring portions 42a, 42b. In addition, in the Y-axis direction, the region of coil 2 from one end to the other can be arranged inside the bases 41a, 41b, so that coil 2 can be placed in a stable state on the bases 41a, 41b.

[0098] The width L2 of the bases 41a and 41b in the X-axis direction is approximately constant along the Y-axis direction. For example, the inner square edges 41a1 and 41b1 of the bases 41a and 41b are not given a recessed shape. The bases 41a and 41b extend continuously from the position of the side edges 41a2 and 41b2 to the position of the end of the connecting wiring portions 42a and 42b in the positive Y-axis direction.

[0099] like Figure 7B As shown, a portion of the lead-out portion 3b of the wire 3 is placed together with the second end 2b of the coil 2 on the upper surface of the base 41b. More specifically, a lead-out bottom 3b1 of the lead-out portion 3b is provided on the upper surface of the base 41b, and the lead-out bottom 3b1 contacts the base 41b. Thus, the lead-out bottom 3b1 of the lead-out portion 3b is supported by the base 41b1.

[0100] In this embodiment, the lead-out portion 3b of the wire 3 extends from below the coil 2 ( Figure 5 The second lead-out position 2d) is shown. Therefore, with the second end 2b of the coil 2 resting on the base 41b, the lead-out portion 3b is configured to extend outward along the upper surface of the base 41b and in the Y-axis direction from the lead-out base 3b1. On the other hand, the lead-out portion 3a of the wire 3 extends from above the coil 2 ( Figure 5 The first lead-out position 2c) shown is led out, therefore, it is not disposed on the upper surface of the base 41a, but disposed at a position separated from the upper surface of the base 41a by a predetermined distance.

[0101] Connect the lead-out portions 3a and 3b of wire 3 to the wiring portions 42a and 42b. For example... Figure 2 As shown, the wiring portions 42a and 42b are disposed inside the core 8. In this embodiment, the leads 3a and 3b are led out in approximately the same direction (positive Y-axis direction side), therefore, the wiring portions 42a and 42b are disposed on the positive Y-axis direction side of the coil 2 of the leads 3a and 3b.

[0102] like Figure 6 As shown, the wiring portions 42a and 42b rise from the bases 41a and 41b along the Z-axis direction. More specifically, the wiring portions 42a and 42b rise from the ends on the positive Y-axis side of the bases 41a and 41b (located on the opposite side to the side edges 41a2 and 41b2), and extend along the Z-axis direction in a state approximately orthogonal to the bases 41a and 41b. The rising positions of the wiring portions 42a and 42b are located on the outer side of the Y-axis direction of the connecting portions 43a and 43b compared to the positions of their ends on the positive Y-axis side. Figure 2 As shown, the ends of the bases 41a and 41b on the positive Y-axis side are positioned outside the Y-axis end of the coil 2. Therefore, the upright positions of the wiring portions 42a and 42b are positioned outside the Y-axis end of the coil 2.

[0103] like Figure 7B As shown, the first wiring portion 42a and the second wiring portion 42b are located at different positions about the X-axis and extend along the Z-axis in a manner that is approximately parallel to each other. Figure 6 As shown, the length L6 of the first connector 42a along the Z-axis is longer than the length L7 of the second connector 42b along the Z-axis. The ratio L7 / L6 of the length L7 of the second connector 42b along the Z-axis to the length L6 of the first connector 42a along the Z-axis is preferably 1 / 4 ≤ L7 / L6 < 1, and more preferably 1 / 3 ≤ L7 / L6 < 2 / 3.

[0104] like Figure 8As shown, with coil 2 mounted on the bases 41a and 41b, the outer peripheral surface of coil 2 is not exposed outside the virtual line VL2 connecting the first terminal 42a and the second terminal 42b in the Y-axis direction, but is positioned inside the virtual line VL2 in the Y-axis direction. This structure allows the outer peripheral surface of coil 2 to be positioned sufficiently separated from the side surface of core 8 in the positive Y-axis direction, ensuring sufficient thickness of core 8 between the outer peripheral surface of coil 2 (the end of coil 2 in the positive Y-axis direction) and the side surface of core 8 in the positive Y-axis direction, thus preventing cracks from forming on the side surface of core 8 in the positive Y-axis direction.

[0105] The length L8 along the Y-axis between the connecting portions 42a and 42b and the side surface of the core 8 on the positive Y-axis side is larger than the length L4 between the side edges 41a2 and 41b2 of the base 41a and 41b and the side surface of the core 8 on the negative Y-axis side. As described above, this is because, in this embodiment, the center of the coil 2 is offset relative to the center of the core 8 towards the negative Y-axis side. The ratio L8 / L5 of the length L8 along the Y-axis between the connecting portions 42a and 42b and the side surface of the core 8 on the positive Y-axis side to the width L5 of the core 8 on the Y-axis side is preferably 1 / 16 to 1 / 4, and more preferably 1 / 8 to 1 / 5.

[0106] like Figure 6 As shown, the wiring portion 42a has a flat plate portion 420, a receiving recess 421a, and a pair of protrusions 422a, 422a. Additionally, the wiring portion 42b has a receiving recess 421b and a pair of protrusions 422b, 422b.

[0107] The flat plate portion 420 is a flat plate shape parallel to the XZ plane, extending along the Z-axis direction in a state approximately orthogonal to the base 41a. The flat plate portion 420 connects the base 41a and a pair of protrusions 422a, 422a. By having the flat plate portion 420 in the connection portion 42a, the Z-axis position of the receiving recess 421a can be shifted upwards from the position of the base 41a. In other words, the flat plate portion 420 is primarily provided to facilitate height adjustment of the receiving recess 421a.

[0108] The flat plate portion 420 is only provided on the wiring portion 42a, and not on the wiring portion 42b. Therefore, the positions of the front ends of the wiring portion 42a and the front ends of the wiring portion 42b in the Z-axis direction are offset along the Z-axis by a distance corresponding to the height of the flat plate portion 420, forming a step along the Z-axis between the aforementioned front ends. Furthermore, the height of the step corresponds to the difference between the length L6 of the wiring portion 42a and the length L7 of the wiring portion 42b along the Z-axis direction.

[0109] like Figure 7BAs shown, the receiving recess 421a houses the lead-out portion 3a of the wire 3. The position of the receiving recess 421a (height in the Z-axis direction) is different from the first lead-out position 2c of the lead-out portion 3a. Figure 5 Corresponding to the position (height in the Z-axis direction) of the receiving recess 421a, the receiving bottom 421a1 of the receiving recess 421a is located at a position corresponding to the approximate center of the coil 2 in the Z-axis direction.

[0110] The receiving recess 421a is formed by a cutout along the Z-axis direction at the top of the wiring portion 42a. One end (upper end) of the receiving recess 421a in the Z-axis direction is open, allowing the lead-out portion 3a of the wire 3 to be inserted (or slid) into the interior of the receiving recess 421a through this open portion. Figure 7A As shown, the depth D2 of the receiving recess 421a in the Z-axis direction is determined, for example, based on the height L9 of the lead-out portion 3a. The ratio of the depth D2 to the height L9, D2 / L9, is preferably 1 < D2 / L9 ≤ 1.5, and more preferably 1 < D2 / L9 ≤ 1.3.

[0111] When the ratio D2 / L9 is set within the aforementioned range, when the lead-out portion 3a of the wire 3 is housed in the receiving recess 421a, a gap G1 can be formed between the lead-out bottom 3a1 of the lead-out portion 3a and the receiving bottom 421a1 of the receiving recess 421a. In this case, the lead-out portion 3a of the wire 3 housed in the receiving recess 421a is located above the receiving bottom 421a1 of the receiving recess 421a at a distance corresponding to the length GL1 of the gap G1 in the Z-axis direction. The ratio GL1 / D2 of the length GL1 of the gap G1 to the depth D2 of the receiving recess 421a is preferably 1 / 32 to 1 / 8, and more preferably 1 / 20 to 1 / 10.

[0112] By adopting this structure, even if the first lead-out position 2c of the lead-out part 3a is affected due to manufacturing errors ( Figure 5 When the lead-out portion 3a is deviated in the Z-axis direction (especially below the Z-axis), it is possible to connect the lead-out portion 3a to the wiring portion 42a in a straight lead-out state without bending the lead-out portion 3a when it is housed in the receiving recess 421a.

[0113] Furthermore, by forming a gap (allowance) G1 between the lead-out portion 3a and the receiving bottom 421a1 of the receiving recess 421a, the depth D2 of the receiving recess 421a is pre-made deeper, preventing the coil 2 from tilting and ensuring that the lead-out portion 3a can be reliably received in the receiving recess 421a. Additionally, even if a first lead-out position 2c of the lead-out portion 3a is created due to design changes, for example... Figure 5 Even when the lead-out portion 3a is positioned differently from the usual position along the Z-axis, it is still possible to reliably accommodate the receiving recess 421a.

[0114] Furthermore, a gap G2 is formed between the end of the lead-out portion 3a opposite to the lead-out bottom 3a1 and the top of the wiring portion 42a in the Z-axis direction. The length GL2 of the gap G2 in the Z-axis direction is larger than the length GL1 of the gap G1 in the Z-axis direction, but it can also be smaller. Thus, by providing a gap G2 in the receiving recess 421a, even if the first lead-out position 2c of the lead-out portion 3a is slightly off due to manufacturing errors, the gap can be mitigated. Figure 5 When there is a deviation in the Z-axis direction (especially above the Z-axis), as described above, without bending the lead-out portion 3a, it is possible to connect the lead-out portion 3a to the wiring portion 42a in a straight lead-out state. Furthermore, to prevent the lead-out portion 3a from being exposed outside the receiving recess 421a, as described later, laser welding can be easily performed on the joint between the wiring portion 42a and the lead-out portion 3a. Moreover, gaps G1 and G2 are not necessary and can be omitted.

[0115] Additionally, the depth D2 in the Z-axis direction of the receiving recess 421a can also be based on, for example,... Figure 6 The length L6 of the wiring portion 42a is determined by the depth D2 to the height L6 shown. The ratio D2 / L6 is preferably 1 / 4 < D2 / L6 ≤ 3 / 4, and more preferably 3 / 8 < D2 / L6 ≤ 5 / 8. By setting the ratio D2 / L6 to such a range, the lead-out portion 3a can be accommodated inside the receiving recess 421a, so that a portion of the lead-out portion 3a does not protrude from the upper end of the receiving recess 421a.

[0116] A pair of protrusions 422a, 422a are formed by sandwiching a receiving recess 421a. The extending direction of the protrusions 422a, 422a is the same as the extending direction of the flat plate 420, which is the Z-axis direction. The length of the protrusions 422a, 422a along the Z-axis direction corresponds to the length D2 of the receiving recess 421a along the Z-axis direction.

[0117] The X-axis spacing between one protrusion 422a and another protrusion 422a (i.e., the X-axis width of the receiving recess 421a) is greater than the plate thickness of the lead-out portion 3a of the wire 3. This is because it is easier to insert the lead-out portion 3a into the receiving recess 421a. The lead-out portion 3a is fixed inside the receiving recess 421a by being sandwiched between the protrusions 422a and 422a.

[0118] like Figure 7B As shown, the receiving recess 421b houses the lead-out portion 3b of the wire 3. The position of the receiving recess 421b (height in the Z-axis direction) is different from the second lead-out position 2d of the lead-out portion 3b. Figure 5 The position (height in the Z-axis direction) corresponds to the position.

[0119] The receiving recess 421b is formed by a cutout at the top of the wiring portion 42b along the Z-axis direction. However, a portion (bottom) of the receiving recess 421b penetrates the end of the terminal base bottom 41b on the positive Y-axis side; strictly speaking, a portion of the receiving recess 421b is formed along the Y-axis direction at the terminal base bottom 41b. Thus, by extending the receiving recess 421b to the terminal base bottom 41b, the bending (standing up) of the pair of protrusions 422b, 422b (described later) towards the Z-axis at the intersection of the terminal base bottom 41b and the wiring portion 42b becomes easier.

[0120] One end (upper end) of the receiving recess 421b in the Z-axis direction is open, allowing the lead-out portion 3b of the wire 3 to be inserted (or slid) into the interior of the receiving recess 421b by means of embedding (or sliding) from the open portion. Figure 7A As shown, when the lead-out portion 3a is housed in the receiving recess 421a, a gap G1 is formed between the lead-out bottom 3a1 of the lead-out portion 3a and the receiving bottom 421a1 of the receiving recess 421a. However, when the lead-out portion 3b is housed in the receiving recess 421b, this gap is not formed. Therefore, when the lead-out portion 3b is housed in the receiving recess 421b, the lead-out bottom 3b1 of the lead-out portion 3b rests on the upper surface of the terminal base bottom 41b, and the lead-out bottom 3b1 contacts the upper surface of the terminal base bottom 41b.

[0121] Furthermore, a gap G2 is formed between the end of the lead-out portion 3b opposite to the lead-out bottom 3b1 and the top of the wiring portion 42b in the Z-axis direction, similar to the case of the receiving recess 421a.

[0122] The depth D3 of the receiving recess 421b in the Z-axis direction can also be determined based on the height L9 of the lead-out portion 3b, just like the depth D2 of the receiving recess 421a in the Z-axis direction. In this case, the ratio D3 / L9 of the depth D3 to the height L9 is preferably 1 < D3 / L9 ≤ 1.5, and more preferably 1 < D3 / L9 ≤ 1.3. Furthermore, the depth D3 of the receiving recess 421b in the Z-axis direction specified here is the depth of the portion of the receiving recess 421b in which the lead-out portion 3b can actually be disposed, and corresponds to the depth of the wiring portion 42b from the top in the Z-axis direction to the upper surface of the base 41b. The depth D3 of the receiving recess 421b in the Z-axis direction is actually approximately equal to the depth D2 of the receiving recess 421a in the Z-axis direction.

[0123] The depth D3 in the Z-axis direction of the receiving recess 421b can also be based on Figure 6The length L7 of the wiring portion 42b shown is determined by the ratio D3 / L7 of the depth D3 to the height L7. Preferably, the ratio D3 / L7 is 1 / 2 < D3 / L7 < 1, and more preferably 5 / 8 < D3 / L7 ≤ 7 / 8. By setting the ratio D3 / L7 to such a range, the lead-out portion 3b can be accommodated inside the receiving recess 421b, so that a portion of the lead-out portion 3b does not protrude from the upper end of the receiving recess 421b to the outside.

[0124] A pair of protrusions 422b, 422b are formed by sandwiching a receiving recess 421b. The extending direction of the protrusions 422b, 422b is the same as that of the protrusions 422a, 422a, which is the Z-axis direction. The length of the protrusions 422b, 422b along the Z-axis direction is L7 ( Figure 6 )correspond.

[0125] The X-axis spacing between one protrusion 422b and another protrusion 422b (i.e., the X-axis width of the receiving recess 421b) is greater than the plate thickness of the lead-out portion 3b of the wire 3. This is because it is easier to insert the lead-out portion 3b into the receiving recess 421b. The lead-out portion 3b is fixed inside the receiving recess 421b by being sandwiched between the protrusions 422b and 422b.

[0126] like Figure 7A As shown, the receiving recesses 421a and 421b are misaligned along the Z-axis. Furthermore, the Z-axis positions of the lead-out portion 3a housed in the receiving recess 421a and the lead-out portion 3b housed in the receiving recess 421b are misaligned.

[0127] In this embodiment, the lead-out portions 3a and 3b are led out from the coil 2 in a misaligned state along the Z-axis direction. Therefore, the wiring portions 42a and 42b are formed in a manner corresponding to this situation, with the receiving recesses 421a and 421b misaligned along the Z-axis direction. The misalignment width along the Z-axis direction between the receiving recesses 421a and 421b corresponds to the lead-out position 2c of the lead-out portion 3a. Figure 5 ) and the lead-out position 2d of lead-out part 3b ( Figure 5 The distance between the receiving recesses 421a and 421b along the Z-axis. The misalignment width between the receiving recesses 421a and 421b along the Z-axis can also correspond to the width of the wires 3 (lead-out portions 3a, 3b) along the Z-axis.

[0128] Furthermore, the misalignment width along the Z-axis between the receiving recesses 421a and 421b can also correspond to the distance between the front ends of the pair of protrusions 422a, 422a and the front ends of the pair of protrusions 422b, 422b. Additionally, the misalignment width along the Z-axis between the receiving recesses 421a and 421b can also correspond to the distance between the receiving bottom 421a1 of the receiving recess 421a and the upper surface of the base bottom 41b. Furthermore, the misalignment width along the Z-axis between the receiving recesses 421a and 421b can also correspond to the length along the Z-axis of the flat plate portion 420 of the wiring portion 42a.

[0129] When viewing the wiring sections 42a and 42b from the front (positive Y-axis direction), as follows: Figure 7A and Figure 8 As shown, the receiving recesses 421a and 421b are positioned inwards from the outer periphery of the coil 2 about the X-axis. That is, the distance L10 between the receiving recesses 421a and 421b is smaller than the outer diameter R2 of the coil 2. Furthermore, the aforementioned distance L10 is smaller than the first lead-out position 2c of the lead-out portion 3a of the wire 3. Figure 5 ) and the second lead-out position 2d of lead-out part 3b ( Figure 5 The distance between them decreases, and the receiving recesses 421a and 421b are positioned between the first lead-out position 2c and the second lead-out position 2d. Therefore, as Figure 8 As shown, the lead-out portions 3a and 3b are inclined inward at a predetermined angle relative to the Y-axis direction and are led out, and are received in the receiving recesses 421a and 421b.

[0130] In this case, such as Figure 7A As shown, the lead-out portion 3a, through its elastic force, abuts only against the outermost (negative X-axis direction) protrusion 422a of the pair of protrusions 422a. Similarly, the lead-out portion 3b, through its elastic force, abuts only against the outermost (positive X-axis direction) protrusion 422b of the pair of protrusions 422b.

[0131] With the lead-out portions 3a and 3b of the wire 3 housed in the receiving recesses 421a and 421b, the connection portions 42a and 42b are irradiated with a laser, such as... Figure 2 As shown, molten material (joint or joint component) 9, composed of welding balls or the like, is formed at the connection portions 42a and 42b. As a result, Figure 6The pair of protrusions 422a, 422a shown are each connected by molten material 9, and the pair of protrusions 422b, 422b are each connected by molten material 9. Laser irradiation of the wiring portions 42a, 42b is performed from a direction inclined at a predetermined angle relative to the Y-axis direction, and in a manner that the laser is irradiated onto the wide surface of the leads 3a, 3b. The molten material 9 is mainly formed on the surface (laser irradiation surface) of the wiring portions 42a, 42b in the positive Y-axis direction.

[0132] like Figure 6 As shown, connecting portions 43a and 43b rise from the bases 41a and 41b at positions different from those of the wiring portions 42a and 42b along the Z-axis direction. Connecting portions 43a and 43b rise from the outer edges 41a3 and 41b3 on the opposite side of the inner edges 41a1 and 41b1 of the bases 41a and 41b in the X-axis direction, and are formed closer to the wiring portions 42a and 42b in the Y-axis direction than the side edges 41a2 and 41b2 of the bases 41a and 41b. Connecting portions 43a and 43b connect the bases 41a and 41b to the mounting portions 44a and 44b.

[0133] The connecting portions 43a and 43b have mounting auxiliary portions 430a and 430b and side lead-out portions 431a and 431b. The side lead-out portions 431a and 431b are connected to the outer edges 41a3 and 41b3 of the base portions 41a and 41b. The side lead-out portions 431a and 431b have surfaces parallel to the XY plane and extend outward in the X-axis direction to the positions of the respective sides of the core 8 in the X-axis direction.

[0134] The mounting auxiliary parts 430a and 430b are connected to the ends of the side leads 431a and 431b in the X-axis direction and extend upward. The mounting auxiliary parts 430a and 430b have surfaces parallel to the YZ plane and extend along each side of the core 8 in the X-axis direction to the mounting surface 8a of the core 8. The side leads 431a and 431b are embedded inside the core 8, while the mounting auxiliary parts 430a and 430b are exposed outside the core 8.

[0135] Mounting parts 44a and 44b are connected to the Z-axis ends of mounting auxiliary parts 430a and 430b, and extend inward in the X-axis direction. Mounting parts 44a and 44b have surfaces parallel to the XY plane, extending along... Figure 2 The core 8 shown is formed on the mounting surface 8a. Mounting portions 44a and 44b are exposed on the mounting surface 8a outside the core 8 and form connection portions with the circuit board (not shown) when the inductor 1 is mounted.

[0136] Mounting portions 44a and 44b are connected to the circuit board or the like via connecting components such as solder or conductive adhesive. At this time, solder fillets can be formed in mounting auxiliary portions 430a and 430b, thereby improving the mounting strength of the inductor 1 relative to the circuit board or the like.

[0137] Next, refer to Figures 9A to 9E The manufacturing method of inductor 1 will be described below. In the method of this embodiment, firstly, a conductive plate such as a metal plate (e.g., a Sn-plated metal plate) is punched and processed into... Figure 9A or Figure 9C The shape is as shown. As shown in the figure, terminals 4a and 4b are formed on the conductive plate after the stamping process, and are connected to the frame 7 via connecting portions 43a and 43b. In the frame 7, the terminals 4a and 4b are arranged at a predetermined interval along the X-axis direction, and this interval is consistent with... Figure 8 The distance L1 shown corresponds to this.

[0138] Next, as Figure 9A As shown, the coil 2 is placed on the bases 41a and 41b in such a way that the second end 2b of the coil 2 contacts the bases 41a and 41b. The coil 2 is arranged across the second end 2b of the coil 2 relative to the bases 41a and 41b which are arranged at predetermined intervals along the X-axis direction.

[0139] At this time, the lead-out portions 3a and 3b of the wire 3 are received in the receiving recesses 421a and 421b of the wiring portions 42a and 42b, and connected to the terminals 4a and 4b. For example, the lead-out portions 3a and 3b can be received by inserting (sliding) downward from the upper end of the receiving recesses 421a and 421b. The lead-out portion 3b of the wire 3 is placed on the base 41b such that the lead-out bottom 3b1 contacts the base bottom 41b. Alternatively, after the lead-out portions 3a and 3b are received in the receiving recesses 421a and 421b, they can be temporarily fixed using adhesive or the like.

[0140] Next, as Figure 9B As shown, a laser is irradiated onto the connectors 42a and 42b from a direction inclined at a predetermined angle relative to the Y-axis, forming a molten material 9 on the connectors 42a and 42b. This connects a pair of protrusions 422a and 422a using the molten material 9, and also connects a pair of protrusions 422b and 422b using the molten material 9. Furthermore, the area where the molten material 9 is formed is not limited to the area shown in the figure, and can be appropriately varied within a range where the leads 3a and 3b and the connectors 42a and 42b can be well connected.

[0141] Next, the coils 2 with terminals 4a and 4b fixed to their respective ends are placed inside the mold, as shown. Figure 9C As shown, this coil 2 combination Figure 3 The first core 5 shown is Figure 4 The first core 6 shown constitutes... Figure 9D The temporary assembly shown. More specifically, the columnar portion 51 of the first core 5 ( Figure 3 Insert the coil 2 into the inside and place the coil 2 on the upper part 501 of the step of the core base bottom 50. At the same time, place the bases 41a and 41b of the terminals 4a and 4b on each step 500 of the core base bottom 50.

[0142] Furthermore, the first core 5 and the second core 6 are combined to house the wiring portions 42a and 42b of terminals 4a and 4b inside the terminal receiving grooves 62a and 62b, and the lead-out portions 3a and 3b of wire 3 inside the connecting grooves 63a and 63b. The columnar portion 51 of the first core 5 and the coil 2 are housed inside the receiving hole 61 of the second core 6. Additionally, the connecting portions 43a and 43b of terminals 4a and 4b protrude from the first core 5 and the second core 6. The first core 5 and the second core 6 can be pre-formed cores. The materials constituting the first core 5 and the second core 6 can be materials with fluidity, or composite magnetic materials using thermoplastic resin or thermosetting resin as adhesives.

[0143] Next, the mold fixtures (upper and lower punches, etc.) are used to... Figure 9D The first core 5 and the second core 6 of the temporary assembly shown are compressed and molded to integrate them, thereby forming core 8. Figure 9E At this point, by applying heat, the first core 5 and the second core 6 can be easily integrated.

[0144] Next, as Figure 9E As shown, with only the connecting parts 43a and 43b remaining, Figure 9D The frame 7 shown is cut and removed using a cutting tool. Then, the connecting portions 43a and 43b are fixed to the second recesses 64 and the third recesses 65. More specifically, as... Figure 9F As shown, the connecting portions 43a and 43b of terminals 4a and 4b are connected from... Figure 9E The inductor is bent approximately vertically in the shown state, and the connecting portions 43a and 43b are fixed to each of the second recesses 64. Furthermore, in this state, the front ends of the connecting portions 43a and 43b are bent approximately vertically and fixed to each of the third recesses 65. Thus, mounting auxiliary portions 430a and 430b for terminals 4a and 4b are formed in the second recesses 64, and mounting portions 44a and 44b for terminals 4a and 4b are formed in the third recesses 65. As described above, the inductor 1 of this embodiment can be obtained.

[0145] In the inductor 1 of this embodiment, such as Figure 6 and Figure 7BAs shown, receiving recesses 421a and 421b are formed in the wiring portions 42a and 42b to accommodate the leads 3a and 3b. Therefore, by accommodating the leads 3a and 3b in the receiving recesses 421a and 421b, the leads 3a and 3b can be connected to the wiring portions 42a and 42b. When connecting the leads 3a and 3b to the wiring portions 42a and 42b, it is not necessary to rivet the terminals 4a and 4b to the leads 3a and 3b, and the leads 3a and 3b can be easily connected to the terminals 4a and 4b.

[0146] In particular, in the inductor 1 of this embodiment, the receiving recesses 421a and 421b are misaligned along the Z-axis direction. Therefore, even if the first lead-out position 2c of the lead-out portion 3a ( Figure 5 ) and the second lead-out position 2d of lead-out part 3b ( Figure 5 Even if the lead-out portion 3a or 3b is misaligned along the Z-axis, it will not unnecessarily bend the lead-out portion 3a or 3b, allowing the lead-out portions 3a and 3b to be led out to terminals 4a and 4b respectively. Therefore, at this point, the lead-out portions 3a and 3b can be easily connected to terminals 4a and 4b.

[0147] Furthermore, in the inductor 1 of this embodiment, the wiring portions 42a and 42b, which have receiving recesses 421a and 421b, are disposed inside the core 8. In addition, the coil 2 is made of flat wire. Therefore, it is easy to manufacture a surface-mount inductor 1 that can easily connect the leads 3a and 3b to the terminals 4a and 4b and can carry a large current, as described above.

[0148] Furthermore, in this embodiment, the length L6 of the wiring portion 42a along the Z-axis is longer than the length L7 of the wiring portion 42b along the Z-axis. Therefore, by staggering the receiving recesses 421a and 421b along the Z-axis by a distance corresponding to the difference between the length L6 of the wiring portion 42a and the length L7 of the wiring portion 42b along the Z-axis, the aforementioned effect can be achieved with a simple structure.

[0149] Furthermore, in this embodiment, the lead-out bottom 3b1 of the lead-out portion 3b housed in the receiving recess 421b is connected to the upper surface of the base 41b. Therefore, by supporting the lead-out portion 3b with the base 41b, even if an external force is applied to the lead-out portion 3b, it is not easy for the lead-out portion 3b to be misaligned in the Z-axis direction. Therefore, the position of the lead-out portion 3b can be positioned at a predetermined position (the upper surface of the base 41b), preventing uneven inductance characteristics and other properties in each product due to uneven positioning of the lead-out portion 3b.

[0150] Furthermore, in this embodiment, the receiving recesses 421a and 421b are formed by cutouts in the wiring portions 42a and 42b along the Z-axis direction. Therefore, by inserting, for example, the lead-out portions 3a and 3b from the top of the wiring portions 42a and 42b along the Z-axis direction into the receiving recesses 421a and 421b, the lead-out portions 3a and 3b can be easily received in the receiving recesses 421a and 421b.

[0151] Furthermore, in this embodiment, the lead-out portion 3a is arranged such that it is sandwiched between each of the pair of protrusions 422a, 422a. Therefore, the lead-out portion 3a can be stably housed in the receiving recess 421a. In addition, by using the molten material 9 to join each of the pair of protrusions 422a, 422a in this state, the lead-out portion 3a can be effectively prevented from detaching from the receiving recess 421a. Similarly, by arranging the lead-out portion 3b between each of the pair of protrusions 422b, 422b, the lead-out portion 3b can be stably housed in the receiving recess 421b. In addition, by using the molten material 9 to join each of the pair of protrusions 422b, 422b in this state, the lead-out portion 3b can be effectively prevented from detaching from the receiving recess 421b.

[0152] In addition, in this embodiment, such as Figure 7B and Figure 8 As shown, when viewing the wiring portions 42a and 42b from the positive Y-axis direction, the receiving recesses 421a and 421b are positioned inward from the outer periphery of the coil 2 about the X-axis direction. In this state, in order to receive the leads 3a and 3b in the receiving recesses 421a and 421b, the leads 3a and 3b need to be moved from their lead-out positions 2c and 2d (…). Figure 5 The leads bend inward toward the receiving recesses 421a and 421b. As a result, an elastic force is generated in the leads 3a and 3b. When the leads 3a and 3b are received in the receiving recesses 421a and 421b, the elastic force of the leads 3a and 3b can fix the leads 3a and 3b to the inside of the receiving recesses 421a and 421b with sufficient fixing strength.

[0153] Furthermore, in this embodiment, the leads 3a and 3b extend outwards in approximately the same direction (positive Y-axis direction side), and the wiring portions 42a and 42b are positioned on the positive Y-axis direction side of the coils 2 of the leads 3a and 3b. Therefore, when laser welding is applied to the wiring portions 42a and 42b, laser light can be irradiated onto each wiring portion 42a and 42b from approximately the same direction, thus facilitating laser welding and simplifying manufacturing.

[0154] Furthermore, the present invention is not limited to the embodiments described above, and various modifications can be made within the scope of the present invention.

[0155] The above embodiments illustrate applications of the inductor according to the present invention, but the present invention can also be applied to coil devices other than inductors.

[0156] In the above embodiment, the conductor 3 is composed of a flat wire, but it can also be composed of a round wire, a square wire, or a conductor other than a flat wire.

[0157] In the above embodiments, the winding shape of the wire 3 is set to a circular spiral, but it can also be, for example, an elliptical spiral or an angular spiral.

[0158] In the above embodiment, the core 8 is formed by using two cores, the first core 5 and the second core 6, but the core 8 of the inductor 1 can also be formed by using only one core. In this case, the core 8 can also be formed inside the mold by powder molding or injection molding.

[0159] In the above embodiments, such as Figure 2 As shown, the wiring portions 42a and 42b are located inside the core 8, but they can also be arranged to protrude from the outside of the core 8.

[0160] Symbol Explanation

[0161] 1…Inductor (coil device)

[0162] 2…coil

[0163] 2a…First end

[0164] 2b…Second end

[0165] 2c…First line-out position

[0166] 2d…Second lead-out position

[0167] 3… wires

[0168] 3a, 3b... Introduction

[0169] 3a1, 3b1… introduce the bottom

[0170] 4a, 4b…terminals

[0171] 41a, 41b... base

[0172] 41a1, 41b1... Inner square edge

[0173] 41a2, 41b2… Lateral edge

[0174] 41a3, 41b3… outer edge

[0175] 42a, 42b... Wiring section

[0176] 420… Flat Panel Section

[0177] 421a, 421b... Receiving recess

[0178] 421a1…Containment Bottom

[0179] 422a, 422b…protrusions

[0180] 43a, 43b... connecting parts

[0181] 430a, 430b... Installation Auxiliary Section

[0182] 431a, 431b... Lateral outlet

[0183] 44a, 44b... Installation Department

[0184] 5…First core 50…Core base bottom 500…Stepped portion 501…Stepped upper portion 51…Columnar portion 52…First recessed portion 6…Second core 60…Main body portion 61…Receiving holes 62a, 62b…Terminal receiving grooves 63a, 63b…Connecting groove 64…Second recessed portion 65…Third recessed portion 66…Bottom

[0185] 7…Framework

[0186] 8…core

[0187] 8a…Mounting surface 8b…Reverse mounting surface 80…Side recess 9…Melted material.

Claims

1. A coil device comprising: A coil, which is made of flat wire; The first terminal has a first wiring portion having a first receiving recess that receives a first lead-out portion of the coil; The second terminal has a second wiring portion having a second receiving recess that accommodates the second lead of the coil. The first receiving recess and the second receiving recess are misaligned along the winding axis of the coil. The first wiring portion and the second wiring portion extend along the winding axis at different positions. The length of the first wiring portion along the winding axis is longer than the length of the second wiring portion along the winding axis. The first receiving recess cuts the first front end of the first wiring portion along the winding axis direction. The second receiving recess cuts the second front end of the second wiring portion along the winding axis direction. The length along the winding axis from the position of the first front end to the position of the bottom of the first receiving recess is shorter than the length along the winding axis from the position of the first front end to the position of the bottom of the second receiving recess.

2. The coil device according to claim 1, wherein, The first terminal has a first base that raises the first wiring portion along the winding axis direction. The second terminal has a second base that elevates the second wiring portion along the winding axis direction. The second lead of the coil, which is housed in the second receiving recess, is connected to the second base.

3. The coil device according to claim 1 or 2, wherein, The first lead of the coil housed in the first receiving recess is located above the bottom of the first receiving recess.

4. The coil device according to claim 1 or 2, wherein, The first receiving recess is formed by a first cut along the winding axis direction in the first wiring portion. The second receiving recess is formed by a second cut in the second wiring portion along the direction of the winding axis.

5. The coil device according to claim 1 or 2, wherein, A pair of first protrusions are formed between the first receiving recess and the first wiring portion. In the second wiring portion, a pair of second protrusions are formed by sandwiching the second receiving recess between them. Each of the first protrusions is connected by a free joint. Each of the two second protrusions is connected by a free joint.

6. The coil device according to claim 4, wherein, A pair of first protrusions are formed between the first receiving recess and the first wiring portion. In the second wiring portion, a pair of second protrusions are formed by sandwiching the second receiving recess between them. Each of the first protrusions is connected by a free joint. Each of the two second protrusions is connected by a free joint.

7. The coil device according to claim 1 or 2, wherein, When viewed from the front, the first and second wiring portions are positioned inside the coil from a direction orthogonal to the winding axis.

8. The coil device according to claim 1 or 2, wherein, The first lead-out portion and the second lead-out portion extend in approximately the same direction. The first wiring portion and the second wiring portion are disposed on one side of the coil from which the first lead and the second lead are drawn.

9. A coil device comprising: Matrix; A coil, which is composed of flat wire and is embedded inside the substrate; The first terminal has a first wiring portion that connects to the first lead-out portion of the coil, and the first wiring portion is disposed inside the base; The second terminal has a second wiring portion that connects to the second lead of the coil, and the second wiring portion is disposed inside the base. A first receiving recess is formed at the first wiring portion to receive the first lead-out portion. A second receiving recess is formed in the second wiring portion to receive the second lead-out portion. At least one of the first lead-out portion and the second lead-out portion extends toward a first side of the substrate. The first wiring portion has a first main surface opposite to the first side surface. The second wiring portion has a second main surface opposite to the first side surface. The first receiving recess extends through the first wiring portion in a direction perpendicular to the first main surface. The second receiving recess extends through the second wiring portion in a direction perpendicular to the second main surface. The length of the first wiring portion opposite to the first side along the winding axis is longer than the length of the second wiring portion opposite to the first side along the winding axis.

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