Coil device

Abstract

The present invention provides a coil device with high installation stability of a terminal piece relative to a flange portion. The coil device (1) comprises: a winding portion (11) wound with a conductive wire (10); a core (20) having a winding core portion (21) provided with the winding portion (11), and a flange portion (22a) formed at the axial end of the winding core portion (21); and a terminal piece (30a) mounted on the flange portion (22a). The terminal piece (30a) comprises a main body portion (31) arranged on an outer end surface (224) of the flange portion (22a), a mounting portion (32) continuous with the main body portion (31) and bent from the outer end surface (224) toward the mounting surface (221), and a wiring portion (33) continuous with the main body portion (31) and bent from the outer end surface (224) toward the side surface (225). The mounting portion (32) comprises a plurality of mounting pieces (321) and (322) separated by a gap (320). The main body (31) is bonded to the outer end surface (224) by an adhesive.

Description

Technical Field

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

[0002] As shown in Patent Document 1, there is currently known a coil device in which a terminal piece is provided on the flange portion of the core. In the coil device of Patent Document 1, the terminal piece has an interlocking portion that is interlocked with the flange portion. The interlocking portion has a mounting portion arranged on the lower surface (mounting surface) of the flange portion, a wiring portion arranged on the upper surface (the surface on the side opposite to the mounting surface) of the flange portion, and a main body portion arranged on the outer end surface of the flange portion. The mounting portion is connected to the pad pattern of the mounting substrate, and the wiring portion is connected to the lead-out portion of the coil. The lower surface and the upper surface of the flange portion are clamped by the mounting portion and the wiring portion, and the terminal piece can be fixed to the flange portion through the interlocking portion.

[0003] In addition, in the coil device of Patent Document 1, when the terminal member is mounted on the flange, the fitting portion rotates around the axis of the main body, and the fitting portion is sometimes fixed to the flange in a direction different from the desired direction. In this case, when the coil device is mounted on a substrate, it may be difficult to arrange the mounting portion at a desired position of the pad pattern of the substrate.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Publication No. 2005-56934 Summary of the invention

[0007] Problems to be solved by the invention

[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 a terminal member with high mounting stability with respect to a flange portion.

[0009] Technical solutions to solve problems

[0010] In order to achieve the above object, the present invention provides a coil device having:

[0011] a winding portion on which a conductive wire is wound;

[0012] a core having a winding core portion provided with the winding portion, and a flange portion formed at an axial end portion of the winding core portion; and

[0013] a terminal member mounted on the flange portion,

[0014] The terminal piece includes a main body portion arranged on the outer end surface of the flange portion, a mounting portion continuous with the main body portion and bent from the outer end surface toward the mounting surface of the flange portion, and a connecting portion continuous with the main body portion and bent from the outer end surface toward the side surface of the flange portion.

[0015] The mounting portion includes a plurality of mounting pieces separated by gaps.

[0016] The main body is bonded to the outer end surface by an adhesive.

[0017] In the coil device of the present invention, the terminal piece has a main body portion arranged on the outer end surface of the flange portion, and a wiring portion that is continuous with the main body portion and bent from the outer end surface of the flange portion toward the side. Therefore, the main body portion and the wiring portion act together as a stopper (rotation stopper), and the terminal piece is difficult to rotate (turn) in a plane parallel to the mounting surface. Thus, the terminal piece is fixed to the flange portion in a desired orientation, which can improve the installation stability of the terminal piece relative to the flange portion. In addition, the main body portion is bonded to the outer end surface by an adhesive. Therefore, the installation stability of the terminal piece relative to the flange portion is improved. In addition, the misalignment of the terminal piece is suppressed, which can effectively prevent the terminal piece from rotating (turning) in a plane parallel to the mounting surface.

[0018] In addition, the terminal member has a mounting portion that is continuous with the main body and is bent from the outer end surface of the flange portion toward the mounting surface. Moreover, the mounting portion has a plurality of mounting pieces separated by gaps. Therefore, the area of ​​the mounting portion is reduced according to the area of ​​the gap. As a result, the area of ​​the pad pattern of the mounting substrate is reduced, and the stray capacitance of the pad pattern can be reduced. In addition, for example, in the case where the coil device is mounted on the mounting substrate by solder, a solder fillet can be formed over a large range from the mounting piece to the main body.

[0019] Alternatively, the lead wire may include a lead-out portion extending from the winding portion, the connection portion may include a connection piece connected to the lead-out portion, and a welding piece branching from the connection piece and bendable relative to the connection piece, and the welding piece may be welded while clamping the lead-out portion. By clamping the lead-out portion with the welding piece, the lead-out portion may be fixed at a desired position of the connection portion. Thus, welding of the lead-out portion becomes easy, and deviation of the welding position of the lead-out portion may be prevented.

[0020] Alternatively, the connection portion may include a temporary rivet piece branching from the connection piece and bendable relative to the connection piece, and the temporary rivet piece is closer to the winding portion than the welding piece. In this case, after the lead-out portion is temporarily fixed by the temporary rivet piece, the lead-out portion can be clamped by the welding piece, and the welding piece and the lead-out portion can be welded together. As a result, welding of the lead-out portion becomes easier, and the accuracy of the welding position of the lead-out portion is further improved.

[0021] The lead wire may include a lead portion extending from the winding portion, and the connection portion and the lead portion may be laser welded together. In this case, the connection portion and the lead portion are integrated, and direct current resistance can be reduced from the connection portion to the lead portion.

[0022] Alternatively, the flange portion has a side cutout portion formed on the side and accommodating at least a portion of the wiring portion, and the side cutout portion extends toward the mounting surface. In this case, when viewed from the side opposite to the mounting surface, the wiring portion is not likely to protrude outward from the flange portion. Therefore, the coil device can be miniaturized and disconnection of the lead-out portion can be prevented.

[0023] Alternatively, the flange portion may include a first flange portion formed at one end of the winding core portion in the axial direction, and a second flange portion formed at the other end of the winding core portion in the axial direction, the terminal member may include a first terminal member installed on the first flange portion, and a second terminal member installed on the second flange portion, the wiring portion may include a first wiring portion provided on the first terminal member, and a second wiring portion provided on the second terminal member, the side cutout portion may include a first side cutout portion formed on the side of the first flange portion and accommodating at least a portion of the first wiring portion, and a second side cutout portion formed on the side of the second flange portion and accommodating at least a portion of the second wiring portion, and when viewed from the axial direction of the winding core portion, the first side cutout portion and the second side cutout portion are located on the same side in a direction perpendicular to the axial direction. In this case, since the first wiring portion and the second wiring portion are both located on the same side in a direction perpendicular to the axial direction of the winding core portion, welding can be performed on the same side. Therefore, welding of the lead-out portion and the wiring portion is easy.

[0024] Alternatively, the depth of the side cutout portion in a direction perpendicular to the mounting surface is greater than 1 / 2 of the height of the flange portion. In this case, the configuration space of the wiring portion is increased, and the degree of freedom of configuration of the wiring portion is improved. Therefore, it is easy to lead the lead-out portion to a desired position of the wiring portion.

[0025] Alternatively, the flange portion has a recess formed on the mounting surface, and at least a portion of the recess is located inside the gap. In this case, the mounting surface is recessed between the plurality of mounting pieces (i.e., the gap) in a manner away from the plurality of mounting pieces. Therefore, for example, when the plurality of mounting pieces are connected to the mounting substrate by solder, it is difficult for the solder to pass through the gap of the mounting portion and adhere to the mounting surface. Thus, damage to the core can be prevented.

[0026] Alternatively, at least one of the plurality of mounting pieces is bonded to the mounting surface by an adhesive. In this case, the mounting stability of the terminal member relative to the flange portion is further improved. In addition, the misalignment of the terminal member is suppressed, which can effectively prevent the terminal member from rotating (rotating) in a plane parallel to the mounting surface.

[0027] Alternatively, the terminal member may include an extended main body portion that is disposed on the outer end surface and extends from the main body portion toward a side opposite to the mounting portion. In this case, the bonding area between the terminal member and the outer end surface of the flange portion is increased according to the area of ​​the extended main body portion. Therefore, the mounting stability of the terminal member relative to the flange portion is further improved.

[0028] Alternatively, there is a plate-like core, which is mounted on the mounting opposite surface of the flange portion on the side opposite to the mounting surface. By mounting the plate-like core on the mounting opposite surface, the inductance characteristics of the coil device are improved. In addition, in the present invention, unlike the prior art, the mounting surface and the mounting opposite surface are not clamped by terminal members, and the main body is bonded to the outer end surface of the flange portion. Therefore, in order to prevent interference between the terminal members and the plate-like core, there is no need to thin the mounting opposite surface and the plate-like core. As a result, the contact area between the mounting opposite surface and the plate-like core is increased, and the inductance characteristics of the coil device are improved. Moreover, the bonding strength between the mounting opposite surface and the plate-like core is increased. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1A It is a perspective view of the coil device according to the first embodiment of the present invention.

[0030] Figure 1B Observed from the Y-axis direction Figure 1A Side view of the coil arrangement shown.

[0031] Figure 1C Observed from the X-axis direction Figure 1A Side view of the coil arrangement shown.

[0032] Figure 1D yes Figure 1A A top view of the coil arrangement is shown.

[0033] Figure 1E yes Figure 1A Bottom view of the coil arrangement shown.

[0034] Figure 1F It is shown Figure 1A A bottom view of a modified example of the coil device shown.

[0035] Figure 2 yes Figure 1A A perspective view of the core is shown.

[0036] Figure 3 yes Figure 1A A perspective view of the terminal piece shown.

[0037] Figure 4 It is a perspective view of a coil device according to a second embodiment of the present invention. DETAILED DESCRIPTION

[0038] The following is a description of the embodiments of the present invention with reference to the accompanying drawings. In addition, the contents of the drawings are only schematically and illustratively shown for the purpose of understanding the present invention, and the appearance or dimensional ratio may be different from the actual object. In addition, the present invention is not limited to the following embodiments.

[0039] First embodiment

[0040] Figure 1A The coil device 1 of the first embodiment of the present invention shown in the figure functions as an inductor, for example, and is mounted on a power supply of various electrical devices, etc. The coil device 1 has a conductor 10, a core 20, and terminal pieces 30a and 30b. In addition to these components, the coil device 1 also has a plate-shaped core 40. However, the plate-shaped core 40 is not essential.

[0041] The conductor 10 has a winding portion 11 in which the conductor 10 is spirally wound, and lead portions 12a and 12b led out from the winding portion 11. The conductor 10 is an insulated coated conductor having a conductive core wire such as a round wire covered with an insulating coating. More specifically, the conductor 10 is a well-known winding wire such as AIW (polyamide-imide copper wire), UEW (polyurethane copper wire), PEW (polyester copper wire), etc. The material constituting the conductor 10 is not particularly limited, and is, for example, copper, copper alloy, silver, or nickel. The diameter of the conductor 10 is not particularly limited, and is, for example, 10 to 300 μm. The conductor 10 may not have an insulating coating.

[0042] The lead portion 12a is led out from one end of the winding portion 11 in the winding direction toward the terminal member 30a and connected to the terminal member 30a (connection portion 33). The lead portion 12b is led out from the other end of the winding portion 11 in the winding direction toward the terminal member 30b and connected to the terminal member 30b (connection portion 33).

[0043] like Figure 2 As shown, the core 20 is a drum-shaped core having a winding core portion 21 and flange portions 22a and 22b. The material constituting the core 20 is not particularly limited, and may be, for example, a metal magnetic body or a ferrite (Ni-Zn ferrite, Mn-Zn ferrite, etc.). The core 20 may also be formed of a composite material including a magnetic material and a resin.

[0044] The cross-sectional shape of the winding core 21 is a quadrilateral, and may also be other polygons (for example, a hexagon or an octagon), a circle, an ellipse, etc. Figure 1A As shown, the winding portion 11 is provided on the winding core portion 21 .

[0045] like Figure 2 As shown, the flange 22a is formed at one axial end of the winding core 21, and the flange 22b is formed at the other axial end of the winding core 21. The shape of the flange 22a is the same as that of the flange 22b, but may be different therefrom.

[0046] The flange portion 22a has a mounting surface 221, a mounting opposite surface 222, an inner end surface 223, an outer end surface 224, a first side surface 225, and a second side surface 226. Similarly, the flange portion 22b has a mounting surface 221, a mounting opposite surface 222, an inner end surface 223, an outer end surface 224, a first side surface 225, and a second side surface 226.

[0047] The mounting surface 221 and the mounting opposite 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. Hereinafter, the axis along the direction in which the inner end surface 223 and the outer end surface 224 are opposite is set as the X axis. The axis along the direction in which the first side surface 225 and the second side surface 226 are opposite is set as the Y axis. In addition, the axis along the direction in which the mounting surface 221 and the mounting opposite surface 222 are opposite is set as the Z axis. The X axis, the Y axis, and the Z axis are orthogonal to each other. The X axis is an axis parallel to the axial direction of the winding core 21.

[0048] Regarding the X-axis, Y-axis, and Z-axis, the direction toward the center of the core 20 is set as the "inside", and the direction away from the center of the core 20 is set as the "outside". In addition, the positive direction side of the Z-axis is set as the "upper side", and the negative direction side of the Z-axis is set as the "lower side". However, the upper side in the Z-axis direction does not necessarily coincide with the upper side in the vertical direction. In addition, the lower side in the Z-axis direction does not necessarily coincide with the lower side in the vertical direction.

[0049] The mounting surface 221 is a surface disposed on a mounting substrate (not shown). A recess 24 is formed on the mounting surface 221. The recess 24 extends from one end of the mounting surface 221 in the X-axis direction to the other end along the X-axis. The inner wall of the recess 24 is an inclined surface or a vertical surface. The recess 24 is located in the center of the mounting surface 221 in the Y-axis direction. The position of the recess 24 is consistent with the gap 320 ( Figure 1A ) position.

[0050] The mounting opposite surface 222 is provided with a plate-shaped core 40 ( Figure 1A ) surface. Figure 1B As shown, the plate-like core 40 is disposed on the mounting opposite surface 222 of the flange portion 22a and the mounting opposite surface 222 of the flange portion 22b. The mounting opposite surface 222 is a flat surface. However, the shape of the mounting opposite surface 222 can also be appropriately changed according to the shape of the abutting surface 41 of the plate-like core 40.

[0051] The inner end surface 223 is a surface connected to the axial end of the winding core 21. The shape of the inner end surface 223 is the same as the shape of the outer end surface 224. Figure 1A As shown, the terminal piece 30 a or 30 b is disposed on the mounting surface 221 , the outer end surface 224 and the first side surface 225 .

[0052] like Figure 2 As shown in FIG. 2 , a side cutout portion 23 is formed on the first side surface 225. The side cutout portion 23 is cut into the inner side of the first side surface 225 in the Y-axis direction. The side cutout portion 23 extends toward the mounting surface 221 along the Z-axis. Figure 1C As shown in FIG. 1 , the upper end of the side cutout portion 23 is located at the center of the first side surface 225. In addition, the lower end of the side cutout portion 23 is located at the mounting surface 221. The depth D of the side cutout portion 23 in the Z-axis direction is less than 1 / 2 of the height H of the flange portion 22a (first side surface 225) in the Z-axis direction. Therefore, the area of ​​the first side surface 225 in the side cutout portion 23 is less than 1 / 2 of the area of ​​the first side surface 225 as a whole.

[0053] like Figure 2 As shown, when viewed from the X-axis direction, the side cutout 23 of the flange 22a and the side cutout 23 of the flange 22b are located on the same side in the Y-axis direction (the positive Y-axis direction side). However, when viewed from the X-axis direction, the side cutout 23 of the flange 22a and the side cutout 23 of the flange 22b may be located on different sides in the Y-axis direction.

[0054] like Figure 3 As shown, the terminal pieces 30a and 30b respectively have a main body 31, a mounting portion 32, and a wiring portion 33. The terminal pieces 30a and 30b also respectively have a main body extension portion 34. However, the main body extension portion 34 is not necessary. The shape of the terminal piece 30a is mirror-symmetrical to the shape of the terminal piece 30b.

[0055] The terminal parts 30a and 30b are made of a conductor such as metal. The material constituting the terminal parts 30a and 30b is not particularly limited, and may be, for example, copper, copper alloy, silver or nickel. A plating film may also be formed on the surface of the terminal parts 30a and 30b. The plating film may be a single layer or a multilayer. The plating film is not particularly limited, and may be, for example, Cu plating, Ni plating, Sn plating, Ni-Sn plating, Cu-Ni-Sn plating, Ni-Au plating or Au plating. The thickness of the terminal parts 30a and 30b is not particularly limited, and is 50 to 300 μm.

[0056] like Figure 1AAs shown, the terminal member 30a is mounted on the flange portion 22a, and the terminal member 30b is mounted on the flange portion 22b. The main body portion 31 has a shape that is laterally long in the Y-axis direction. The main body portion 31 is arranged on the outer end surface 224 of the flange portion 22a or 22b. In more detail, the main body portion 31 is arranged below the center of the outer end surface 224 in the Z-axis direction (on the side of the mounting surface 221).

[0057] like Figure 3 As shown, the mounting portion 32 is continuous with the main body 31 and is bent in an L shape. The mounting portion 32 has mounting pieces 321 and 322. In the present embodiment, the number of mounting pieces is two, and may be three or more. The mounting pieces 321 and 322 are connected to a mounting substrate (not shown) by, for example, solder or a conductive adhesive. A fillet such as solder or a conductive adhesive may also be formed on the main body 31.

[0058] The mounting piece 321 and the mounting piece 322 are separated in the Y-axis direction via a gap 320. The gap 320 is formed between the mounting piece 321 and the mounting piece 322 from one end to the other end in the extending direction of the mounting pieces 321 and 322.

[0059] like Figure 1A and Figure 1B As shown, the mounting portion 32 (mounting pieces 321 and 322) is bent (curved) from the outer end surface 224 toward the mounting surface 221. Figure 1C As shown, a portion of the mounting piece 321 is disposed on the outer end surface 224, and a portion of the mounting piece 322 is disposed on the outer end surface 224. Figure 1B As shown in the figure, a part of the mounting piece 321 is arranged on the mounting surface 221. Although the detailed illustration is omitted, a part of the mounting piece 322 is arranged on the mounting surface 221. The mounting piece 321 extends along the Z axis at the outer end surface 224. The mounting piece 321 extends along the X axis from one end (the end on the outer end surface 224 side) of the mounting surface 221 in the X axis direction to the other side (the inner end surface 223 side) at the mounting surface 221. The same applies to the mounting piece 322.

[0060] The mounting piece 321 has a bent portion 323. The bent portion 323 is located between a portion of the mounting piece 321 arranged parallel to the outer end surface 224 (located at the base end portion closer to the base end side than the bent portion 323) and a portion arranged parallel to the mounting surface 221 (located at the front end portion closer to the front end side than the bent portion 323). Figure 1B As shown, the bent portion 323 is located at the intersection of the outer end surface 224 and the mounting surface 221. The bent portion 323 is bent (curved) from the outer end surface 224 toward the mounting surface 221 in an orthogonal manner.

[0061] like Figure 3 As shown, the mounting piece 322 has a bent portion 324. Figure 1C and Figure 1E As shown in FIG. 1 , the bent portion 324 is located between a portion of the mounting piece 322 that is arranged parallel to the outer end surface 224 (located at the base end portion closer to the base end side than the bent portion 324) and a portion that is arranged parallel to the mounting surface 221 (located at the front end portion closer to the front end side than the bent portion 324). The bent portion 324 is located at the intersection of the outer end surface 224 and the mounting surface 221. The bent portion 324 is bent (curved) in an orthogonal manner from the outer end surface 224 toward the mounting surface 221.

[0062] At least a portion of the recess 24 formed on the mounting surface 221 (in the present embodiment, the entire recess 24) is located inside the gap 320, that is, between the mounting piece 321 and the mounting piece 322. In other words, the mounting pieces 321 and 322 are arranged outside the Y-axis direction of the recess 24 in a manner not to block the recess 24. The mounting surface 221 is recessed between the mounting piece 321 and the mounting piece 322 (that is, the gap 320) so as to be away from the mounting pieces 321 and 322. Therefore, for example, when the mounting pieces 321 and 322 are connected to the land pattern of the mounting substrate by solder, it is difficult for the solder to pass through the gap 320 and adhere to the mounting surface 221. Thus, it is possible to prevent the core 20 from being damaged.

[0063] The mounting portion 32 and the main body portion 31 are located on one side (the second side 226 side) of the center of the mounting surface 221 in the Y-axis direction. On the other hand, the connection portion 33 is located on the other side (the first side 225 side) of the center of the mounting surface 221 in the Y-axis direction. Therefore, the balance of the coil device 1 is improved on one side and the other side relative to the center of the mounting surface 221 in the Y-axis direction, and the mounting stability of the coil device 1 can be improved.

[0064] The mounting piece 321 is located inside one end (the end on the first side surface 225 side) of the mounting surface 221 in the Y-axis direction. Therefore, a portion of the mounting surface 221 is exposed from the mounting portion 32 on one side in the Y-axis direction. In addition, the mounting piece 322 is located inside the other end (the end on the second side surface 226 side) of the mounting surface 221 in the Y-axis direction. Therefore, a portion of the mounting surface 221 is exposed from the mounting portion 32 on the other side in the Y-axis direction.

[0065] like Figure 3 As shown in FIG. 1 , the connection portion 33 is continuous with the main body portion 31 and is bent (curved) in an L shape. The connection portion 33 includes a connection piece 330, a temporary rivet piece 332, and a welding piece 333. Figure 1A As shown, the wiring portion 33 (the wiring piece 330 ) is bent (curved) from the outer end surface 224 toward the first side surface 225 .

[0066] like Figure 1AAs shown, a portion of the terminal piece 330 is disposed on the outer end surface 224, and a portion of the terminal piece 330 is disposed on the first side surface 225. The terminal piece 330 extends along the Y-axis on the outer end surface 224. The terminal piece 330 extends along the X-axis on the first side surface 225 from one end of the first side surface 225 in the X-axis direction (the end on the outer end surface 224 side) to the other side (the inner end surface 223 side).

[0067] The terminal piece 330 has a bent portion 331. The bent portion 331 is located between a portion of the terminal piece 330 arranged parallel to the outer end surface 224 (located at a base end portion closer to the base end side than the bent portion 331) and a portion of the terminal piece 330 arranged parallel to the first side surface 225 (located at a front end portion closer to the front end side than the bent portion 331). The bent portion 331 is located at the intersection of the outer end surface 224 and the first side surface 225, and is bent (curved) from the outer end surface 224 toward the first side surface 225.

[0068] like Figure 1E As shown in FIG. 2 , a gap is formed between the connecting piece 330 and the first side surface 225, and the connecting piece 330 does not abut against the first side surface 225. For example, by making the position of the gap 320 between the mounting piece 321 and the mounting piece 322 correspond to the position of the recess 24 of the mounting surface 221, a gap of a predetermined width can be formed between the connecting piece 330 and the first side surface 225. Figure 1F As shown, the connecting piece 330 may also abut against the first side surface 225. By abutting the connecting piece 330 against the first side surface 225, the bending portion 331 can be prevented from deforming. Figure 1E and Figure 1F In the embodiment, the main body 31 abuts against the outer end surface 224 , but the main body 31 and the outer end surface 224 may not abut against each other.

[0069] like Figure 1B and Figure 1C As shown, at least a portion of the wiring portion 33 is accommodated in the side cutout portion 23. More specifically, a portion of the wiring piece 330 (the portion on the front end side from the bending portion 331) is accommodated in the side cutout portion 23. In addition, a portion of the rivet piece 332 and a portion of the welding piece 333 are also accommodated in the side cutout portion 23. In this embodiment, since the wiring portion 33 of the terminal member 30a and the wiring portion 33 of the terminal member 30b are both arranged on the same side in the Y-axis direction, welding can be performed on the same side. Therefore, it is easy to weld the lead-out portion 12a or 12b and the wiring portion 33.

[0070] like Figure 1CAs shown in FIG. 1 , when viewed from the X-axis direction, the terminal piece 330 does not protrude outward in the Y-axis direction from the end portion of the mounting surface 222 on one side in the Y-axis direction (on the first side surface 225 side). Therefore, when viewed from the side opposite to the mounting surface 221, the terminal piece 330 is hidden by the mounting surface 222 at the position of the side cutout portion 23. Figure 1D As shown, when viewed from the side opposite to the mounting surface 221, the connection piece 330 is hidden by the planar core 40 at the position of the side cutout portion 23. In this way, since the connection piece 330 does not protrude outward from the outer edge of the planar core 40, the coil device 1 can be miniaturized. In addition, the lead-out portion 12a connected to the connection piece 330 can be prevented from being disconnected.

[0071] like Figure 3 As shown, the welding piece 333 is branched from the connecting piece 330 and is configured to be bendable relative to the connecting piece 330. Figure 3 In FIG. 1 , the solid line indicates the state of the welding piece 333 of the terminal 30b before bending, and the double-dotted line indicates the state after bending. The welding piece 333 is moved upward from the lower end of the terminal piece 330 ( Figure 2 The front end of the welding piece 333 is formed to be wide, but the shape of the welding piece 333 is not particularly limited. When the welding piece 333 is bent, the front end of the welding piece 333 (the part closer to the front end than the bent position) faces the terminal piece 330.

[0072] like Figure 1B As shown, the welding piece 333 of the terminal 30a is welded while clamping the lead-out portion 12a. The lead-out portion 12a is located between the terminal piece 330 and the welding piece 333, and is clamped by the terminal piece 330 and the welding piece 333. In addition, the welding piece 333 of the terminal 30b is welded while clamping the lead-out portion 12b. The lead-out portion 12b is located between the terminal piece 330 and the welding piece 333, and is clamped by the terminal piece 330 and the welding piece 333.

[0073] The lead portion 12a is laser welded together with the connection portion 33. Since the lead portion 12a is melted together with the welding piece 333 and / or the connection piece 330, a welding ball 50 is formed on the connection portion 33. The lead portion 12b is laser welded together with the connection portion 33. Since the lead portion 12b is melted together with the welding piece 333 and / or the connection piece 330, a welding ball 50 is formed on the connection portion 33. As an example, the welding ball 50 is formed at the front end of the welding piece 333. In this way, the connection portion 33 is integrated with the lead portion 12a or 12b through the welding ball 50, thereby reducing the DC resistance from the connection portion 33 to the lead portion 12a or 12b.

[0074] Furthermore, the lead portion 12a or 12b can be fixed to a desired position of the connection portion 33 by sandwiching the lead portion 12a or 12b with the welding piece 333. This facilitates welding of the lead portion 12a or 12b and prevents deviation in the welding position of the lead portion 12a or 12b.

[0075] In addition, the lead portions 12a and 12b may be connected to the connection portion 33 (connection piece 330 and / or welding piece 333) by, for example, solder, conductive adhesive, thermocompression bonding, ultrasonic bonding, resistance soldering, ultraviolet curing resin bonding, or the like.

[0076] like Figure 3 As shown, the temporary rivet sheet 332 is branched from the connecting sheet 330 and is configured to be bendable relative to the connecting sheet 330. Figure 3 In the figure, the solid line indicates the state of the temporary rivet piece 332 of the terminal piece 30b before bending, and the double-dotted line indicates the state after bending. The temporary rivet piece 332 extends from the upper end of the terminal piece 330 toward the bottom ( Figure 2 When the temporary rivet piece 332 is bent, the front end portion (the portion closer to the front end side than the bent position) of the temporary rivet piece 332 is opposite to the terminal piece 330.

[0077] like Figure 1B As shown, the temporary riveting piece 332 of the terminal piece 30a clamps the lead-out portion 12a. The lead-out portion 12a is located between the terminal piece 330 and the temporary riveting piece 332, and is clamped by the terminal piece 330 and the temporary riveting piece 332. In addition, the temporary riveting piece 332 of the terminal piece 30b clamps the lead-out portion 12b. The lead-out portion 12b is located between the terminal piece 330 and the temporary riveting piece 332, and is clamped by the terminal piece 330 and the temporary riveting piece 332.

[0078] The temporary rivet piece 332 and the welding piece 333 are arranged at different positions along the X-axis. The temporary rivet piece 332 is closer to the winding portion 11 than the welding piece 333. In more detail, the temporary rivet piece 332 is located on the inner end face 223 side relative to the welding piece 333 being located on the outer end face 224 side. In the present embodiment, before the lead-out portion 12a is clamped by the welding piece 333, the lead-out portion 12a can be clamped by the temporary rivet piece 332. Moreover, after the lead-out portion 12a is temporarily fixed by the temporary rivet piece 332, the lead-out portion 12a can be clamped by the welding piece 333, and the welding piece 333 can be welded together with the lead-out portion 12a. As a result, the welding of the lead-out portion 12a becomes easy, and the accuracy of the welding position of the lead-out portion 12a is improved.

[0079] The size of the welding piece 333 is larger than the size of the temporary rivet piece 332. Thus, the contact area between the lead portion 12a and the welding piece 333 is ensured, and the lead portion 12a can be stably clamped by the welding piece 333. In addition, when the lead portion 12a is welded together with the welding piece 333 and / or the connecting piece 330, the melting range is ensured, and the conduction between the lead portion 12a and the connecting portion 33 is easily ensured.

[0080] like Figure 1E As shown, a portion of the welding sheet 333 is accommodated in the side cutout portion 23, and the rest of the welding sheet 333 is exposed from the side cutout portion 23. However, the entire welding sheet 333 may be accommodated in the side cutout portion 23. In addition, a portion of the temporary rivet sheet 332 is accommodated in the side cutout portion 23, and the rest of the temporary rivet sheet 332 is exposed from the side cutout portion 23. However, the entire temporary rivet sheet 332 may be accommodated in the side cutout portion 23.

[0081] like Figure 1B and Figure 1C As shown, at least a portion of the solder ball 50 is accommodated in the side cutout portion 23. In the present embodiment, a portion of the solder ball 50 is accommodated in the side cutout portion 23, and the remaining portion of the solder ball 50 is exposed from the side cutout portion 23. However, the entire solder ball 50 may be accommodated in the side cutout portion 23. As a result, the size of the coil device 1 in the Y-axis direction becomes smaller, and the miniaturization of the coil device 1 can be achieved.

[0082] like Figure 1D As shown, from the mounting surface 221 ( Figure 2 ) is observed from the side opposite to the top, at least a portion of the solder ball 50 is hidden by the plate-like core 40. Figure 1D As shown by the double-dashed line in FIG. 3 , the solder ball 50 may be formed further inside the soldering sheet 333 in the X-axis direction. For example, when viewed from the Z-axis direction, more than 30% of the solder ball 50 may be hidden by the plate-like core 40. Although detailed illustrations are omitted, the plate-like core 40 is not disposed on the core 20 ( Figure 2 ), when viewed from the side opposite to the mounting surface 221, at least a portion of the solder ball 50 is hidden by the flange portion 22a or 22b (mounting opposite surface 222). In the present embodiment, a portion of the solder ball 50 is hidden by the plate-like core 40 and the flange portion 22a, but the entire solder ball 50 may be hidden by the plate-like core 40 and the flange portion 22a. Similarly, a portion of the solder ball 50 is hidden by the plate-like core 40 and the flange portion 22b, but the entire solder ball 50 may be hidden by the plate-like core 40 and the flange portion 22b.

[0083] This prevents at least a portion of the solder ball 50 from being exposed outside the outer edges of the flanges 22a and 22b when viewed from the side opposite to the mounting surface 221. As a result, the size of the coil device 1 is reduced, and the coil device 1 can be miniaturized.

[0084] like Figure 1B As shown, the height position of the upper end of the temporary rivet sheet 332 (the bent portion of the temporary rivet sheet 332) is substantially equal to the height position of the lower end of the winding core portion 21. In the present embodiment, the height position of the upper end of the temporary rivet sheet 332 is separated from the height position of the lower end of the winding core portion 21 by a distance L downward. However, the distance L may be less than 5 times the diameter of the conductor 10, or may be less than 2 times the diameter of the conductor 10. In addition, the height position of the upper end of the temporary rivet sheet 332 may also be equal to the height position of the lower end of the winding core portion 21. That is, L=0 may also be used.

[0085] Thus, the lead portion 12a can be led straightly along the X-axis from the lower end of the winding core 21 toward the upper end of the temporary rivet piece 332. In addition, the lead portion 12a can be riveted at the upper end of the temporary rivet piece 332 (near the bent portion of the temporary rivet piece 332), which can prevent the lead portion 12a from being misaligned or falling off. In addition, the lead portion 12a can be led from the lower end of the winding core 21 to the upper end of the temporary rivet piece 332 without excessive bending, which can prevent the wire 10 from being broken.

[0086] like Figure 1C As shown in FIG. 2 , the extended main body portion 34 is disposed on the outer end surface 224 and extends from the main body portion 31 toward the side opposite to the mounting surface 221. The extended main body portion 34 extends to the center of the outer end surface 224 in the Z-axis direction. However, the length of the extended main body portion 34 in the Z-axis direction is not particularly limited, and the extended main body portion 34 may also extend upward from the center of the outer end surface 224 in the Z-axis direction.

[0087] In this embodiment, the bonding area between the terminal member 30a and the outer end surface 224 can be increased by expanding the area of ​​the main body portion 34. Therefore, the mounting stability of the terminal member 30a with respect to the outer end surface 224 is improved.

[0088] like Figure 1C As shown, the main body 31 is bonded to the outer end surface 224 by an adhesive 60. Figure 1CIn the figure, the adhesive 60 is indicated by a double-dashed line, but the range of the adhesive 60 is not limited to the area indicated by the double-dashed line. The adhesive 60 is attached to at least a portion of the main body 31. The adhesive 60 can be attached to a portion of the main body 31, or it can be attached to the entire main body 31. In addition, the adhesive 60 can also be attached to multiple locations (for example, two locations) of the main body 31. For example, the adhesive 60 can also be attached to a first area on one side of the Y-axis direction of the main body 31 and a second area (an area different from the first area) on the other side of the Y-axis direction of the main body 31. In addition, the adhesive 60 can also be attached to at least a portion of the extended main body 34.

[0089] like Figure 1E As shown, the mounting sheet 321 is bonded to the mounting surface 221 by the adhesive 60. In addition, the mounting sheet 322 is bonded to the mounting surface 221 by the adhesive 60. Figure 1E In the figure, the adhesive 60 is indicated by a double-dashed line, but the range of the adhesive 60 is not limited to the area indicated by the double-dashed line. In the present embodiment, both the mounting pieces 321 and 322 are bonded to the mounting surface 221 by the adhesive 60, but only one of the mounting pieces 321 and 322 may be bonded to the mounting surface 221 by the adhesive 60.

[0090] like Figure 1A As shown in FIG. 1 , the plate-like core 40 has a rectangular parallelepiped shape (flat shape). The plate-like core 40 may be made of the same material as the core 20, or may be made of a material different from the core 20. The plate-like core 40 is bonded to the mounting opposite surface 222 ( Figure 2 ). By mounting the planar core 40 on the mounting opposite surface 222 , the inductance characteristic of the coil device 1 is improved.

[0091] Next, a method for manufacturing the coil device 1 will be described. First, prepare Figure 1A The wire 10, the core 20, the terminal pieces 30a and 30b, and the plate-shaped core 40 are shown. The length of the core 20 in the X-axis direction is not particularly limited, and is, for example, 1 to 6 mm. The length of the core 20 in the Y-axis direction is not particularly limited, and is, for example, 0.5 to 4 mm. The length of the core 20 in the Z-axis direction is not particularly limited, and is, for example, 0.5 to 3 mm.

[0092] Next, the terminal member 30a is bonded to the flange portion 22a, and the terminal member 30b is bonded to the flange portion 22b. Figure 1C and Figure 1EAs shown, the main body 31 is bonded to the outer end surface 224 by the adhesive 60. In addition, as needed, the mounting pieces 321 and 322 are bonded to the mounting surface 221. In addition, after the winding portion 11 is formed on the winding core 21, the terminal member 30a may be bonded to the flange portion 22a, and the terminal member 30b may be bonded to the flange portion 22b.

[0093] Next, the conductor 10 is wound around the winding core 21 to form the winding portion 11. Figure 1B As shown, the wire 10 is led out from one end of the winding portion 11 in the X-axis direction toward the connection portion 33 of the terminal member 30a. Then, the temporary rivet piece 332 is bent, and the wire 10 is clamped by the temporary rivet piece 332. Thereafter, the wire 10 is further led out to the outer end surface 224 side of the flange portion 22a, and the welding piece 333 is bent, and the wire 10 is clamped by the welding piece 333.

[0094] In addition, the wire 10 is led out from the other end of the winding portion 11 in the X-axis direction toward the connection portion 33 of the terminal member 30b. Then, the temporary caulking piece 332 is bent, and the wire 10 is clamped by the temporary caulking piece 332. Thereafter, the wire 10 is further led out to the outer end surface 224 side of the flange portion 22b, and the welding piece 333 is bent, and the wire 10 is clamped by the welding piece 333.

[0095] Next, for example, the lead portion 12a is melted together with the welding piece 333 and / or the connecting piece 330 of the terminal member 30a by laser welding. As a result, a welding ball 50 is formed on the connecting portion 33, and the lead portion 12a and the connecting portion 33 are integrated. In addition, the lead portion 12b is melted together with the welding piece 333 and / or the connecting piece 330 of the terminal member 30b. As a result, a welding ball 50 is formed on the connecting portion 33, and the lead portion 12b and the connecting portion 33 are integrated.

[0096] Next, the plate-like core 40 is bonded to the mounting facing surfaces 222 of the flanges 22a and 22b by adhesive. Figure 1A The coil arrangement 1 is shown.

[0097] like Figure 1A As shown, in the present embodiment, the terminal member 30a has a main body portion 31 disposed on the outer end surface 224, and a connecting portion 33 that is continuous with the main body portion 31 and bends from the outer end surface 224 toward the first side surface 225. Therefore, the main body portion 31 and the connecting portion 33 act together as a stopper (rotation stopper), and the terminal member 30a is difficult to rotate (rotate) in a plane parallel to the mounting surface 221. Thus, the terminal member 30a is fixed to the flange portion 22a in a desired orientation, which can improve the installation stability of the terminal member 30a relative to the flange portion 22a.

[0098] In addition, if Figure 1CAs shown, the main body 31 is bonded to the outer end surface 224 by an adhesive 60. Therefore, the installation stability of the terminal member 30a relative to the flange portion 22a is improved. In addition, the misalignment of the terminal member 30a is suppressed, which can effectively prevent the terminal member 30a from rotating (rotating) in a plane parallel to the mounting surface 221.

[0099] In addition, if Figure 1A As shown, the terminal member 30a has a mounting portion 32 that is continuous with the main body 31 and is bent from the outer end surface 224 toward the mounting surface 221. Moreover, the mounting portion 32 has mounting pieces 321 and 322 separated by a gap 320. Therefore, the area of ​​the mounting portion 32 is reduced according to the area of ​​the gap 320. As a result, the area of ​​the pad pattern of the mounting substrate is reduced, and the stray capacitance of the pad pattern can be reduced. In addition, for example, when the coil device 1 is mounted on the mounting substrate by solder, a solder fillet can be formed in a large range from the mounting pieces 321 and 322 to the main body 31.

[0100] In addition, in this embodiment, unlike the prior art, the main body 31 is bonded to the outer end surface 224 without clamping the mounting surface 221 and the mounting opposite surface 222 by the terminal member 30a. Therefore, in order to prevent interference between the terminal member 30a and the planar core 40, it is not necessary to thin the mounting opposite surface 222 and the planar core 40. As a result, the contact area between the mounting opposite surface 222 and the planar core 40 is increased, and the inductance characteristics of the coil device 1 are improved. Moreover, the bonding strength between the mounting opposite surface 222 and the planar core 40 becomes higher.

[0101] In addition, if Figure 1E As shown, the mounting pieces 321 and 322 are bonded to the mounting surface 221 by the adhesive 60. Therefore, the mounting stability of the terminal member 30a relative to the flange portion 22a is further improved. In addition, the misalignment of the terminal member 30a is suppressed, which can effectively prevent the terminal member 30a from rotating (rotating) in a plane parallel to the mounting surface 221.

[0102] Second embodiment

[0103] In addition to the following points, Figure 4 The coil device 1A of the second embodiment shown has the same structure as the coil device 1 of the first embodiment. The same reference numerals are used for the parts that overlap with the coil device 1 of the first embodiment, and detailed description thereof will be omitted.

[0104] The coil device 1A includes a core 20A having a flange 22aA and a terminal 30aA. In the flange 22a of the first embodiment, the side cutouts 23 are formed on the first side surface 225 , whereas in the flange 22aA of the present embodiment, the side cutouts 23 are formed on the second side surface 226 .

[0105] In addition, in the terminal member 30a of the first embodiment, the wiring portion 33 is adjacent to the mounting piece 321, while in the terminal member 30aA of the present embodiment, the wiring portion 33 is adjacent to the mounting piece 322. The wiring portion 33 (the wiring piece 330) is continuous with the main body 31 and is bent (curved) from the outer end surface 224 toward the second side surface 226.

[0106] In this embodiment, the same effect as in the first embodiment can be obtained. Moreover, in this embodiment, when viewed from the X-axis direction, the side cutout portion 23 of the flange portion 22aA and the side cutout portion 23 of the flange portion 22b are located on different sides in the Y-axis direction. In addition, when viewed from the X-axis direction, the wiring portion 33 of the terminal member 30aA and the wiring portion 33 of the terminal member 30b are located on different sides in the Y-axis direction. Therefore, in the Y-axis direction, the balance of the coil device 1A is improved, and the installation stability of the coil device 1A to the mounting substrate is improved.

[0107] In addition, the present invention is not limited to the above-mentioned embodiment, and various changes can be made within the scope of the present invention.

[0108] In the above-mentioned embodiments, the example in which the coil device 1 is applied to an inductor is described. However, the coil device 1 may be applied to other electronic components (for example, a transformer).

[0109] In the above embodiments, it is also possible to Figure 1A The coil arrangement 1 shown omits the plate-shaped core 40 .

[0110] like Figure 1E As shown, the mounting pieces 321 and 322 are bonded to the mounting surface 221 by the adhesive 60. However, the mounting pieces 321 and 322 may not be bonded to the mounting surface 221 by the adhesive 60.

[0111] like Figure 1C As shown in FIG. 1 , the depth D of the side cutout 23 in the Z-axis direction is less than 1 / 2 of the height H of the flange 22a (first side surface 225) in the Z-axis direction. However, the depth D of the side cutout 23 in the Z-axis direction may be greater than 1 / 2 of the height H of the flange 22a in the Z-axis direction. In this case, the configuration space of the connection portion 33 is increased, and the degree of freedom of configuration of the connection portion 33 is improved. Therefore, it is easy to lead the lead portion 12a to a desired position of the connection portion 33.

[0112] like Figure 1E As shown, in the above-mentioned embodiments, the entire recess 24 is located inside the gap 320 , but a portion of the recess 24 may be located inside the gap 320 .

[0113] Description of Reference Numerals

[0114] 1. 1A coil device

[0115] 10 Wire

[0116] 11 Winding section

[0117] 12a, 12b lead-out portion

[0118] 20, 20A core

[0119] 21 roll core

[0120] 22a, 22b, 22aA flange portion

[0121] 221 Mounting surface

[0122] 222 Installation opposite side

[0123] 223 inner end face

[0124] 224 outer end face

[0125] 225 First side

[0126] 226 Second side

[0127] 23 Lateral incision

[0128] 24 recesses

[0129] 30a, 30b, 30aA Terminals

[0130] 31 Main body

[0131] 32 Installation

[0132] 320 Gap

[0133] 321, 322 mounting plate

[0134] 323, 324 Flexion part

[0135] 33 Connection section

[0136] 330 Lug

[0137] 331 Flexion part

[0138] 332 Temporary Rivet Plate

[0139] 333 welding piece

[0140] 34 Extended main body

[0141] 40 plate core

[0142] 41 abutment surface

[0143] 50 solder balls

[0144] 60 Adhesive

Claims

1. A coil device, wherein: have: a winding portion on which a conductive wire is wound; a core having a winding core portion provided with the winding portion, and a flange portion formed at an axial end portion of the winding core portion; as well as a terminal member mounted on the flange portion, The terminal piece includes a main body portion arranged on the outer end surface of the flange portion, a mounting portion continuous with the main body portion and bent from the outer end surface toward the mounting surface of the flange portion, and a connecting portion continuous with the main body portion and bent from the outer end surface toward the side surface of the flange portion. The mounting portion includes a plurality of mounting pieces separated by gaps. The main body is bonded to the outer end surface by an adhesive.

2. The coil device according to claim 1, wherein: The conductive wire has a lead-out portion led out from the winding portion, The connection portion includes a connection piece connected to the lead portion, and a welding piece branched from the connection piece and bendable relative to the connection piece. The welding pieces are welded while sandwiching the lead-out portion.

3. The coil device according to claim 2, wherein: The connection portion has a temporary rivet piece branched from the connection piece and bendable relative to the connection piece, The temporary rivet piece is closer to the rolled portion than the welding piece.

4. The coil device according to any one of claims 1 to 3, wherein: The conductive wire has a lead-out portion led out from the winding portion, The connection portion is laser welded together with the lead portion.

5. The coil device according to any one of claims 1 to 3, wherein: The flange portion has a side cutout portion formed on the side surface and accommodating at least a portion of the wiring portion. The side cutout portion extends toward the mounting surface.

6. The coil device according to claim 5, wherein: The flange portion includes a first flange portion formed at one axial end of the winding core portion and a second flange portion formed at the other axial end of the winding core portion. The terminal member includes a first terminal member mounted on the first flange portion and a second terminal member mounted on the second flange portion. The wiring portion includes a first wiring portion provided for the first terminal member and a second wiring portion provided for the second terminal member. The side cutout portion includes a first side cutout portion formed on a side surface of the first flange portion and accommodating at least a portion of the first connecting portion, and a second side cutout portion formed on a side surface of the second flange portion and accommodating at least a portion of the second connecting portion. When viewed from the axial direction of the winding core, the first side cutout portion and the second side cutout portion are located on the same side in a direction perpendicular to the axial direction.

7. The coil device according to claim 5, wherein: In a direction perpendicular to the mounting surface, a depth of the side cutout portion is greater than 1 / 2 of a height of the flange portion.

8. The coil device according to any one of claims 1 to 3, wherein: The flange portion has a recess formed on the mounting surface, At least a portion of the recess is located inside the gap.

9. The coil device according to any one of claims 1 to 3, wherein: At least one of the plurality of mounting pieces is bonded to the mounting surface by an adhesive.

10. The coil device according to any one of claims 1 to 3, wherein: The terminal member includes an extended main body portion that is disposed on the outer end surface and extends from the main body portion toward a side opposite to the mounting portion.

11. The coil device according to any one of claims 1 to 3, wherein: It also has a plate-like core. The plate-like core is mounted on a mounting facing surface of the flange portion on the side opposite to the mounting surface.

Images