Electronic components and coil components

Abstract

To provide electronic components such as coil components that can improve the mounting strength of terminals. [Solution] The electronic component 1 has a terminal 41a and a mounting portion 50a to which the terminal 41a is attached. The terminal 41a has a main piece 43 that is press-fitted into the mounting portion 50a. The mounting portion 50a has a wall surface 510 facing the main piece 43 and a fixing portion 513 that protrudes from the wall surface 510 and fixes the main piece 43. The wall surface 510 has a receiving recess 512 that can accommodate the deformed portion 519 of the fixing portion 513.

Description

Technical Field

[0001] The present invention relates to electronic components such as coil components.

Background Art

[0002] Patent Document 1 discloses a common mode choke coil having terminals. In such a common mode choke coil, a U-shaped metal terminal is attached so as to sandwich the flange portion of the core.

[0003] In recent years, it has also been proposed to attach the terminals by press-fitting them into an attachment portion such as a terminal block.

[0004] However, when attaching the terminals by press-fitting them into an attachment portion such as a terminal block, the press-fitting may be incomplete, and there may be cases where the terminals cannot be attached with sufficient strength.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] In view of such circumstances, the present invention has been made, and its object is to provide an electronic component such as a coil component capable of improving the attachment strength of terminals.

Means for Solving the Problems

[0007] In order to achieve the above object, the inventors of the present invention conducted intensive research and found that when the terminals are press-fitted into an attachment portion such as a terminal block, a part of the terminals is lifted from the attachment portion such as the terminal block due to a deformed portion generated during the press-fitting, thereby reducing the attachment strength of the terminals. Based on this finding, the present invention has been completed.

[0008] Therefore, an electronic component according to one aspect of the present invention is Terminals and It has a mounting portion to which the aforementioned terminal is attached, The terminal has a main piece that is press-fitted into the mounting portion, The mounting portion has a wall surface facing the main piece and a fixing portion that protrudes from the wall surface and fixes the main piece. The aforementioned wall surface has a recess formed therein that can accommodate the deformed portion of the fixed part.

[0009] With this configuration, the deformation of the fixing part that occurs when the terminal is press-fitted into the mounting part is accommodated in a recess formed in the wall surface of the mounting part. Therefore, it is possible to prevent the main piece of the terminal from lifting away from the wall surface, and the mounting strength of the terminal can be improved. Furthermore, with this configuration, the terminal is precisely positioned and mounted in the mounting part, so even if there are multiple terminals, it does not affect the coplanarity (flatness) when mounted on a substrate or the like. Therefore, the mounting strength of electronic components on substrates and the like can also be improved.

[0010] Furthermore, a coil component according to one aspect of the present invention is Wire and The terminal to which the aforementioned wire is connected, It has a mounting portion to which the aforementioned terminal is attached, The terminal has a main piece that is press-fitted into the mounting portion, The mounting portion has a wall surface facing the main piece and a fixing portion that protrudes from the wall surface and fixes the main piece. The aforementioned wall surface has a recess formed therein that can accommodate the deformed portion of the fixed part.

[0011] With this configuration, any deformation of the fixing part that occurs when the terminal to which the wire connects is press-fitted into a mounting part such as a terminal block is accommodated in a recess formed in the wall surface of the mounting part. Therefore, it is possible to prevent the main piece of the terminal from lifting away from the wall surface of the mounting part, thereby improving the mounting strength of the terminal. Furthermore, with this configuration, the main piece of the terminal is precisely positioned and mounted on the mounting part, so even coil components such as common mode choke coils with multiple terminals are not affected in terms of coplanarity (flatness) when mounted on a circuit board or the like. Therefore, the mounting strength of the coil component on a circuit board or the like can also be improved.

[0012] Preferably, the receiving recess is formed in the base portion of the wall surface connected to the base end of the fixed part with which the main piece engages. Since the deformation of the fixed part mainly occurs at the base end with which the main piece of the terminal engages, the receiving recess is formed in the base portion of the wall surface connected to the base end so that the deformation can be reliably accommodated in the receiving recess.

[0013] Preferably, the main piece has opposing surfaces that are substantially parallel to the wall surface. By arranging the opposing surfaces of the main piece substantially parallel to the wall surface, the main piece of the terminal can be more firmly adhered to the wall surface of the mounting portion.

[0014] Preferably, the fixing portion has a tapered surface at the tip of the fixing portion in the protruding direction to guide the press-fitting of the terminal. By providing a tapered surface at the tip of the fixing portion, the main piece of the terminal is made easier to press-fit into the mounting portion, making the terminal mounting work easier.

[0015] Preferably, the fixing portion has a cut surface into which the main piece of the terminal engages. When the main piece of the terminal is press-fitted into the mounting portion, the main piece crushes a part of the fixing portion, forming a cut surface, thereby firmly engaging the main piece and the fixing portion. As a result, this configuration improves the mounting strength of the terminal.

[0016] Preferably, the accommodation recess houses the deformation part connected to the cutting surface. By housing the deformation part generated when forming the cutting surface in the fixed part, which is connected to the cutting surface and housed in the accommodation recess, it is possible to prevent the deformation part from entering between the terminal and the wall surface of the mounting part.

[0017] Preferably, the main piece has a flat plate shape having a facing surface facing the wall surface and an opposite surface on the opposite side of the facing surface. The side surface of the main piece has an engagement groove cut out from the facing surface to the opposite surface, and the engagement groove may engage with the fixed part, and the side surface of the main piece may have an engagement convex part that engages with the fixed part. By configuring in this way, the terminal can be securely fixed to the mounting part at a predetermined height position, and the mounting strength of the terminal is improved.

Brief Description of the Drawings

[0018] [Figure 1] FIG. 1 is an overall perspective view of a coil component according to an embodiment. [Figure 2] FIG. 2 is an exploded perspective view of the coil component according to FIG. 1. [Figure 3] FIG. 3 is a side view of a part of the coil component according to FIG. 1. [Figure 4] FIG. 4 is a plan view of a part of the coil component according to FIG. 1. [Figure 5A] FIG. 5A is a front view of a part of the coil component according to FIG. 1. [Figure 5B] FIG. 5B is a front view of a part of a coil component according to another embodiment. [Figure 6] FIG. 6 is a cross-sectional view taken along line VI-VI shown in FIG. 1. [Figure 7] FIG. 7 is a cross-sectional view taken along line VII-VII shown in FIG. 1. [Figure 8] FIG. 8 is a cross-sectional view taken along line VIII-VIII shown in FIG. 1. [Figure 9] FIG. 9 is a partial perspective view showing the configuration of the terminal of the coil component shown in FIG. 1. [Figure 10A]Figure 10A is a partial perspective view showing the configuration of the terminal block, which is the mounting section for the terminals of the coil component shown in Figure 1. [Figure 10B] Figure 10B is a front view of the terminal block shown in Figure 10A. [Figure 10C] Figure 10C is a magnified view of the XC portion shown in Figure 10A. [Figure 11A] Figure 11A is a partial perspective view showing the configuration of the terminal block before the terminals of the coil component shown in Figure 1 are attached. [Figure 11B] Figure 11B is a front view of the terminal block shown in Figure 11A before the terminals are attached. [Figure 11C] Figure 11C is a magnified view of the XIC portion shown in Figure 11A. [Figure 12] Figure 12 is an explanatory diagram showing the process of attaching terminals to the terminal block shown in Figure 11A before the terminals are attached. [Figure 13A] Figure 13A is a perspective view showing the terminal block with terminals attached using the procedure shown in Figure 12. [Figure 13B] Figure 13B is a magnified view of the portion XIIIB shown in Figure 13A. [Figure 14] Figure 14 is a cross-sectional view along the line XIV-XIV shown in Figure 13B. [Figure 15] Figure 15 is a partial perspective view showing the configuration of the cover for the coil component shown in Figure 1. [Modes for carrying out the invention]

[0019] Embodiments of the present invention will be described with reference to the drawings. Although the explanation will be given with reference to the drawings as necessary, the contents shown in the drawings are merely schematic and illustrative for the purpose of understanding the present invention, and the appearance and dimensional ratios may differ from those of the actual product. Furthermore, although the following description will specifically describe electronic components according to embodiments of the present invention, using coil components as an example, the invention is not limited to these embodiments.

[0020] (First Embodiment) The coil component 1, an electronic component according to one embodiment of the present invention shown in Figure 1, is suitably used as, for example, a common mode filter or a common mode choke coil. As shown in Figure 1, the coil component 1 according to this embodiment has a substantially rectangular parallelepiped shape overall. The external dimensions of the coil component 1 are not limited, but as shown in Figure 1, for example, the length L0 in the X-axis direction can be 23.5 to 32.5 mm, the width W0 in the Y-axis direction can be 23.9 to 31.1 mm, and the height H0 in the Z-axis direction can be 14.4 to 21.6 mm. In this embodiment, the coil component 1 has a shape that is substantially symmetrical in the X-axis direction and the Y-axis direction, but it is not necessarily symmetrical and may have different parts.

[0021] As shown in Figure 1, the coil component 1 generally consists of wires (first wire 20 and second wire 30), terminals to which the wires connect (first terminals 41a, 41b and second terminals 42a, 42b), and terminal blocks 50a, 50b which serve as mounting parts to which these terminals (41a, 41b, 42a, 42b) are attached. As shown in Figure 2, the coil component 1 further includes a core 10, bobbins 60 (first bobbin 60a and second bobbin 60b), and a case 100.

[0022] As shown in Figure 2, the core 10 has a first winding core portion 11 and a second winding core portion 12 extending in the X-axis direction. The first winding core portion 11 serves as the winding core for the first wire 20, and the second winding core portion 12 serves as the winding core for the second wire 30. The core 10 also has connecting portions 13a and 13b extending in the Y-axis direction, which connect the ends of the first winding core portion 11 and the second winding core portion 12, respectively. In the drawing, the X, Y, and Z axes are approximately perpendicular to each other.

[0023] Core 10 contains a magnetic material. Examples of magnetic materials include ferrites such as Ni-Zn and Mn-Zn, or metallic magnetic materials such as Fe-Ni alloys, Fe-Si alloys, Fe-Si-Cr alloys, Fe-Co alloys, Fe-Si-Al alloys, and amorphous iron. Core 10 can be manufactured by molding and sintering powders of these magnetic materials. Alternatively, Core 10 may be molded by solidifying the magnetic material with a resin. The resin is not particularly limited, but examples include epoxy resins, phenolic resins, polyester resins, polyurethane resins, polyimide resins, other synthetic resins, or other non-magnetic materials.

[0024] As shown in Figure 2, the core 10 can be divided into a first core 10a having a connecting portion 13a and a second core 10b having a connecting portion 13b. The first core 10a and the second core 10b may each have a symmetrical, substantially U-shaped form.

[0025] The connecting portion 13a has an inner end surface 14a to which the base ends of the first core portion 11 and the second core portion 12 are connected, and an outer end surface 15a positioned opposite to the inner end surface 14a along the X-axis. The connecting portion 13a also has a side surface that connects the inner end surface 14a and the outer end surface 15a. The connecting portion 13a has a roughly rectangular parallelepiped shape, and its side surfaces include a first side surface 16a, a second side surface 17a, a third side surface 18a, and a fourth side surface 19a.

[0026] The connecting portion 13b has the same shape as the connecting portion 13a. The connecting portion 13b has an inner end face 14b, an outer end face 15b, and a side surface connecting the inner end face 14b and the outer end face 15b. The connecting portion 13b has a roughly rectangular parallelepiped shape, and its side surfaces include a first side surface 16b, a second side surface 17b, a third side surface 18b, and a fourth side surface 19b.

[0027] As shown in Figure 8, the first core 10a has a surface 11a facing the first core portion 11 and a surface 12a facing the second core portion 12. The first core portion 11 of the second core 10b has a surface 11b that faces the surface 11a along the X-axis. The second core portion 12 of the second core 10b has a surface 12b that faces the surface 12a along the X-axis.

[0028] As shown in Figure 8, the opposing surfaces 11a, 11b, 12a, and 12b of the first core 10a and the second core 10b are positioned offset from both the first butt joints 61a, 61b and the second butt joints 62a, 62b of the bobbin 60, which will be described later. The position of the opposing surfaces 11a, 11b, 12a, and 12b of the core 10 differs from the position of the butt joints 61a, 61b, 62a, and 62b, which further improves the strength of the coil component 1.

[0029] As shown in Figure 8, the core 10 has a ring shape in which the opposing surface 11a of the first core 10a and the opposing surface 11b of the second core 10b are fixed with an adhesive (not shown), and the opposing surface 12a of the first core 10a and the opposing surface 12b of the second core 10b are fixed with an adhesive (not shown). The opposing surfaces 11a, 11b and the opposing surfaces 12a, 12b may be in direct contact with each other, but gaps may be formed between the opposing surfaces 11a, 11b and between the opposing surfaces 12a, 12b. The core 10 is housed in a bobbin 60. As shown in Figure 7, the core 10 may be bonded and fixed to the bobbin 60 with an adhesive 70. The adhesive 70 is preferably insulating.

[0030] As shown in Figure 2, the bobbin 60 has a first winding drum 61 around which the first wire 20 is wound, a second winding drum 62 around which the second wire 30 is wound, and flange portions 63a and 63b connecting the first winding drum 61 and the second winding drum 62.

[0031] The bobbin 60 is formed of an insulating material. The insulating material is not particularly limited, but it is preferable that it is a material that is easy to form into thin first and second winding drums and has excellent tracking resistance. Such insulating materials can be, for example, heat-resistant polyamide (semi-aromatic polyamide), heat-resistant nylon (PA9T, PA6T, etc.), PPS, etc.

[0032] Alternatively, thermoplastic resins are preferred as the insulating material for forming the bobbin. Examples of thermoplastic resins include general-purpose plastics as well as super engineering plastics. Examples of super engineering plastics include PEEK, PBN, PBI, PPS, LCP, PAI, PTFE, PSF, PCTFE, PAR, PI, PES, PFA, ETFE, and PVDF. Among these, PAI, PPS, and PEEK, which have a heat resistance of 240°C or higher, can be suitably used, and LCP, which has a heat resistance of 280°C or higher, can also be suitably used. These materials have high impact resistance and excellent toughness, and are easy to machine, so they can be suitably used for fine processing such as joining bobbins together.

[0033] The bobbin 60 can be divided into a first bobbin 60a and a second bobbin 60b. The second bobbin 60b has the same shape as the first bobbin 60a, but may have a slightly different shape. The following description of the first bobbin 60a also applies to the second bobbin 60b to the extent that its properties are not different.

[0034] As shown in Figure 8, the first butt joint 61a of the first bobbin 60a is inserted into the first butt joint 61b of the second bobbin 60b. The second butt joint 62b of the second bobbin 60b is inserted into the second butt joint 62a of the first bobbin 60a. The first bobbin 60a and the second bobbin 60b are connected by the first butt joints 61a and 61b of the first winding drum 61 and the second butt joints 62a and 62b of the second winding drum 62.

[0035] The first butt joints 61a and 61b are positioned offset from the second butt joints 62a and 62b in the X-axis direction. The second butt joints 62a and 62b are positioned closer to the flange portion 63a in the X-axis direction than the first butt joints 61a and 61b. By having the butt joints of the respective winding drum portions 61 and 62 in different positions, the effects of stress caused by deformation of the substrate on which the coil component 1 is mounted can be mitigated, improving the strength of the coil component 1 itself, as well as further improving the strength after the coil component 1 has been surface-mounted.

[0036] As shown in Figure 8, the flange portion 63a has an inner flange wall 64a that covers the inner end face 14a and a side flange wall 65a that covers the side of the connecting portion 13a. A terminal block 50a is attached to the flange portion 63a to which terminals (first terminal 41a and second terminal 42a) are fixed.

[0037] As shown in Figure 8, the flange portion 63b has an inner flange wall 64b that covers the inner end face 14b and a flange side wall 65b that covers the side surface of the connecting portion 13b. A terminal block 50b to which terminals (first terminal 41b and second terminal 42b) are fixed is attached to the flange portion 63b. As shown in Figure 7, the terminal blocks 50a and 50b are fixed to the core 10 and bobbin 60 with adhesive 70.

[0038] The terminals attached to the terminal block (first terminals 41a, 41b and second terminals 42a, 42b) are made of metals such as tough pitch steel, phosphor bronze, brass, iron, nickel, nickel alloy, and stainless steel. These terminals can be integrally formed by punching, pressing, and bending conductive plates. Furthermore, it is preferable that a plating film of tin or a tin-containing alloy is formed on the outer surface of the terminals (first terminals 41a, 41b and second terminals 42a, 42b) as a solder adhesion strengthening layer.

[0039] As shown in Figure 9, the terminals (first terminals 41a, 41b and second terminals 42a, 42b) are formed by bending a conductor plate. Each terminal (first terminals 41a, 41b and second terminals 42a, 42b) has a main piece 43, a mounting piece 44, a base piece 45, a rising piece 46, and a connecting piece 47. The thickness T of the conductor plate is not particularly limited and may be, for example, 0.2 mm to 1 mm.

[0040] As shown in Figure 9, the main piece 43 has a flat plate shape with an opposing surface 430a facing the wall surface 510 (see Figure 10A) of the outer end wall 51 of the terminal block, and an opposing surface 430b on the opposite side in the X-axis direction from the opposing surface 430a. The sides 430c and 430d of the main piece 43 each have an engagement groove 431 cut out from the opposing surface 430a to the opposing surface 430b. The engagement groove 431 has engagement surfaces 432, 432 that are substantially perpendicular to the Z-axis.

[0041] The Z-axis width W3 (distance between engagement surfaces 432, 432) of the engagement groove 431 of the main piece 43 of the terminal is not particularly limited. From the viewpoint of ease of mounting the terminal to the terminal block and mounting strength, the width W3 is preferably 0.1 times or more, and more preferably 0.5 times or less, the Z-axis height H1 of the main piece 43.

[0042] As shown in Figures 10A and 10B, terminal blocks 50a and 50b have an outer end wall 51 and a side wall 52. Terminal blocks 50a and 50b have similar shapes, but may have slightly different shapes. The description of one terminal block 50a or 50b applies to the other to the extent that its properties are not different.

[0043] As shown in Figure 8, in terminal block 50a, the outer end wall 51 of the terminal block covers the outer end surface 15a of the core, and the side wall 52 of the terminal block covers the flange side wall 65a. Similarly to terminal block 50a, terminal block 50b also has the outer end wall 51 of the terminal block covering the outer end surface 15b of the core, and the side wall 52 of the terminal block covering the flange side wall 65b.

[0044] Terminal blocks 50a and 50b are formed of an insulating material. The insulating material forming terminal blocks 50a and 50b may be the same as or different from that of the bobbin 60. The insulating material forming terminal blocks 50a and 50b is not particularly limited and may be a thermosetting resin or a thermoplastic resin.

[0045] Examples of thermosetting resins used to form terminal blocks 50a and 50b include UP, UF, MF, PUR, SI, PL-FLE, PL-PEM, EP, EG, and FRP. Various thermosetting resins can be selected depending on the required properties. For example, from the viewpoint of strength at high temperatures, phenolic resins, urea resins, and epoxy resins can be used; from the viewpoint of electromagnetic properties, urea resins and epoxy resins can be used; and from the viewpoint of flame retardancy, melamine resins can be used.

[0046] Examples of thermoplastic resins used to form terminal blocks 50a and 50b include general-purpose plastics and super engineering plastics. Examples of super engineering plastics include PEEK, PBN, PBI, PPS, LCP, PAI, PTFE, PSF, PCTFE, PAR, PI, PES, PFA, ETFE, and PVDF. Among these, PAI, PPS, and PEEK, which have a heat resistance of 240°C or higher, are suitable, and LCP, which has a heat resistance of 280°C or higher, is also suitable. These materials have high impact resistance, excellent toughness, and are easy to machine. As described later, these materials deform appropriately when terminals are press-fitted and attached, making the installation work easy and improving the attachment strength of the terminals. In this embodiment, LCP (Liquid Crystal Polymer) is particularly suitable.

[0047] As shown in Figure 10A, terminal blocks 50a and 50b have a fixing portion 513 that protrudes in the X-axis direction from the wall surface 510 of the outer end wall 51 of the terminal block. The protruding height of the fixing portion 513 is not particularly limited, but it is preferably greater than the thickness T of the terminal (see Figure 9). As shown in Figure 5A, the fixing portion 513 has a positioning wall 514 that runs along the side surfaces 430c and 430d of the main piece 43 of each terminal. The positioning wall 514 runs along the side surfaces 430c and 430d of the main piece 43 of each terminal, thereby defining the mounting position of each terminal in the Y-axis direction. Note that the side surfaces 430c and 430d and the positioning wall 514 do not have to be in contact, but they may be.

[0048] As shown in Figure 5A, in this embodiment, the fixing portion 513 has a convex shape relative to the side surface of the main piece 43 of the terminal. As described later, the terminal blocks 50a and 50b can fix the terminal by press-fitting the main piece 43 of the terminal into the fixing portion 513. In addition, adhesive 71 may be placed between the wall surface 510 (see Figure 10A) of the terminal blocks 50a and 50b and the opposing surface 430a (see Figure 9) of the terminal. By placing adhesive 71, the terminal and the terminal block can be fixed more firmly.

[0049] As shown in Figures 10A and 10B, terminal blocks 50a and 50b have a receiving recess 512 formed in the wall surface 510 facing the main piece of the terminal, which is capable of accommodating the deformed portion 519 (see Figure 10C) of the fixing portion 513. As shown in Figure 10B, the receiving recess 512 is formed in the base portion 511 of the wall surface 510 that connects to the base end 515 of the fixing portion 513.

[0050] Figure 10C is an enlarged view of the convex portion of the fixing portion 513 on the upper left side of the terminal block 50a (50b) and the area around the housing recess 512 (the XC portion shown in Figure 10A). As shown in Figure 10C, the housing recess 512 is recessed in the X-axis direction compared to the wall surface 510. The deformable portion 519 is housed in the housing recess 512.

[0051] As shown in Figure 10C, the fixing portion 513 has a cut surface 518 formed by crushing a part of the fixing portion 513 when the terminal is press-fitted. A deformed portion 519 that occurred when the cutting surface 518 was formed is connected to the cut surface 518. However, the deformed portion 519 may be separated from the cut surface 518. In addition, a tapered surface 516a is formed at the tip 516 of the fixing portion 513. Note that the description with respect to Figure 10C also applies to the convex shape portion and the receiving recess 512 of the fixing portion 513 on the right or lower side, to the extent that the properties are not different, in addition to the convex shape portion and the area around the receiving recess 512 (XC portion) of the fixing portion 513 on the upper left side.

[0052] The terminals (first terminals 41a, 41b and second terminals 42a, 42b) are press-fitted into the terminal block 50 before terminal mounting, as shown in Figures 11A, 11B, and 11C. As shown in Figure 11C, in the terminal block 50 before terminal mounting, the side surface 517 of the convex portion of the fixing part 513 is smooth and no machined surface is formed. As shown in Figure 11C, the terminal block 50 before terminal mounting has the same configuration as terminal blocks 50a and 50b, except that no machined surface or deformed portion is formed.

[0053] As shown in Figure 11B, the fixing portion 513 of the terminal block 50 before terminal mounting is convex in the Y-axis direction so as to fit into the engagement groove 431 (see Figure 9) of the terminal. In the terminal block 50 before terminal mounting, the width W4 in the Z-axis direction of the convex shape of the fixing portion 513 is designed to be slightly wider than the width W3 (see Figure 9) of the engagement groove 431 of the terminal. In this way, by pushing the terminal into the terminal block, the side surface 517 of the convex portion of the fixing portion 513 is crushed and deformed, allowing it to be press-fitted and mounted. The difference between the width W4 and the width W3 is preferably smaller than, for example, the thickness T of the terminal (see Figure 9), more preferably 0.5 times or less of the thickness T of the terminal, and particularly preferably 0.2 times or less of the thickness T of the terminal.

[0054] As shown in Figure 12, the terminals can be attached by pushing them in so that the opposing surfaces 430a of the first terminal 41a (41b) and the second terminal 42a (42b) face the wall surface 510 of the terminal block 50 along the X-axis, and the engagement groove 431 engages with the convex portion of the fixing part 513. In this embodiment, a tapered surface 516a (see Figure 11C) is formed on the tip 516 of the fixing part 513, which allows for positioning of the fixing part 513 and the terminal, making press-fitting easier. When attaching the terminals, adhesive 71 may be applied to the wall surface 510 of the terminal block 50.

[0055] As described above, when the engagement groove 431 of the main piece 43 of the terminal is pressed in so that it engages with the convex portion of the fixing part 513, the terminal is pressed into and attached to the terminal block 50a (50b) as shown in Figures 13A and 13B. Note that Figure 13B is an enlarged view of the upper left area (part XIIIB) of Figure 13A relating to Figure 13B, but the explanation also applies to the convex portion of the fixing part 513, the receiving recess 512, and the main piece 43 on the right or lower side, as long as their properties are not different.

[0056] As can be seen by comparing Figure 11C and Figure 13B, when a terminal is attached to the terminal block, a portion of the side surface 517 of the convex portion of the fixing part 513 is scraped by the engaging surface 432 of the engaging groove 431 of the main piece 43, forming a cut surface 518. In addition, a portion of the side surface 517 that is scraped when forming the cut surface 518 becomes a deformed portion 519. The engaging surfaces 432, 432 of the engaging groove 431 sandwich the fixing part 513 from above and below in the Z-axis direction, allowing the terminal to be positioned in the Z-axis direction and firmly attached to the terminal block.

[0057] As shown in Figure 14, the receiving recess 512 has a space between its bottom surface 512a and the opposing surface 430a of the main piece, and the deformable portion 519 is accommodated in this space. Therefore, the deformable portion 519 is prevented from entering between the opposing surface 430a of the main piece 43 of the terminal and the wall surface 510 of the terminal block.

[0058] The depth D1 of the receiving recess 512 in the X-axis direction (distance from the wall surface 510 to the bottom surface 512a) shown in Figure 14 is not particularly limited. It is preferable that the depth D1 is deep enough to accommodate the deformed portion 519 in the receiving recess 512. For example, the depth D1 may be 0.1 to 0.5 times the plate thickness T of the main piece 43, or it may be 0.2 mm to 0.8 mm. Also, from a similar viewpoint, it is preferable that the volume of the receiving recess 512 is larger than the volume of the deformed portion 519.

[0059] As shown in Figure 14, the main piece 43 of the terminal is in contact with the wall surface 510 of the terminal block. If adhesive 71 (see Figure 12A) is used to fix the terminal to the terminal block, it may contact the wall surface 510 via the adhesive 71. Adhesive 71 may also be placed in the space between the bottom surface 512a and the opposing surface 430a of the main piece, to the extent that it does not prevent the deformable portion 519 from being accommodated in this space.

[0060] As shown in Figure 3, when the terminals are attached to the terminal block, the rising piece 46 is positioned to extend from the base piece 45 in a direction away from the terminal blocks 50a and 50b along the Z-axis. The connecting piece 47 is positioned to extend away from the inner end walls 64a and 64b of the flange. The connecting piece 47 also has a crimping piece 48 for fixing the wire lead portions 22a, 22b, 32a, and 32b. As will be described later, the connecting piece 47 is connected to the wire lead portions 22a, 22b, 32a, and 32b.

[0061] As shown in Figure 7, when the terminals are attached to the terminal block, the mounting piece 44 is positioned approximately parallel to the bottom surface 54 of the terminal block side wall, with a predetermined gap W1 between it and the bottom surface 54. The base piece 45 is positioned approximately parallel to the top surface 53 of the terminal block side wall, with a predetermined gap W2 between it and the top surface 53. This configuration further improves the creepage distance between the terminals (first terminals 41a, 41b and second terminals 42a, 42b) and the core 10.

[0062] Furthermore, the terminals (first terminals 41a, 41b and second terminals 42a, 42b) have a predetermined gap from the terminal blocks 50a, 50b in the Z-axis direction, which improves the strength after surface mounting of the coil component 1. The predetermined gaps W1, W2 are not particularly limited, but are preferably 0 or more, and more preferably 0.1 times or more the thickness T of the metal plate constituting the terminal.

[0063] As shown in Figure 4, terminal block 50a has a ridged portion 57 that undulates along the Y-axis, and this ridged portion 57 is positioned between the first terminal 41a and the second terminal 42a. Similarly, terminal block 50b also has a ridged portion 57 that undulates along the Y-axis, and this ridged portion 57 is positioned between the first terminal 41b and the second terminal 42b. This configuration further improves the insulation between the first terminal 41a and the second terminal 42a, and between the first terminal 41b and the second terminal 42b.

[0064] As shown in Figure 4, the first wire 20 has a coil portion 21 wound around the first winding drum 61 and lead portions 22a and 22b drawn out from the coil portion 21. Lead portion 22a is connected to the connecting piece of the first terminal 41a. Lead portion 22b is connected to the connecting piece of the first terminal 41b.

[0065] As shown in Figure 4, the second wire 30 has a coil portion 31 wound around the second winding drum 62 and lead portions 32a and 32b drawn out from the coil portion 31. Lead portion 32a is connected to the connecting piece of the second terminal 42a. Lead portion 32b is connected to the connecting piece of the second terminal 42b.

[0066] As shown in Figure 3, the wire leads 22a, 22b, 32a, and 32b are connected to the connecting piece 47 and / or each crimping piece 48 by methods such as laser welding, soldering, thermocompression bonding, arc welding, and resistance welding.

[0067] The first wire 20 and the second wire 30 are not particularly limited, and conductive core wires such as flat wires, round wires, stranded wires, Litz wires, braided wires, etc., made of copper, or wires in which these conductive core wires are insulated can be used. The diameter D (see Figure 7) of the first wire 20 and the second wire 30 is not particularly limited and may be, for example, 0.9 to 2.7 mm, preferably an outer diameter of 0.3 to 0.28 times the plate thickness T (see Figure 9) of the first terminals 41a, 41b and the second terminals 42a, 42b, and more preferably an outer diameter of 0.5 to 2 times.

[0068] As shown in Figure 4, in the coil component of this embodiment, the distance between the fixing portion 513 of terminal block 50a and the fixing portion 513 of terminal block 50b is equal to the length L0 in the X-axis direction of the coil component of this embodiment. That is, the fixing portion 513 of terminal block 50a and the fixing portion 513 of terminal block 50b are each positioned at the outermost edge in the X-axis direction (see Figure 13B). This configuration prevents the terminals (first terminals 41a, 41b and second terminals 42a, 42b) from coming into contact with other components when mounting the coil component.

[0069] As shown in Figure 15, the cover 100 has a top plate 101, a cover-side partition 102, and an outer wall 103. The cover 100 is mounted on terminal blocks 50a and 50b as shown in Figure 7. The top plate 101 covers the upper part of the first wire 20 and the second wire 30 in the Z-axis direction.

[0070] As shown in Figure 8, the cover-side partition 102 engages with a flange-side partition 64a1 formed on the inner end wall 64a of the flange and a flange-side partition 64b1 formed on the inner end wall 64b of the flange, separating the coil portions 21 and 31 of the first wire 20 and the second wire 30. The cover 100 may be made of an insulating material as exemplified by the bobbin 60, but may also be made of a different insulating material. The insulating material used for the cover 100 can be, for example, LCP.

[0071] In this embodiment, as shown in Figure 1, the cover 100, with its top plate 101 and outer wall 103, can protect the first terminals 41a, 41b and the second terminals 42a, 42b, as well as the first wire 20 and the second wire 30, and also prevents leakage of current from the first terminals 41a, 41b and the second terminals 42a, 42b, as well as the first wire 20 and the second wire 30, to other components. Furthermore, the coil component 1 can be easily transported by adsorbing the flat top plate 101 of the cover with a suction nozzle or the like.

[0072] As shown in Figure 7, the core 10 is housed in the bobbin 60. The first winding core portion 11 of the core 10 is covered by the first winding body portion 61 of the bobbin 60, and the second winding core portion 12 is covered by the second winding body portion 62 of the bobbin 60. The connecting portions 13a and 13b of the core 10 are completely covered by the flange portions 63a and 63b of the bobbin 60 and the terminal blocks 50a and 50b. Therefore, the core 10 can be insulated from the first wire 20 and the second wire 30.

[0073] Furthermore, as shown in Figure 6, the flange side wall 65a of the first bobbin 60a covers the sides 16a, 17a, 18a, and 19a of the connecting portion 13a. In addition, the flange side wall 65a of the first bobbin 60a is covered by the terminal block side wall 52. The same applies to the flange side wall 65b of the second bobbin 60b.

[0074] In this way, the bobbins 60 (first bobbin 60a and second bobbin 60b) and terminal blocks 50a and 50b double-cover the sides of the connecting portions 13a and 13b of the core 10, thereby improving the creepage distance between the first wire 20 and the second wire 30 and the core 10. Also, as shown in Figure 7, the creepage distance between the main pieces 43 of the terminals (first terminals 41a and 41b and second terminals 42a and 42b) and the core 10 is also improved. As a result, the coil component 1 is more effectively insulated and can handle the increasing demand for higher voltages in recent years, such as 800kV or more.

[0075] As shown in Figure 13B, in this embodiment, the deformation portion 519 of the fixing portion 513 that occurs when the main pieces 43 of the terminals (first terminals 41a, 41b and second terminals 42a, 42b) are pressed into the terminal block is accommodated in the receiving recess 512 formed in the wall surface 510 of the terminal block. Therefore, it is possible to prevent the main pieces 43 of the terminals from lifting away from the wall surface 510 (reference surface), and the opposing surfaces 430a of the main pieces 43 are arranged substantially parallel to the wall surface 510.

[0076] This arrangement allows the main piece 43 to be more firmly bonded to the wall surface 510 of the terminal blocks 50a and 50b. In this embodiment, since the opposing surface 430a of the main piece 43 can be positioned substantially parallel to the wall surface 510, even when using adhesive 71 (see Figure 12), the adhesive 71 spreads well, increasing the bonding strength between the main piece 43 and the wall surface 510.

[0077] As shown in Figure 10C, the fixing portion 513 has a tapered surface 516a at its protruding tip 516 that guides the press-fitting of the terminal. By providing a tapered surface 516a at the tip 516 of the fixing portion 513, the main piece 43 of the terminal is made easier to press-fit into the terminal block, making the terminal installation work easier.

[0078] As shown in Figure 10C, the deformed portion 519 of the fixing portion 513 occurs from the tapered surface 516a of the fixing portion 513, where the main piece 43 of the terminal engages, to the base end 515. Therefore, by forming the receiving recess 512 in the base portion 511 of the wall surface 510 connected to the base end 515, the deformed portion 519 can be reliably accommodated in the receiving recess 512.

[0079] As described above, as shown in Figure 9, the main piece 43 of the terminal has a flat plate shape with an opposing surface 430a facing the wall surface 510 and an opposing surface 430b on the opposite side of the opposing surface 430a. Engagement grooves 431 are formed on the sides 430c and 430d of the main piece 43, cut out from the opposing surface 430a to the opposing surface 430b.

[0080] As described above, as shown in Figures 10C and 13B, when the main piece 43 of the terminal is press-fitted into the terminal blocks 50a and 50b, the engaging surface 432 of the engaging groove 431 of the main piece 43 crushes a portion of the fixing part 513, forming a cut surface 518. As a result, the engaging surface 432 of the engaging groove 431 of the main piece 43 and the cut surface 518 of the fixing part 513 engage firmly. Consequently, the mounting strength of the terminal is improved.

[0081] As shown in Figures 6 and 7, the terminals (first terminals 41a, 41b and second terminals 42a, 42b) are fixed to the terminal block by press-fitting. The convex portion of the fixing part 513 of the terminal block (see Figure 5A) plays a role in positioning the terminals in the Z-axis direction. Therefore, the terminals can be securely fixed to the terminal block at a predetermined height position.

[0082] In addition, as described above, since the main piece 43 of the terminal does not float away from the wall surface 510 (reference plane), the main piece 43 of the terminal is accurately positioned and attached to the terminal blocks 50a and 50b. Therefore, in this embodiment, the mounting surfaces 440 of the mounting pieces 44 of the first terminals 41a and 41b and the second terminals 42a and 42b are arranged on the same plane, and do not affect the coplanarity (flatness) when mounting on a substrate or the like. Thus, the mounting strength of the coil component 1 on a substrate or the like can also be improved.

[0083] (Second Embodiment) As shown in Figure 5B, the coil component according to this embodiment differs from the first embodiment only in the configuration of the main terminal piece and the fixing part of the terminal block that serves as the terminal mounting part. The description of the common parts will be omitted, and the following will mainly describe the differing parts in detail. The parts not described below are the same as those described in the first embodiment.

[0084] As shown in Figure 5B, in this embodiment, the first terminal 41a (41b) and the second terminal 42a (42b) have engaging projections 431a on the side surface of the main piece 43a. The engaging projections 431a have engaging surfaces 432, 432 that are substantially perpendicular to the Z-axis. In addition, the fixing portion 513a of the terminal block 50c has a concave shape relative to the side surface of the main piece 43a of the terminal. The terminal can be fixed to the terminal block 50c by press-fitting the main piece 43a of the terminal into the fixing portion 513a.

[0085] In this embodiment as well, it is preferable that the side surface 517 of the concave portion of the fixing portion 513a can be crushed and deformed in order to press-fit and attach the terminal to the terminal block before the terminal is attached. That is, in this embodiment, the width in the Z-axis direction of the concave portion of the fixing portion 513a of the terminal block before the terminal is attached is designed to be slightly narrower than the width in the Z-axis direction of the engaging protrusion 431a of the terminal (distance between engaging surfaces 432, 432).

[0086] In this embodiment, as in the first embodiment, when the main piece 43a of the terminal is pressed into the terminal block 50c so that the engaging projection 431a engages with the concave portion of the fixing portion 513, a portion of the side surface 517 of the concave portion of the fixing portion 513a of the fixing portion 513 is scraped by the engaging surface 432 of the engaging projection 431a of the main piece 43a, forming a cut surface. As a result, the engaging surface 432 of the engaging projection 431a of the main piece 43a and the fixing portion 513 engage firmly.

[0087] Furthermore, the concave portion of the terminal block's fixing part 513 (see Figure 5B) plays a role in positioning the terminal in the Z-axis direction. Therefore, the terminal can be securely fixed to the terminal block at a predetermined height. Consequently, in this embodiment as well, the mounting surfaces of the terminal mounting pieces are arranged on the same plane, and this does not affect the coplanarity (flatness) when mounting to a substrate or the like. Thus, the mounting strength of the coil component to the substrate or the like can also be improved.

[0088] Furthermore, the embodiments described above also include various design modifications that do not depart from the gist of the claims, within the scope of the technical realm.

[0089] In the above-described embodiment, the first terminals 41a, 41b and the second terminals 42a, 42b each have an S-shape with a terminal main piece 43, a mounting piece 44, a base piece 45, a rising piece 46, and a connecting piece 47, but they may have other shapes. For example, the first terminals 41a, 41b and the second terminals 42a, 42b may have a U-shape without the rising piece 46 and the connecting piece 47.

[0090] Furthermore, the above-described embodiment can be applied not only to coil components but also to electronic components in which terminals are attached to a mounting portion by press-fitting. [Explanation of symbols]

[0091] 1…Coil component 10... Cores 10a...First core 10b...Second core 11…Volume 1 core 11a, 11b...Opposing surface 12…Volume 2 core 12a, 12b...Opposing surface 13a, 13b...Connection part 14a, 14b…Inner end surface 15a, 15b...outer end surface 16a,16b…1st side 17a,17b…Second side 18a,18b...Third side 19a,19b…4th side 20…First wire 21... Coil section 22a, 22b... Lead section 30…Second wire 31... Coil section 32a, 32b... Lead section 41a, 41b...1st terminal 42a, 42b...Second terminal 43,43a...Main terminal piece 430a... Opposite side 430b... Opposite rear 430c,430d…side 431...Engagement groove 431a...Engagement convex part 432...Engagement surface 44…Implementation piece 440…Implementation aspect 45...Bass piece 46...Rise piece 47…Connecting piece 48... Crimping piece 50... Terminal block before terminal installation 50a,50b,50c…Terminal block 51…Terminal block outer end wall 510... Wall surface 511…Fundamental part 512... Storage recess 512a…Bottom surface 513,513a...Fixed part 514... Positioning wall 515...Proximal end 516... Tip 516a... Tapered surface 517... Side view 518…Cutting surface 519...Deformed part 52…Terminal block side wall 53…Top surface 54...Bottom 57...Uneven part 60... Bobbin 60a...First bobbin 60b...Second bobbin 61…Volume 1 body 61a, 61b... First butt joint 62…Volume 2 body 62a, 62b... Second butt joint 63a, 63b... Flange section 64a, 64b…Flange inner end wall 64a1, 64b1... Flange-side partition section 65a, 65b… Flange sidewall 70, 71… Adhesives 100...cover 101... Tabletop 102...Cover side partition 103... Exterior wall

Claims

1. Terminals and It has a mounting portion to which the aforementioned terminal is attached, The terminal has a main piece that is press-fitted into the mounting portion, The mounting portion has a wall surface facing the main piece and a fixing portion that protrudes from the wall surface and fixes the main piece. An electronic component having a recess formed on the wall surface that can accommodate the deformed portion of the fixed part.

2. Wire and The terminal to which the aforementioned wire is connected, It has a mounting portion to which the aforementioned terminal is attached, The terminal has a main piece that is press-fitted into the mounting portion, The mounting portion has a wall surface facing the main piece and a fixing portion that protrudes from the wall surface and fixes the main piece. The coil component has a recess formed on its wall surface that can accommodate the deformed portion of the fixed part.

3. The coil component according to claim 2, wherein the receiving recess is formed in the base portion of the wall surface connected to the base end of the fixing portion with which the main piece engages.

4. The coil component according to claim 2 or 3, wherein the main piece has opposing surfaces facing substantially parallel to the wall surface.

5. The coil component according to claim 2 or 3, wherein the fixing portion has a tapered surface at the tip of the fixing portion in the protruding direction that guides the press-fitting of the terminal.

6. The coil component according to claim 2 or 3, wherein the fixing portion has a cut surface into which the main piece of the terminal engages.

7. The coil component according to claim 6, wherein the deformed portion connected to the cut surface is housed in the receiving recess.

8. The main piece has a flat plate shape with an opposing surface facing the wall and an opposing surface on the opposite side of the opposing surface. The side surface of the main piece has an engagement groove cut out from the opposing surface to the opposite surface, The coil component according to claim 2 or 3, wherein the engagement groove engages with the fixing portion.

9. The main piece has a flat plate shape with an opposing surface facing the wall and an opposing surface on the opposite side of the opposing surface. The coil component according to claim 2 or 3, wherein the side surface of the main piece has an engaging projection that engages with the fixing portion.

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