Coil device

Abstract

The invention provides a coil device with high bonding quality between a mounting part and a mounting substrate. A coil device (1) is provided with: a wire (10) having a winding part (11) and a lead-out part (12a) led out from the winding part (11); a core (20) having a core part (21) provided with the winding part (11), and a flange part (22a) formed at one end of the core part (21) in the axial direction; and a terminal piece (30a) having a mounting portion (31) connectable to the mounting substrate, a wiring portion (32) connected to the lead-out portion (12a), and a connecting portion (36) connecting the mounting portion (31) and the wiring portion (32). The attachment section (31) and the wiring section (32) are disposed on the attachment surface (221) of the flange section (22a). The connecting portion (36) extends from the mounting portion (31) to the wiring portion (32) via an end surface (224) of the flange portion (22a) and a side surface (225) of the flange portion (22a).

Description

Technical Field

[0001] The invention relates to a coil arrangement having a terminal element. Background Art

[0002] For example, as shown in Patent Document 1, various technologies have been proposed for a coil device having a terminal member. In the coil device of Patent Document 1, the terminal member has a mounting portion and a wiring portion. The mounting portion is, for example, a portion connected to a pad pattern of a mounting substrate by welding. The wiring portion is, for example, a portion to which a lead portion of a wire is connected by laser welding.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2020-074459 Summary of the invention

[0006] Technical problem to be solved by the invention

[0007] As a technology for connecting the lead portion to the wiring portion, various technologies such as welding, laser welding, thermal compression, and resistance welding are known. If the lead portion is connected to the wiring portion by these technologies, heat is transmitted from the wiring portion to the mounting portion, and the temperature of the mounting portion rises. Therefore, the bonding property of the mounting portion relative to the mounting substrate is reduced, and the bonding strength between the mounting portion and the mounting substrate may be reduced. As a result, poor installation such as the coil device detaching from the mounting substrate may occur.

[0008] The present invention has been made in view of such actual circumstances, and an object of the present invention is to provide a coil device having high bonding quality between a mounting portion and a mounting substrate.

[0009] Technical solutions to the problem

[0010] In order to achieve the above-mentioned object, the coil device of the present invention,

[0011] have:

[0012] A conductive wire having a winding portion and a lead portion led out from the winding portion;

[0013] a core having a core portion provided with the winding portion, and a flange portion formed at one axial end of the core portion; and

[0014] The terminal member has a mounting portion connectable to a mounting substrate, a wiring portion connected to the lead-out portion, and a connecting portion connecting the mounting portion and the wiring portion.

[0015] The mounting portion and the wiring portion are arranged on the mounting surface of the flange portion.

[0016] The connecting portion extends from the mounting portion to the connecting portion via an end surface of the flange portion and a side surface of the flange portion.

[0017] In the coil device of the present invention, the connecting portion extends from the mounting portion to the wiring portion via the end face of the flange portion and the side face of the flange portion. That is, the connecting portion does not extend along the shortest path connecting the mounting portion and the wiring portion (the path along the mounting surface), but extends along a path that detours through the shortest path (the path via the end face and the side face of the flange portion). Therefore, compared with the case where the connecting portion extends along the above-mentioned shortest path, the length of the connecting portion along the extension direction becomes longer, and the distance of the connecting portion passing through the mounting portion and the wiring portion becomes longer. As a result, the amount of heat propagated from the wiring portion to the mounting portion is reduced, and the temperature rise of the mounting portion is moderated. Therefore, the bonding property of the mounting portion relative to the mounting substrate is improved, and the bonding quality between the mounting portion and the mounting substrate can be improved.

[0018] In addition, for example, when the mounting portion is bonded to the mounting surface of the flange portion, the temperature rise of the mounting portion is moderate, so that the adhesive layer between the mounting portion and the mounting surface of the flange portion is less likely to deteriorate. As a result, the bonding property of the mounting portion relative to the mounting surface is improved, and the bonding quality between the mounting portion and the mounting surface is improved.

[0019] Alternatively, the flange portion may include a recessed portion formed on the mounting surface, the mounting portion may be disposed on the mounting surface at a position different from the recessed portion, and the wiring portion may be disposed inside the recessed portion. In this case, when the mounting portion is connected to the mounting substrate, the wiring portion is disposed separately from the mounting substrate, and it is difficult for the wiring portion to contact the mounting substrate. Therefore, a short circuit between the wiring portion and the mounting substrate can be prevented.

[0020] At least a portion of the lead portion may also be disposed between the wiring portion and the mounting surface. In this case, for example, when the lead portion is connected to the wiring portion, positional deviation caused by the elasticity of the lead portion can be prevented by the wiring portion or the mounting surface. Thus, the lead portion can be connected to the wiring portion at a desired position, and the bonding quality between the lead portion and the wiring portion is improved.

[0021] Alternatively, the wiring portion may include: a first pressing piece that presses the lead-out portion toward the mounting surface; and a second pressing piece that presses the lead-out portion toward the mounting surface at an end surface side closer to the flange portion than the first pressing piece and is connected to the lead-out portion. For example, by pressing the lead-out portion toward the mounting surface by the first pressing piece before connecting the lead-out portion to the second pressing piece, the position of the lead-out portion is unlikely to shift, and the lead-out portion can be connected to a desired position of the second pressing piece. In addition, by pressing the lead-out portion toward the mounting surface by the second pressing piece, contact between the lead-out portion and the second pressing piece can be ensured, and the lead-out portion can be connected to the second pressing piece.

[0022] The first pressing piece and the second pressing piece may also have a riveted structure. In this case, by riveting the first pressing piece and the second pressing piece, the lead-out portion can be easily pressed toward the mounting surface.

[0023] Alternatively, the wiring portion may include a terminal groove portion that accommodates at least a portion of the lead portion, and the terminal groove portion is formed on an inner surface of the wiring portion that is opposite to the mounting surface. In this case, the lead portion is positioned by the terminal groove portion, and the position of the lead portion relative to the wiring portion is unlikely to shift. As a result, the lead portion can be connected to the wiring portion at a desired position, and the joining quality between the lead portion and the wiring portion is improved.

[0024] The flange portion may also include a flange groove portion that accommodates at least a portion of the lead portion, and the flange groove portion extends along the mounting surface at a position opposite to the wiring portion. In this case, the lead portion is positioned by the flange groove portion, and the position of the lead portion relative to the wiring portion is unlikely to shift. As a result, the lead portion can be connected to the wiring portion at a desired position, and the joining quality between the lead portion and the wiring portion is improved.

[0025] Alternatively, the terminal member may include a first terminal member and a second terminal member, wherein the first terminal member is disposed on one side of the flange portion, and the second terminal member is disposed on another side of the flange portion. By providing the flange portion with two terminal members, the installation stability of the coil device is improved when the coil device is installed on a mounting substrate.

[0026] It is also possible to further include a plate-shaped core mounted on the core, the plate-shaped core being joined to the non-mounting surface of the flange portion located on the opposite side of the mounting surface. In this case, a closed magnetic circuit is formed by the core and the plate-shaped core, and the magnetic properties of the coil device are improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a perspective view of the coil device according to the first embodiment of the present invention.

[0028] Figure 2 yes Figure 1 An exploded perspective view of the coil device shown.

[0029] Figure 3 yes Figure 2 A perspective view of the core is shown.

[0030] Figure 4 yes Figure 2 A perspective view of the terminal piece shown.

[0031] Figure 5 Observed from the Y-axis direction Figure 1 Side view of the coil arrangement shown.

[0032] Figure 6 Observed from the X-axis direction Figure 1 Side view of the coil arrangement shown.

[0033] Figure 7 It is a perspective view of a coil device according to a second embodiment of the present invention.

[0034] Figure 8 yes Figure 7 A perspective view of the terminal piece shown.

[0035] Fig. 9 It is an exploded perspective view of a coil device according to a third embodiment of the present invention.

[0036] Fig.10 yes Fig. 9 A perspective view of the core is shown.

[0037] Fig.11 It is a perspective view of a coil device according to a fourth embodiment of the present invention.

[0038] Fig.12 yes Fig.11 A perspective view of the core is shown.

[0039] Fig.13 yes Fig.11 A perspective view of the terminal piece shown.

[0040] Fig.14 It is a perspective view of a coil device according to a fifth embodiment of the present invention.

[0041] Fig.15 yes Fig.14 A perspective view of the terminal piece shown.

[0042] Explanation of symbols

[0043] 1, 1A, 1B, 1C, 1D…coil device, 10, 60…conducting wire, 11, 61…winding portion, 12a, 12b, 62a, 62b…lead-out portion, 13…film, 20, 20B, 20C…core, 21…core portion, 22a, 22b, 22aB, 22bB, 22aC, 22bC…flange portion, 221…mounting surface, 222…non-mounting surface, 223…inner end surface, 224…outer end surface, 225…first side surface, 226…second side surface, 23…first region, 24, 24_1, 24_2…second region, 25, 25_1, 25_2…recessed portion, 26…notch portion, 27…flange groove portion, 28… convex portion, 29…step forming surface, 30a, 30b, 30aC_1, 30aC_2, 30bC_1, 30bC_2, 30aA, 30bA, 30aD, 30bD…terminal member, 31…installation portion, 32, 32A, 32D…connection portion, 321…inner surface, 322…outer surface, 33…first pressing piece, 34…second pressing piece, 340…expansion portion, 35…groove portion, 36, 36C…connection portion, 361, 361C…side facing portion, 362…end facing portion, 362w…wide width portion, 362n…narrow width portion, 363…side rising portion, 37…terminal groove portion, 40…melting portion, 50…plate-shaped core. DETAILED DESCRIPTION

[0044] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. The contents of the drawings are merely schematic and exemplary for the purpose of understanding the present invention, and the appearance, dimensional ratio, etc. may be different from the actual objects. In addition, the present invention is not limited to the following embodiments.

[0045] First Embodiment

[0046] Figure 1 The coil device 1 shown functions as an inductor, for example, and can be mounted on a power supply of an electrical device, etc. The coil device 1 includes a conductor 10, a core 20, and terminal members 30a and 30b. The coil device 1 also includes a planar core 50 in addition to these components, but the planar core 50 is not essential.

[0047] like Figure 2 As shown, the conductor 10 has a winding portion 11 wound in a coil shape, and lead portions 12a and 12b led out from the winding portion 11. The conductor 10 is not particularly limited, but is an insulating coated conductor such as a copper wire covered with an insulating coating 13. The wire diameter of the conductor 10 is not particularly limited, but is, for example, 10 to 300 μm. The coating 13 is removed at the front end of each of the lead portions 12a and 12b.

[0048] The core 20 is a drum core and has a core portion 21 and flange portions 22a and 22b. The core 20 is a magnetic body and is made of a ferrite composition, a metal composition, or a composite composition of them and a resin. The conductor 10 is wound on the outer peripheral surface of the core portion 21, and a winding portion 11 is formed. A gap is formed between the end of the winding portion 11 in the winding axis direction and the flange portion 22a. In addition, a gap is formed between the end of the winding portion 11 in the winding axis direction and the flange portion 22b. As shown in FIG. Figure 3 As shown, the cross-sectional shape perpendicular to the axial direction of the core 21 is an octagon, but it may also be a quadrilateral, a hexagon, other polygons, a circle, an ellipse, or the like.

[0049] The flange portion 22a is formed at one axial end of the core portion 21, and the flange portion 22b is formed at the other axial end of the core portion 21. The flange portions 22a and 22b respectively have a mounting surface 221, a non-mounting surface 222, an inner end surface 223, an outer end surface 224, a first side surface 225, and a second side surface 226. The mounting surface 221 and the non-mounting surface 222 are opposite, the inner end surface 223 and the outer end surface 224 are opposite, and the first side surface 225 and the second side surface 226 are opposite.

[0050] exist Figure 2 In the above, the X-axis is an axis along the direction in which the inner end surface 223 and the outer end surface 224 are opposite to each other. The Y-axis is an axis along the direction in which the first side surface 225 and the second side surface 226 are opposite to each other. The Z-axis is an axis along the direction in which the mounting surface 221 and the non-mounting surface 222 are opposite to each other. The X-axis, the Y-axis, and the Z-axis are perpendicular to each other. In addition, the X-axis corresponds to the axial direction of the core 21.

[0051] The flanges 22a and 22b have a recess 25 formed on the mounting surface 221. The recess 25 is formed on the side of the mounting surface 221 close to the first side surface 225. The mounting surface 221 is notched by the recess 25 on the side close to the first side surface 225. The depth of the recess 25 is not particularly limited, but is a depth capable of accommodating the wiring portion 32 of the terminal member 30a or 30b described later.

[0052] The mounting surface 221 has a first region 23 as a region where the recess 25 is not formed, and a second region 24 as a region where the recess 25 is formed. The first region 23 and the second region 24 are both flat surfaces and are adjacent to each other along the Y axis. The length of the first region 23 in the Y axis direction is longer than the length of the second region 24 in the Y axis direction, but may be equal to or shorter than the length of the second region 24 in the Y axis direction.

[0053] A step is formed along the Z axis between the first region 23 and the second region 24. A step forming surface 29 connecting the first region 23 and the second region 24 extends from one end to the other end of the mounting surface 221 in the X axis direction. A notch (chamfered portion) 26 is formed at each outer edge of the first region 23 and the second region 24 to prevent breakage or chipping.

[0054] The recessed portion 25 of the flange portion 22a and the recessed portion 25 of the flange portion 22b are located on opposite sides of the Y-axis direction relative to the core portion 21. Therefore, when the coil device 1 is mounted on a mounting substrate (not shown), the stability of the coil device 1 relative to the mounting substrate is improved compared to the case where the recessed portion 25 of the flange portion 22a and the recessed portion 25 of the flange portion 22b are located on the same side of the Y-axis direction relative to the core portion 21. In addition, the recessed portion 25 of the flange portion 22a and the recessed portion 25 of the flange portion 22b may also be located on the same side of the Y-axis direction relative to the core portion 21.

[0055] like Figure 4 As shown, the terminal member 30a has a mounting portion 31, a wiring portion 32 and a connecting portion 36. In addition, the terminal member 30b has a mounting portion 31, a wiring portion 32 and a connecting portion 36. The terminal member 30a and the terminal member 30b have the same shape, but may also have different shapes. The terminal members 30a and 30b are made of a conductor such as metal. A plating film such as Sn or Ni is formed entirely or partially on the surface of the terminal members 30a and 30b. The thickness of each of the terminal members 30a and 30b is not particularly limited, but is 50 to 300 μm. The plate thickness of the mounting portion 31, the wiring portion 32 and the connecting portion 36 is equal, but may also be different.

[0056] The mounting portion 31 is a portion that can be connected to the mounting substrate. The mounting portion 31 has a portion that is connected to the mounting surface 221 ( Figure 3 ) is parallel to the first region 23. Figure 1 As shown, the mounting portion 31 is arranged in the first region 23 . That is, the mounting portion 31 is arranged on the mounting surface 221 at a position different from that of the recessed portion 25 .

[0057] In a state where the terminal members 30a and 30b are fixed to the flange portions 22a and 22b, respectively, the mounting portion 31 is bonded to the first region 23 ( Figure 3 Thus, an adhesive layer is formed between the mounting portion 31 and the first region 23, which can prevent the terminals 30a and 30b from being separated. The mounting portion 31 may also be connected to the land pattern of the mounting substrate by solder or a conductive adhesive.

[0058] The length of the mounting portion 31 in the Y-axis direction is not particularly limited, but the stability of the coil device 1 with respect to the mounting substrate is improved on the mounting surface 221 .

[0059] The connection part 32 is a part connected to the lead part 12a or 12b. The lead part 12a may be connected to the connection part 32 by welding, laser welding, thermocompression welding, ultrasonic bonding, resistance welding, ultraviolet curing resin bonding, etc. The same is true for the lead part 12b.

[0060] In this embodiment, the lead portions 12a and 12b are connected to the connection portion 32 by laser welding. Figure 1 As shown, a fusion portion (fusion ball) 40 is formed at the connection portion of the connection portion 32 of the terminal 30a and the lead portion 12a. In addition, a fusion portion 40 is formed at the connection portion of the connection portion 32 of the terminal 30b and the lead portion 12b. The lead portions 12a and 12b are integrated with the connection portion 32 through the fusion portion 40.

[0061] At least a portion of the wiring portion 32 is disposed in the second region 24 ( Figure 3 ). In addition, at least a portion of the wiring portion 32 is arranged inside the recess 25. Therefore, when the mounting portion 31 is connected to the mounting substrate, the wiring portion 32 is separated from the mounting substrate and arranged, and it is difficult for the wiring portion 32 to contact the mounting substrate. As a result, a short circuit between the wiring portion 32 and the mounting substrate can be prevented. A portion of the wiring portion 32 is arranged on the first side surface 225, but the entire wiring portion 32 may be arranged in the second area 24. The wiring portion 32 is not joined to the second area 24 by an adhesive, but a gap is formed between the wiring portion 32 and the second area 24.

[0062] like Figure 4 As shown in FIG. 1 , the connection portion 32 includes a first pressing piece 33, a second pressing piece 34, and a groove portion 35 formed between the first pressing piece 33 and the second pressing piece 34. The first pressing piece 33 and the second pressing piece 34 are located on opposite sides of each other across the groove portion 35. The first pressing piece 33 is located on the inner end surface 223 ( Figure 3 The second pressing piece 34 is located on the outer end surface 224 ( Figure 3 )side.

[0063] The first pressing piece 33 and the second pressing piece 34 are configured to be bendable and have a riveted structure. Figure 4 , the state before the first pressing piece 33 is bent is represented by a solid line, and the state after the first pressing piece 33 is bent is represented by a two-dot chain line. In addition, the state before the second pressing piece 34 is bent is represented by a solid line, and the state after the second pressing piece 34 is bent is represented by a two-dot chain line.

[0064] The first pressing piece 33 is composed of a plate piece having an elongated shape, and is configured to be able to be bent at a substantially right angle from a state in which it is erected along the Z axis. The second pressing piece 34 is composed of a plate piece having an L shape, and is configured to be able to be bent at a substantially right angle from a state in which it is erected along the Z axis. Figure 1 As shown, the first pressing piece 33 is in a bent state and is in contact with the second area 24 ( Figure 3 ) are arranged in parallel. In addition, the second pressing piece 34 is arranged in parallel with the second region 24 in a bent state.

[0065] like Figure 4 As shown, the second pressing piece 34 has an expansion portion 340. The expansion portion 340 is formed at the front end of the second pressing piece 34, and the length of the expansion portion 340 along the X-axis is longer than the length of other portions along the X-axis.

[0066] like Figure 1 and Figure 5 As shown, at least a portion of the lead portion 12a is disposed between the connection portion 32 and the second region 24 ( Figure 3 ) between the connecting portion 32 and the mounting surface 221. A gap is formed between the connecting portion 32 and the second region 24, and at least a portion of the lead portion 12a is disposed inside the gap.

[0067] In addition, at least a portion of the lead portion 12b is disposed between the connection portion 32 and the second region 24 of the mounting surface 221, and is sandwiched (held) by the connection portion 32 and the second region 24. A gap is formed between the connection portion 32 and the second region 24, and at least a portion of the lead portion 12b is disposed inside the gap.

[0068] The first pressing piece 33 has a riveted structure, and presses the lead portion 12a or 12b toward the mounting surface 221. The second pressing piece 34 has a riveted structure, and presses the lead portion 12a or 12b toward the mounting surface 221 on the side closer to the outer end surface 224 than the first pressing piece 33. By riveting the first pressing piece 33 and the second pressing piece 34, the lead portion 12a or 12b can be easily pressed toward the mounting surface 221. In addition, the lead portion 12a or 12b may also abut against the second area 24 of the mounting surface 221, or a gap may be formed between the lead portion 12a or 12b and the mounting surface 221.

[0069] The lead portion 12a or 12b is in contact with the inner surface (the surface opposite to the mounting surface 221) of the second pressing piece 34. In addition, the lead portion 12a or 12b is connected to the expansion portion 340 of the second pressing piece 34 by, for example, laser welding. The fusion portion 40 is formed in the second pressing piece 34 (expansion portion 340), but is not formed in the first pressing piece 33. The lead portion 12a or 12b is in contact with the inner surface (the surface opposite to the mounting surface 221) of the first pressing piece 33, but is not integrated with the first pressing piece 33 through the fusion portion 40.

[0070] For example, by pressing the lead portion 12a toward the mounting surface 221 by the first pressing piece 33 before connecting the lead portion 12a to the second pressing piece 34, the position of the lead portion 12a is unlikely to be displaced, and the lead portion 12a can be connected to the desired position of the second pressing piece 34. In addition, by pressing the lead portion 12a toward the mounting surface 221 by the second pressing piece 34, the contact between the lead portion 12a and the second pressing piece 34 can be ensured, and the lead portion 12a can be connected to the second pressing piece 34. The same is true for the lead portion 12b.

[0071] like Figure 4 As shown in the figure, the connecting portion 36 is a portion connecting the mounting portion 31 and the wiring portion 32. One end of the connecting portion 36 in the extending direction is continuously connected to the outer end of the mounting portion 31 in the X-axis direction. In addition, the other end of the connecting portion 36 in the extending direction is continuously connected to the respective ends (bases) of the first pressing piece 33 and the second pressing piece 34.

[0072] like Figure 3 and Figure 4 As shown in FIG. 1 , the connecting portion 36 is bent into an L-shape at the intersection (ridgeline) of the first side surface 225 and the outer end surface 224, and has an L-shape (bent structure) when viewed from above. The connecting portion 36 has a side surface facing portion 361 and an end surface facing portion 362 that is orthogonal to the side surface facing portion 361. Figure 5 As shown, the side facing portion 361 is disposed on the first side surface 225 so as to face the first side surface 225. The side facing portion 361 is in contact with the first side surface 225, but a gap may be formed between the side facing portion 361 and the first side surface 225. The length of the side facing portion 361 along the Z axis is not particularly limited, but is less than 1 / 2 of the length of the first side surface 225 along the Z axis.

[0073] The first pressing piece 33 and the second pressing piece 34 extend in a manner of standing up from one end in the Z-axis direction of the side surface facing portion 361. Between the side surface facing portion 361 and the first side surface 225, no adhesive is filled.

[0074] like Figure 6 As shown in FIG. 1 , the end surface facing portion 362 is arranged on the outer end surface 224 in a manner facing the outer end surface 224. When viewed from the X-axis direction, the end surface facing portion 362 has an L-shape (curved structure). The end surface facing portion 362 is in contact with the outer end surface 224, but a gap may be formed between the end surface facing portion 362 and the outer end surface 224. In addition, the end surface facing portion 362 (especially, the wide width portion 362w described later) may be bonded to the outer end surface 224 by an adhesive.

[0075] The end surface facing portion 362 has a wide portion 362w and a narrow portion 362n. One end of the wide portion 362w in the Z-axis direction is aligned with the mounting portion 31 ( Figure 4 ) are connected continuously.

[0076] The length L1 of the wide portion 362w in the Z-axis direction is longer than the length L2 of the narrow portion 362n in the Z-axis direction. In addition, the area of ​​the wide portion 362w is larger than the area of ​​the narrow portion 362n. The ratio L1 / L2 of L1 and L2 is not particularly limited, but is greater than 2. In addition, the length L1 of the wide portion 362w in the Z-axis direction is not particularly limited, but is greater than 1 / 2 of the length of the outer end surface 224 in the Z-axis direction.

[0077] The length L3 of the wide portion 362w along the Y axis is longer than the length L4 of the narrow portion 362n along the Y axis. The ratio L3 / L4 of L3 and L4 is not particularly limited, but is greater than 1. In addition, the length L3 of the wide portion 362w in the Y axis direction is not particularly limited, but is greater than 1 / 2 of the length of the outer end surface 224 in the Y axis direction.

[0078] The narrow width portion 362n is adjacent to the wide width portion 362w and extends along the Y axis. The narrow width portion 362n continuously connects the wide width portion 362w and the side facing portion 361 ( Figure 4 The narrow width portion 362 n is located on the outer end surface 224 closer to the non-mounting surface 222 than the second region 24 .

[0079] like Figure 5 and Figure 6 As shown, the connection portion 36 extends from the mounting portion 31 to the connection portion 32 via two surfaces of the flange portion 22a, namely, the outer end surface 224 and the first side surface 225. The connection portion 36 has a structure that is bent into an L shape from the wide portion 362w to the narrow portion 362n, and is bent into an L shape from the narrow portion 362n to the side facing portion 361. In this way, the connection portion 36 is bent in two places, but it can also be bent in three or more places. For example, at Figure 6 In the example shown, the end surface facing portion 362 is bent at one location on the outer end surface 224, but may be bent at two or more locations.

[0080] When the coil device 1 is mounted on a mounting substrate, a fillet of solder, conductive adhesive or the like may be formed on the connection portion 36. In this case, the connection between the mounting portion 31 and the mounting substrate can be strengthened by the fillet.

[0081] like Figure 5As shown, the lead portion 12a is led out from the core portion 21 to the outer end surface 224. The same is true for the lead portion 12b. In addition, the molten portion 40 is formed at the end of the expansion portion 340 in the X-axis direction, and a part of the molten portion 40 is located at a position closer to the outside of the X-axis direction than the outer end surface 224. This is because when the lead portion 12a or 12b is connected to the wiring portion 32, the laser is irradiated to the wiring portion 32 (the second pressing piece 34) at the outside of the X-axis direction than the outer end surface 224. In this case, it is possible to prevent the flange portion 22a or 22b from being damaged during laser irradiation.

[0082] like Figure 2 As shown in FIG. 1 , the plate-like core 50 is a plate body having a rectangular parallelepiped shape and is mounted on the core 20. The plate-like core 50 is made of the same material as the core 20, but may also be made of a material different from that of the core 20. Figure 1 As shown, the plate-like core 50 is bonded to the respective non-mounting surfaces 222 of the flange portions 22a and 22b by an adhesive. A notch portion (chamfered portion) is formed at the outer edge of the plate-like core 50 to prevent breakage or defect. By mounting the plate-like core 50 on the core 20, a closed magnetic circuit consisting of the core 20 and the plate-like core 50 is formed, and the magnetic properties of the coil device 1 are improved.

[0083] Next, a method for manufacturing the coil device 1 will be described. First, prepare Figure 2 The conductor 10, the core 20, and the terminal pieces 30a and 30b are shown. For example, the length of the core 20 in the X-axis direction is 1 to 6 mm, the length of the core 20 in the Y-axis direction is 0.5 to 3 mm, and the length of the core 20 in the Z-axis direction is 0.5 to 3 mm, but the size of the core 20 is not particularly limited.

[0084] Next, the mounting portion 31 of the terminal member 30a is bonded to the flange portion 22a by an adhesive, and the terminal member 30a is mounted on the flange portion 22a. Also, the mounting portion 31 of the terminal member 30b is bonded to the flange portion 22b by an adhesive, and the terminal member 30b is mounted on the flange portion 22b. Figure 4 As shown in FIG. 1 , the first pressing plate 33 and the second pressing plate 34 are erected. Figure 2 As shown, the conductor 10 is wound around the core 21 to form a winding portion 11 .

[0085] Next, one side of the conductor 10 is led out from the core 21 to the outer end surface 224 side of the flange 22a in a manner passing through the second region 24 of the flange 22a. Figure 4 The first pressing piece 33 shown is bent at a right angle, and the first pressing piece 33 presses one side of the wire 10 toward the mounting surface 221. Next, the wire 10 is cut off by the cutting piece at the outer side of the outer end surface 224 in the X-axis direction. Figure 4The second pressing piece 34 shown is bent at a right angle, and the second pressing piece 34 presses one end of the wire 10 toward the mounting surface 221. In addition, the coating 13 on one end of the wire 10 is peeled off at an appropriate timing.

[0086] Similarly, the other side of the conductor 10 is led out from the core 21 to the outer end surface 224 side of the flange 22b in a manner passing through the second region 24 of the flange 22b. Figure 4 The first pressing piece 33 shown in FIG. 1 is bent at a right angle, and the first pressing piece 33 presses the other side of the wire 10 toward the mounting surface 221. Next, the other side of the wire 10 is cut by the cutting piece at the outer side of the outer end surface 224 in the X-axis direction. Figure 4 The second pressing piece 34 shown is bent at a right angle, and the second pressing piece 34 presses the other end of the wire 10 toward the mounting surface 221. In addition, the coating 13 on the other end of the wire 10 is peeled off at an appropriate timing.

[0087] Then, if Figure 5 As shown, laser is irradiated toward the expansion portion 340 of the terminal member 30a to connect the lead portion 12a to the expansion portion 340. Similarly, laser is irradiated toward the expansion portion 340 of the terminal member 30b to connect the lead portion 12b to the expansion portion 340. In addition, the expansion portion 340 is shortened in the X-axis direction by melting (by forming a melting portion 40). Next, the plate-like core 50 is bonded to the non-mounting surfaces 222 of the flange portions 22a and 22b respectively by an adhesive. As described above, the coil device 1 can be manufactured.

[0088] like Figure 1 As shown, in the coil device 1 of the present embodiment, the connection portion 36 extends from the mounting portion 31 to the wiring portion 32 via the outer end surface 224 of the flange portion 22a and the first side surface 225. That is, the connection portion 36 does not extend along the shortest path connecting the mounting portion 31 and the wiring portion 32 (the path along the mounting surface 221), but extends along a path that detours through the shortest path (the path via the outer end surface 224 of the flange portion 22a and the first side surface 225). Therefore, compared with the case where the connection portion 36 extends along the shortest path, the length of the connection portion 36 along the extension direction becomes longer, and the distance of the connection portion 36 passing between the mounting portion 31 and the wiring portion 32 becomes longer. As a result, when the lead portion 12a and the wiring portion 32 are laser-welded, the amount of heat propagated from the wiring portion 32 to the mounting portion 31 is reduced, and the temperature rise of the mounting portion 31 is moderated. As a result, the plating film on the surface of the mounting portion 31 is less likely to deteriorate, the bonding property of the mounting portion 31 to the mounting substrate is improved, and the bonding quality between the mounting portion 31 and the mounting substrate can be improved.

[0089] In addition, since the temperature rise of the mounting portion 31 is moderate, the adhesive between the mounting portion 31 and the mounting surface 221 is less likely to deteriorate. As a result, the bonding property of the mounting portion 31 to the mounting surface 221 is improved, and the bonding quality between the mounting portion 31 and the mounting surface 221 can be improved.

[0090] In addition, at least a portion of the lead portion 12a is disposed between the connection portion 32 and the mounting surface 221. Therefore, when the lead portion 12a is connected to the connection portion 32, positional deviation caused by the elasticity of the lead portion 12a can be prevented by the connection portion 32 or the mounting surface 221. Thus, the lead portion 12a can be connected to the connection portion 32 at a desired position, and the bonding quality between the lead portion 12a and the connection portion 32 is improved.

[0091] Second Embodiment

[0092] Figure 7 The coil device 1A of the second embodiment shown has the same configuration as the coil device 1 of the first embodiment except for the following points. The same reference numerals are used for the portions that overlap with the coil device 1 of the first embodiment, and detailed description thereof is omitted.

[0093] The coil device 1A is different from the coil device 1 of the first embodiment in that it has terminal members 30aA and 30bA. The terminal members 30aA and 30bA are different from the terminal portions 30a and 30b of the first embodiment in that they have connecting portions 32A.

[0094] like Figure 8 As shown, the connection portion 32A has a terminal groove portion 37. The terminal groove portion 37 is formed on the inner surface 321 of each of the first pressing piece 33 and the second pressing piece 34, and is recessed from the inner surface 321 toward the outer surface 322. However, the inner surface 321 is a surface opposite to the mounting surface 221, and the outer surface 322 is a surface on the opposite side of the inner surface 321.

[0095] The terminal groove 37 extends along the X-axis. More specifically, the terminal groove 37 extends linearly from one end of the first pressing piece 33 in the X-axis direction to the other end. In addition, the terminal groove 37 extends linearly from one end of the second pressing piece 34 in the X-axis direction to the other end. The cross-sectional shape of the terminal groove 37 is a quadrilateral, but may also be other polygonal, circular, elliptical, etc.

[0096] The depth of the terminal groove 37 is less than the diameter of the wire 10. However, the depth of the terminal groove 37 may be equal to the diameter of the wire 10 or greater than it. Figure 7 As shown, at least a portion of the lead portion 12a is received in the terminal groove portion 37 of the terminal member 30aA. Also, at least a portion of the lead portion 12b is received in the terminal groove portion 37 of the terminal member 30bA.

[0097] In this embodiment, the same effects as those of the first embodiment can also be obtained. In addition, in this embodiment, since at least a portion of the lead portion 12a is accommodated in the terminal groove portion 37, the lead portion 12a is positioned by the terminal groove portion 37, and the position of the lead portion 12a relative to the connection portion 32A is less likely to shift. As a result, the lead portion 12a can be connected to the connection portion 32A at a desired position, and the bonding quality between the lead portion 12a and the connection portion 32A is improved.

[0098] Third Embodiment

[0099] Fig. 9 The coil device 1B of the third embodiment shown has the same configuration as the coil device 1 of the first embodiment except for the following points. The same reference numerals are used for the portions that overlap with the coil device 1 of the first embodiment, and detailed description thereof is omitted.

[0100] The coil device 1B is different from the coil device 1 of the first embodiment in that it includes a core 20B. The core 20B is different from the core 20 of the first embodiment in that it includes flange portions 22aB and 22bB.

[0101] like Fig.10 As shown in FIG. 2 , the flange portions 22aB and 22bB have flange groove portions 27. The flange groove portions 27 are formed in the second region 24 of the mounting surface 221 and are aligned with the flange groove portions 27. Fig. 9 The illustrated connecting portion 32 (the first pressing piece 33 and the second pressing piece 34 ) is located at a position where they face each other and extends along the mounting surface 221 .

[0102] The flange groove 27 extends linearly from one end to the other end of the mounting surface 221 in the X-axis direction along the X-axis. The flange groove 27 has a quadrilateral cross-sectional shape, but may also have other polygonal, circular, elliptical, and the like shapes.

[0103] The depth of the flange groove 27 is less than the diameter of the wire 10. However, the depth of the flange groove 27 may be equal to the diameter of the wire 10 or greater than it. Fig. 9 As shown, at least a portion of the lead portion 12a is received in the flange groove portion 27 of the flange portion 22aB. Also, at least a portion of the lead portion 12b is received in the flange groove portion 27 of the flange portion 22bB.

[0104] In this embodiment, the same effects as those of the first embodiment can also be obtained. In addition, in this embodiment, at least a portion of the lead portion 12a is accommodated in the flange groove portion 27. Therefore, the lead portion 12a is positioned by the flange groove portion 27, and the position of the lead portion 12a relative to the connection portion 32 is less likely to shift. As a result, the lead portion 12a can be connected to the connection portion 32 at a desired position, and the joining quality between the lead portion 12a and the connection portion 32 is improved.

[0105] Fourth Embodiment

[0106] Fig.11 The coil device 1C of the fourth embodiment shown has the same configuration as the coil device 1 of the first embodiment except for the following points. The same reference numerals are used for the portions that overlap with the coil device 1 of the first embodiment, and detailed description thereof will be omitted.

[0107] The coil device 1C includes a core 20C, terminal pieces 30aC_1 and 30aC_2, and terminal pieces 30bC_1 and 30bC_2. The coil device 1C includes a conductor 60 in addition to the conductor 10. The coil device 1C functions as a transformer, for example, and can be mounted on a power supply of an electrical device. One of the conductors 10 and 60 constitutes a primary coil, and the other of the conductors 10 and 60 constitutes a secondary coil.

[0108] The conductor 60 includes a winding portion 61 wound in a coil shape, and lead portions 62a and 62b led out from the winding portion 61. Although detailed illustration is omitted, the conductor 10 is wound around the outer peripheral surface of the core portion 21 of the core 20C, and the winding portion 11 is formed on the outer peripheral surface of the core portion 21 (see Figure 2 ). The conductor 60 is wound around the outer circumference of the winding portion 11, and a winding portion 61 is formed on the outer circumference of the winding portion 11. However, the winding method of the conductors 10 and 60 is not limited thereto, and for example, the conductor 10 may be wound around one side of the core portion 21 in the X-axis direction, and the conductor 60 may be wound around the other side of the core portion 21 in the X-axis direction.

[0109] like Fig.12 As shown, the core 20C has flanges 22aC and 22bC. The flanges 22aC and 22bC have recesses 25_1 and 25_2, and a protrusion 28. The recess 25_1 is formed at one end of the mounting surface 221 in the Y-axis direction, and the one end of the mounting surface 221 in the Y-axis direction is notched by the recess 25_1. The recess 25_2 is formed at the other end of the mounting surface 221 in the Y-axis direction, and the other end of the mounting surface 221 in the Y-axis direction is notched by the recess 25_2.

[0110] The protrusion 28 is formed at the center of the outer end surface 224 in the Y-axis direction and extends along the Z-axis. The protrusion 28 protrudes outward from the outer end surface 224 along the X-axis. The protrusion length of the protrusion 28 is not particularly limited, but is greater than the terminal member 30aC_1 ( Fig.11 ) thickness. However, the protruding length of the convex portion 28 may be equal to or smaller than the thickness of the terminal member 30aC_1. A notch portion (chamfered portion or tapered surface) is formed along the Z axis in the convex portion 28 to prevent breakage or defect.

[0111] like Fig.11As shown, the convex portion 28 of the flange portion 22aC insulates the terminal member 30aC_1 and the terminal member 30aC_2 by separating them. In addition, the convex portion 28 of the flange portion 22bC insulates the terminal member 30bC_1 and the terminal member 30bC_2 by separating them.

[0112] The terminal 30aC_1 is arranged on the first side 225 side of the flange 22aC, and the terminal 30aC_2 is arranged on the second side 226 side of the flange 22aC. In addition, the terminal 30bC_1 is arranged on the first side 225 side of the flange 22bC, and the terminal 30bC_2 is arranged on the second side 226 side of the flange 22bC.

[0113] like Fig.13 As shown, the terminal pieces 30aC_1 and 30aC_2, and the terminal pieces 30bC_1 and 30bC_2 have a connecting portion 36C. The connecting portion 36C has a side facing portion 361C, and the side facing portion 361C has a side rising portion 363. The side rising portion 363 is located closer to the mounting surface 221 (than the narrow width portion 362n) in the side facing portion 361C. Fig.12 In other words, the side rising portion 363 is a portion extending in a manner perpendicular to the narrow width portion 362n. The length of the connecting portion 36C along the extending direction is increased by the length of the side facing portion 361C along the Z axis.

[0114] In this embodiment, the length of the mounting portion 31 along the Y axis is shorter than the length of the mounting portion 31 along the Y axis in the first embodiment. In addition, the length of the wide portion 362w along the Y axis is shorter than the length of the wide portion 362w along the Y axis in the first embodiment. In addition, the length of the wide portion 362w along the Z axis is longer than the length of the wide portion 362w along the Z axis in the first embodiment.

[0115] like Fig.11 As shown, lead portion 12a is connected to connection portion 32 of terminal member 30aC_1, and lead portion 12b is connected to connection portion 32 of terminal member 30bC_1. Lead portion 62a is connected to connection portion 32 of terminal member 30aC_2, and lead portion 62b is connected to connection portion 32 of terminal member 30bC_2.

[0116] In this embodiment, the same effect as in the first embodiment can be obtained. In addition, in this embodiment, the flange portion 22aC is provided with two terminal pieces 30aC_1 and 30aC_2, and the flange portion 22bC is provided with two terminal pieces 30bC_1 and 30bC_2. Therefore, when the coil device 1C is mounted on the mounting substrate, the mounting stability of the coil device 1C is improved.

[0117] In addition, by adding the side rising portion 363 to the side facing portion 361C, the length of the connecting portion 36C along the extension direction is increased by the amount thereof. Therefore, by increasing the distance of the connecting portion 36C between the mounting portion 31 and the connecting portion 32, when the lead portion 12a and the connecting portion 32 are laser-welded, the amount of heat propagated from the connecting portion 32 to the mounting portion 31 is reduced. In addition, when the lead portion 62a and the connecting portion 32 are laser-welded, the amount of heat propagated from the connecting portion 32 to the mounting portion 31 is reduced. As a result, the temperature rise of the mounting portion 31 is moderated, the plating film on the surface of the mounting portion 31 is less likely to deteriorate, and the bonding property of the mounting portion 31 to the mounting substrate is improved. In addition, the adhesive between the mounting portion 31 and the mounting surface 221 is less likely to deteriorate, and the bonding property of the mounting portion 31 to the mounting surface 221 is improved.

[0118] Fifth Embodiment

[0119] Fig.14 The coil device 1D of the fifth embodiment shown has the same configuration as the coil device 1 of the first embodiment except for the following points. The same reference numerals are used for the portions that overlap with the coil device 1 of the first embodiment, and detailed description thereof will be omitted.

[0120] The coil device 1D is different from the coil device 1 of the first embodiment in that it has terminal members 30aD and 30bD. Fig.15 As shown, the terminal members 30aD and 30bD are different from the terminal members 30a and 30b of the first embodiment in that they have a connection portion 32D. The connection portion 32D is a plate body parallel to the mounting surface 221 and does not have the first pressing piece 33 and the second pressing piece 34 ( Figure 4 That is, the connection portion 32D is a connection portion 32 ( Figure 4 ) The groove 35 is omitted. Fig.15 In FIG. 1 , the shape of the connecting portion 32D after laser welding is indicated by a solid line, and the shape of the connecting portion 32D before laser welding is indicated by a two-dot chain line.

[0121] like Fig.14 As shown, the lead portion 12a is led out linearly along the X-axis on the outer surface 322 of the connection portion 32D of the terminal member 30aD. The lead portion 12a is connected to the outer surface 322 at the end portion of the connection portion 32D on the outer side in the X-axis direction by, for example, laser welding. In addition, the lead portion 12b is led out linearly along the X-axis on the outer surface 322 of the connection portion 32D of the terminal member 30bD. The lead portion 12b is connected to the outer surface 322 at the end portion of the connection portion 32D on the outer side in the X-axis direction by, for example, laser welding.

[0122] This embodiment can also achieve the same effects as those of the first embodiment. In addition, as in this embodiment, when the lead portion 12a is connected to the outer surface 322 of the connecting portion 32D, the process of connecting the lead portion 12a to the connecting portion 32D is easy.

[0123] In addition, the present invention is not limited to the above-mentioned embodiment, and various modifications can be made within the scope of the present invention.

[0124] For example, in the first embodiment described above, Figure 4 The side facing portions 361 of the terminal members 30a and 30b shown in the figure are added with the side rising portions 363 ( Fig.13 ). The same is true for the second embodiment, the third embodiment, and the fifth embodiment. In this case, the length of the connecting portion 36 along the extension direction becomes longer, and the distance of the connecting portion 36 passing between the mounting portion 31 and the connecting portion 32 becomes longer. As a result, the amount of heat propagated from the connecting portion 32 to the mounting portion 31 is reduced, and the temperature rise of the mounting portion 31 is further alleviated. Therefore, the effect described in the first embodiment can be effectively obtained.

[0125] The techniques of the second embodiment, the third embodiment, and the fifth embodiment described above can also be applied to the fourth embodiment described above.

[0126] In the first embodiment described above, if Figure 1 As shown, the connecting portion 36 extends from the mounting portion 31 toward the positive direction of the Y axis, but it may also be as shown in FIG. Fig.13 Like the terminal piece 30aC_2 of FIG. 3 , it extends from the mounting portion 31 toward the negative direction of the Y axis. The second embodiment, the third embodiment, and the fifth embodiment described above are also the same.

[0127] In the first embodiment described above, the connecting portion 32 includes two pressing pieces, namely the first pressing piece 33 and the second pressing piece 34, but may include a single pressing piece. The same is true for the second to fourth embodiments described above.

[0128] In the fourth embodiment described above, the coil device 1C may include the plate-like core 50 .

Claims

1. A coil device, wherein: have: A conductive wire having a winding portion and a lead portion led out from the winding portion; a core having a core portion provided with the winding portion, and a flange portion formed at one axial end of the core portion; as well as The terminal member has a mounting portion connectable to a mounting substrate, a wiring portion connected to the lead-out portion, and a connecting portion connecting the mounting portion and the wiring portion. The mounting portion and the wiring portion are arranged on the mounting surface of the flange portion. The connecting portion extends from the mounting portion to the connecting portion via an end surface of the flange portion and a side surface of the flange portion.

2. The coil device according to claim 1, wherein: The flange portion has a recess formed on the mounting surface, The mounting portion is arranged on the mounting surface at a position different from the recessed portion. The connection portion is disposed inside the recess.

3. The coil device according to claim 1 or 2, wherein: At least a portion of the lead portion is disposed between the wiring portion and the mounting surface.

4. The coil device according to claim 1 or 2, wherein: The connection portion includes: a first pressing piece that presses the lead portion toward the mounting surface; and a second pressing piece that presses the lead portion toward the mounting surface on an end surface side closer to the flange portion than the first pressing piece and is connected to the lead portion.

5. The coil device according to claim 4, wherein: The first pressing piece and the second pressing piece have a riveted structure.

6. The coil device according to claim 1 or 2, wherein: The connection portion has a terminal groove portion that accommodates at least a portion of the lead portion. The terminal groove is formed on an inner surface of the wiring portion that is opposite to the mounting surface.

7. The coil device according to claim 1 or 2, wherein: The flange portion has a flange groove portion that receives at least a portion of the lead-out portion. The flange groove portion extends along the mounting surface at a position opposite to the wiring portion.

8. The coil device according to claim 1 or 2, wherein: The terminal member comprises a first terminal member and a second terminal member, The first terminal is arranged on one side surface of the flange portion. The second terminal is disposed on the other side surface of the flange portion.

9. The coil device according to claim 1 or 2, wherein: Also having a plate-like core mounted on the core, The plate-like core is joined to a non-mounting surface of the flange portion located on the opposite side of the mounting surface.

Images