Substrate mounted component and method for manufacturing substrate mounted component

Abstract

To suppress performance degradation of substrate mounted components caused by conductive defects.SOLUTION: A terminal 161 for the coil has a rectangular cross-section viewed from its tip side and is electrically connected to a contact formed on the circuit board. A conductive wire 12 of the coil is wound around the terminal 161 for the coil. A portion of the conductive wire 12 is welded to the terminal 161 for the coil to form a welded portion W.SELECTED DRAWING: Figure 9

Description

[Technical field]

[0001] The present disclosure relates to a board-mounted component that is mounted on a circuit board. The present disclosure also relates to a method for manufacturing the board-mounted component. [Background technology]

[0002] Patent Document 1 discloses a transformer as an example of a board-mounted component. The transformer includes a base. The base supports a conductive terminal. The conductive terminal has a first portion and a second portion. The first portion is electrically connected to a contact formed on a circuit board. A conductive wire used in the transformer is wound around the second portion. An electrical connection between the conductive wire and the second portion is established by soldering or laser welding, thereby establishing an electrical connection between the conductive wire and the contact. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2019-102703 A Summary of the Invention [Problem to be solved by the invention]

[0004] There is a demand for suppressing the degradation of performance of circuit board mounted components caused by poor electrical conductivity. [Means for solving the problem]

[0005] One embodiment of the present disclosure is a board-mounted component mounted on a circuit board, a plurality of conductive terminals electrically connected to contacts formed on the circuit board; A conductive wire; It is equipped with the conductive wire is joined to each of the plurality of conductive terminals to form a joined portion, In at least one of the plurality of conductive terminals, the conductive wire is wound in a first direction to form a plurality of first layer turns; Next, the winding direction is reversed in a plane extending so as to intersect with a direction in which the first layer turns of the conductive terminal are arranged, and forming a plurality of second layer turns by winding in a second direction opposite to the first direction so as to cover at least a portion of the plurality of first layer turns, At least the final turn included in the plurality of second layer turns is spaced apart from the portion to be joined.

[0006] One embodiment of the present disclosure provides a method for manufacturing a board-mounted component to be mounted on a circuit board, comprising the steps of: providing a plurality of conductive terminals, each of which is electrically connected to a contact formed on the circuit board; winding a conductive wire around each of the plurality of conductive terminals; joining a conductive wire to each of the plurality of conductive terminals; Contains In at least one of the plurality of conductive terminals, the conductive wire is wound in a first direction to form a plurality of first layer turns; Next, the winding direction is reversed in a plane extending so as to intersect with a direction in which the first layer turns of the conductive terminal are arranged, and forming a plurality of second layer turns by winding in a second direction opposite to the first direction so as to cover at least a portion of the plurality of first layer turns; The joined portion formed by the joining step is spaced apart from at least the final turn included in the plurality of second layer turns.

[0007] According to the configurations of the above-mentioned embodiments, the direction in which the conductive wire forming the second layer turn extends can be made to coincide with the direction in which the conductive wire forming the first layer turn extends. This allows the second layer turn to be wound between two adjacent first layer turns, thereby suppressing lateral slippage of the conductive wire in the width direction. As a result, it becomes easier to maintain the stability of the winding state.

[0008] In addition, since at least a part of the final turn of the second layer turns is separated from the connected part, it is possible to prevent stress that would displace a part of the conductive wire that is being connected to another conductive terminal from being transmitted to the connection part with the connected part, which has a relatively high rigidity, thereby preventing the conductive wire from breaking due to the stress.

[0009] Therefore, it is possible to suppress the deterioration of the performance of the board-mounted components caused by poor electrical conductivity. [Brief description of the drawings]

[0010] [Figure 1] 1 is an exploded perspective view illustrating a configuration of a transformer according to an embodiment; [Diagram 2] This shows an example of the external appearance of the transformer in FIG. 1 as seen from the upper right front direction. [Diagram 3] This shows an example of the external appearance of the transformer in Figure 1 as seen from the lower left rear direction. [Figure 4] This shows an example of the appearance of the transformer in FIG. 1 as seen from below. [Diagram 5] 5 illustrates a cross section taken along line VV in FIG. 4 and seen in the direction of the arrow. [Figure 6] 2 is a diagram for explaining a method of manufacturing the transformer of FIG. 1. [Figure 7] 2 is a diagram for explaining a method of manufacturing the transformer of FIG. 1. [Figure 8] 2 is a diagram for explaining a method of manufacturing the transformer of FIG. 1. [Figure 9] 2 is a diagram for explaining a method of manufacturing the transformer of FIG. 1. [Figure 10] 3 shows a manufacturing method according to a comparative example. [Figure 11] 2 shows another example of the shape of the coil terminal in the transformer of FIG. 1. [Figure 12] 2 shows another example of the shape of the coil terminal in the transformer of FIG. 1. [Figure 13] FIG. 10 is a perspective view illustrating a design of the transformer according to FIGS. 1 to 9. [Figure 14]FIG. 14 is a front view illustrating the design of the transformer of FIG. 13. [Figure 15] FIG. 14 is a rear view illustrating the design of the transformer of FIG. 13. [Figure 16] FIG. 14 is a plan view illustrating a design of the transformer of FIG. 13. [Figure 17] FIG. 14 is a bottom view illustrating the design of the transformer of FIG. 13. [Figure 18] FIG. 14 is a left side view illustrating the design of the transformer of FIG. 13. [Figure 19] FIG. 14 is a right side view illustrating the design of the transformer of FIG. 13. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] An example of an embodiment will be described in detail below with reference to the accompanying drawings. In the accompanying drawings, an arrow F indicates the forward direction of the illustrated structure. An arrow B indicates the rearward direction of the illustrated structure. An arrow U indicates the upward direction of the illustrated structure. An arrow D indicates the downward direction of the illustrated structure. An arrow R indicates the rightward direction of the illustrated structure. An arrow L indicates the leftward direction of the illustrated structure. These directional expressions are used for convenience of explanation and do not limit the posture or direction of the illustrated structure in actual use.

[0012] The term "front-rear direction" as used herein means a direction along the above-mentioned front and rear directions. The term "up-down direction" as used herein means a direction along the above-mentioned top and bottom directions. The term "left-right direction" as used herein means a direction along the above-mentioned left and right directions.

[0013] The expression "extending in the front-to-rear direction" used in this specification includes extending at an angle relative to the front-to-rear direction, and means extending at an angle closer to the front-to-rear direction than the up-down and left-to-right directions.

[0014] The expression "extending in the vertical direction" used in this specification includes extending at an angle relative to the vertical direction, and means extending at an angle closer to the vertical direction than the front-rear and left-right directions.

[0015] The expression "extending in the left-right direction" used in this specification includes extending at an angle relative to the left-right direction, and means extending at an angle closer to the left-right direction than the front-back and up-down directions.

[0016] FIG. 1 is an exploded perspective view illustrating the appearance of a transformer 10 according to one embodiment. FIG. 2 illustrates the appearance of the transformer 10 as viewed from the upper right front direction. FIG. 3 illustrates the appearance of the transformer 10 as viewed from the lower left rear direction. FIG. 4 illustrates the appearance of the transformer 10 as viewed from below. FIG. 5 illustrates a cross section of the transformer 10 as viewed in the direction of the arrow along line VV in FIG. 4. The transformer 10 is an example of a board-mounted component mounted on a circuit board.

[0017] 1 and 5, a transformer 10 includes a core 11 and a conductive wire 12. The core 11 has a hollow portion 11a extending in the front-rear direction. The conductive wire 12 is wound around the core 11 to form a coil.

[0018] The transformer 10 includes a first core 131. The first core 131 is made of a material including a magnetic substance. An example of the material is ferrite.

[0019] The first core 131 has a first inner portion 131a and a first outer portion 131b. The first inner portion 131a extends into the hollow portion 11a from the front end portion of the core portion 11. The first outer portion 131b faces the conductive wires 12 from above and from the left and right directions.

[0020] The transformer 10 includes a second core 132. The second core 132 is made of a material including a magnetic substance. An example of the material is ferrite.

[0021] The second core 132 has a second inner portion 132a and a second outer portion 132b. The second inner portion 132a extends into the hollow portion 11a from the rear end of the core portion 11. The second outer portion 132b faces the conductive wire 12 from above and from the left and right directions.

[0022] 1 to 5, the transformer 10 includes a shield case 14. The shield case 14 is made of a conductive material. Examples of the conductive material include aluminum and copper. The shield case 14 is provided to suppress an electromotive force that may be generated in the conductive wire 12 due to a magnetic field as noise coming from outside the transformer 10. The shield case 14 has a box shape that opens downward, and thereby surrounds the first core 131 and the second core 132 from the front-rear, upper, and left-right directions.

[0023] 2 and 3, the transformer 10 includes a base 15 and a plurality of terminals 16. The base 15 is made of an electrically insulating material. Each of the plurality of terminals 16 is made of a conductive material.

[0024] Each of the plurality of terminals 16 is integrally formed with the base 15. Each of the plurality of terminals 16 has a coil terminal 161 and a mounting terminal 162.

[0025] An end (not shown) of the conductive wire 12 wound around the core 11 is electrically connected to the coil terminal 161. The mounting terminal 162 is electrically connected to a circuit element formed on the circuit board when the transformer 10 is mounted on the circuit board by solder reflow. This electrically connects the conductive wire 12 to the circuit element on the circuit board. The mounting terminal 162 is an example of a first portion of a conductive terminal. The coil terminal 161 is an example of a second portion of a conductive terminal.

[0026] 1, the transformer 10 includes a shield plate 17. The shield plate 17 is made of a conductive material. Preferably, the shield plate 17 is made of the same material as the shield case 14.

[0027] The shield plate 17 has a first portion 17a. As illustrated in Fig. 5, the first portion 17a is disposed so as to face the conductive line 12 in the upward direction. The upward direction is an example of the second direction. When the transformer 10 is mounted on a circuit board, the first portion 17a is disposed between the conductive line 12 and the circuit board.

[0028] 1, 3, and 4, the shield plate 17 extends in the left-right direction. The shield plate 17 has a second portion 17b and a third portion 17c. The second portion 17b extends continuously from the left end of the first portion 17a and is inseparably connected to the left side wall 14a of the shield case 14. The third portion 17c extends continuously from the right end of the first portion 17a and is inseparably connected to the right side wall 14b of the shield case 14.

[0029] The shielding case 14 has a box shape that opens downward. Therefore, the shielding case 14 cannot cover the conductive wires 12 from below. However, by providing the shielding plate 17, it is possible to ensure a portion of the transformer 10 where the conductive wires 12 are surrounded from the radial outside of the core 11. In other words, the shielding plate 17 can suppress the electromotive force that may be generated in the conductive wires 12 by a magnetic field as noise coming from below the transformer 10.

[0030] A method for manufacturing the transformer 10 configured as above will be described with reference to FIGS.

[0031] 6, the conductive wire 12 is wound around the coil terminal 161. Specifically, the conductive wire 12 is wound around the coil terminal 161 so as to include a first layer turn 121 and a second layer turn 122.

[0032] The second layer turn 122 is located on the outer periphery side of the first layer turn 121. The first layer turn 121 is wound in a clockwise direction when viewed from the tip side of the coil terminal 161. The second layer turn 122 is wound in a counterclockwise direction when viewed from the tip side of the coil terminal 161. In other words, the winding direction of the first layer turn 121 and the winding direction of the second layer turn 122 are opposite. The clockwise direction is an example of a first direction. The counterclockwise direction is an example of a second direction.

[0033] 7, the conductive wire 12 is first wound around the coil terminal 161 so as to form a plurality of first layer turns 121. The plurality of first layer turns 121 are formed so as to be aligned along the longitudinal direction of the coil terminal 161.

[0034] 6 and 7, the coil terminal 161 has a protruding portion 161a. The protruding portion 161a is formed on a side surface 161c different from a tip surface 161b of the coil terminal 161. The protruding portion 161a has a surface that extends so as to intersect with the direction in which the multiple first layer turns 121 are arranged. After the multiple first layer turns 121 have been formed, the conductive wire 12 is hung on the protruding portion 161a, thereby reversing the winding direction.

[0035] 8, the conductive wire 12 is wound around the coil terminal 161 to form a plurality of second layer turns 122. The plurality of second layer turns 122 are formed to be aligned along the longitudinal direction of the coil terminal 161. The plurality of second layer turns 122 are formed to cover at least a portion of the plurality of first layer turns 121.

[0036] After the conductive wire 12 has been formed with the multiple first layer turns 121, it is relayed to another coil terminal 161. The above winding method is used except for the coil terminal 161 where the end of the conductive wire 12 is located.

[0037] Next, as illustrated in Fig. 9, the conductive wire 12 is joined to the coil terminal 161. In this embodiment, the joining is performed by laser welding. Instead of laser welding, the joining may be performed by TIG welding. The thermally melted coil terminal 161 and the conductive wire 12 form a welded portion W. The welded portion W is an example of a joined portion.

[0038] 2, 3, and 5, the welded portion W is located at the tip of each coil terminal 161. As illustrated in Fig. 9, at least the final turn 122a included in the multiple second layer turns 122 is separated from the welded portion W.

[0039] 10 shows a comparative example of a winding method for a conductive wire 12. In this example, after a plurality of first layer turns 121 are formed, a plurality of second layer turns 122 are formed without reversing the winding direction.

[0040] With this winding method, the extension direction of the conductive wire 12 forming the second layer turn 122 intersects with the extension direction of the conductive wire 12 forming the first layer turn 121. In this case, the second layer turn 122 overlapping the first layer turn 121 is likely to slip laterally in the width direction of the conductive wire 12, making it difficult to maintain the stability of the winding state.

[0041] In addition, at least a portion of the final turn 122a included in the multiple second layer turns 122 is included in the welded portion W. In this case, if a stress is applied that displaces the portion 122b of the conductive wire 12 that is used for relaying to another coil terminal 161, there is a risk that the conductive wire 12 will break at the connection portion with the welded portion W, which has a relatively high rigidity.

[0042] On the other hand, with the winding method according to this embodiment, the extension direction of the conductive wire 12 forming the second layer turn 122 can be made to coincide with the extension direction of the conductive wire 12 forming the first layer turn 121. This allows the second layer turn 122 to be wound between two adjacent first layer turns 121, suppressing lateral slippage of the conductive wire 12 in the width direction. As a result, it becomes easier to maintain the stability of the winding state.

[0043] In addition, since at least a portion of the final turn 122a included in the multiple second layer turns 122 is separated from the welded portion W, it is possible to prevent stress that would displace the portion 122b of the conductive wire 12 that is used for relaying to another coil terminal 161 from being transmitted to the connection portion with the welded portion W, which has a relatively high rigidity. As a result, it is possible to prevent the conductive wire 12 from breaking due to the stress.

[0044] Therefore, the deterioration of the performance of the transformer 10 caused by poor electrical conductivity can be suppressed.

[0045] 11 shows another example of the shape of the coil terminal 161. In this example, a recess 161d is formed in the tip surface 161b of the coil terminal 161. The recess 161d has a surface that extends so as to intersect with the direction in which the multiple first layer turns 121 are arranged. In this example as well, the winding direction of the conductive wire 12 is reversed on this surface.

[0046] In other words, as long as a surface can be formed that extends so as to intersect with the direction in which the multiple first layer turns 121 are arranged in order to reverse the winding direction of the conductive wire 12, at least one of the convex portion and the concave portion can be provided at an appropriate position on the coil terminal 161.

[0047] 12 shows another example of the shape of coil terminal 161. In this example, the winding direction of conductive wire 12 is reversed at tip surface 161b of coil terminal 161. Tip surface 161b is an example of a surface that extends so as to intersect with the arrangement direction of multiple first layer turns 121. In other words, at least one of a convex portion and a concave portion does not necessarily have to be provided in order to reverse the winding direction of conductive wire 12.

[0048] The configurations referred to above are merely examples for facilitating understanding of the present disclosure. Each configuration example may be appropriately modified or combined with other configuration examples within the scope of the present disclosure.

[0049] In the above embodiment, the coil terminal 161 and the conductive wire 12 are joined by welding. However, the coil terminal 161 and the conductive wire 12 may be joined by soldering. In this case, the solidified solder fillet corresponds to the above-mentioned welded portion W. The solidified solder fillet is an example of a joined portion.

[0050] The above-described winding method for a conductive wire can be applied to any suitable board-mounted component, so long as the component has a plurality of conductive terminals that are electrically connected to contacts formed on a circuit board and the conductive wire is wound around the conductive terminals. Examples of such board-mounted components include motors and actuators.

[0051] The design of the transformer according to the embodiment described with reference to Figs. 1 to 9 is illustrated in Figs. 13 to 19. Fig. 13 is a perspective view. Fig. 14 is a front view. Fig. 15 is a rear view. Fig. 16 is a plan view. Fig. 17 is a bottom view. Fig. 18 is a left side view. Fig. 19 is a right side view.

[0052] Each of the configurations listed below also constitutes part of this disclosure. Item 1: A board-mounted component to be mounted on a circuit board, a plurality of conductive terminals electrically connected to contacts formed on the circuit board; A conductive wire; It is equipped with the conductive wire is joined to each of the plurality of conductive terminals to form a joined portion, In at least one of the plurality of conductive terminals, the conductive wire is wound in a first direction to form a plurality of first layer turns; Next, the winding direction is reversed in a plane extending so as to intersect with a direction in which the first layer turns of the conductive terminal are arranged, and forming a plurality of second layer turns by winding in a second direction opposite to the first direction so as to cover at least a portion of the plurality of first layer turns, At least a final turn included in the plurality of second layer turns is away from the portion to be joined. Board mounted components. Item 2: a winding forming at least one of the plurality of second layer turns is wound along between windings forming two adjacent ones of the plurality of first layer turns; Item 1. A board-mounted component as described in item 1. Item 3: The winding direction of the conductive wire is reversed using at least one of a protrusion and a recess formed on the conductive terminal. 3. A board-mounted component according to item 1 or 2. Item 4: At least one of the protrusion and the recess is formed on a side surface different from a tip surface of the conductive terminal. Item 3. A board-mounted component as described in item 3. Item 5: The conductive line is part of a transformer. 5. The board-mounted component according to any one of items 1 to 4. [Explanation of symbols]

[0053] 10: transformer, 12: conductive wire, 121: first layer turn, 122: second layer turn, 122a: final turn, 161: coil terminal, 161a: convex portion, 161b: tip surface, 161c: side surface, 161d: concave portion, W: welded portion

Claims

1. A board-mounted component to be mounted on a circuit board, a conductive terminal having a rectangular cross section as viewed from the tip side thereof and electrically connected to a contact formed on the circuit board; A conductive wire wound around the conductive terminal; It is equipped with A portion of the conductive wire is joined to the conductive terminal to form a joined portion. Board mounted components.

2. The conductive wire is A portion forming a plurality of first layer turns; a portion covering a portion of the first layer turns to form a plurality of second layer turns; Contains The board-mounted component according to claim 1 .

3. The conductive wire is wound in a first direction to form the first plurality of layer turns; Next, the winding direction is reversed in a plane extending so as to intersect with a direction in which the first layer turns of the conductive terminal are arranged, and forming the plurality of second layer turns by winding the plurality of first layer turns in a second direction opposite to the first direction so as to cover at least a portion of the plurality of first layer turns, At least a final turn included in the plurality of second layer turns is away from the portion to be joined. The board-mounted component according to claim 2 .

4. The conductive line is part of a transformer. The board-mounted component according to claim 1 .

5. A method for manufacturing a board-mounted component to be mounted on a circuit board, comprising the steps of: preparing a conductive terminal having a rectangular cross section as viewed from a tip side thereof, the conductive terminal being electrically connected to a contact formed on the circuit board; wrapping a conductive wire around the conductive terminal; forming a joined portion by joining a portion of the conductive wire to the conductive terminal; Contains A method for manufacturing board mounted components.

6. The conductive wire is welded to the conductive terminal. The method for manufacturing the board-mounted component according to claim 5 .

7. The conductive wire is soldered to the conductive terminal. The method for manufacturing the board-mounted component according to claim 5 .

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