JP3670640B2

JP3670640B2 - Manufacturing method of substrate surface mount type toroidal coil

Info

Publication number: JP3670640B2
Application number: JP2002334798A
Authority: JP
Inventors: 濤雄佐藤; 陽太郎豊嶋
Original assignee: 積進工業株式会社
Priority date: 2002-11-19
Filing date: 2002-11-19
Publication date: 2005-07-13
Anticipated expiration: 2022-11-19
Also published as: JP2004172263A

Description

【０００１】
【発明の属する技術分野】
本発明は、産業機器及び民生機器分野における電源回路及びその他の電気回路に利用される制御コイルを有する基板表面実装型トロイダルコイルの製造方法に関する。
【０００２】
【従来の技術】
従来、平滑用チョークコイルの構造としては、EI、EE、ドラム、ドラム＋スリーブ、トロイダルタイプ、ギャップ付きトロイダルがある。
平滑用チョークコイルは、インダクタンスと定格電流で形状のサイズが変わり、一般的に同一インダクタンスの場合、定格電流が大きいと形状も大きくなる。
従来の製品群の材質は、EI、EE、ドラム、ドラム＋スリーブ型はフェライトコア、トロイダル型は金属（アモルファス、鉄系合金）、ギャップ付きトロイダルはアモルファス、フェライトコアで構成されている。
そして、従来の公知技術として、特開平１１−１９５５３３号公報がある。
【０００３】
【特許文献】
前記特開平１１−１９５５３３号公報は、図１２に示すように、ガラスエボキシ樹脂等よりなり筒状コイルを収納する開口部２１aを有する絶縁基板２１と、絶縁基板２１上に形成された表面実装用の電極パターンと、絶縁基板２１の下面に貼付した貼着シート２３と、開口部２１aに収納されると共に電極パターンに接続する端末３b、３cを有する閉磁路型筒状コイル５と、粘着シート２３上に閉磁路型筒状コイル５を位置決め固着し、絶縁基板２１上に形成された電極パターンにコイルの端末３b、３cを半田１６で半田付け又は熱圧着等の固着手段で接続し、封止樹脂１７で封止するSMD型コイル及びその製造方法がある。
このように、SMDタイプ（小型で基板表面装着タイプ）ではドラムタイプ、ドラム＋スリーブタイプが主流でトロイダルタイプはなかった。
【０００４】
【発明が解決しようとする課題】
そこで、本発明は、SMDタイプ（基板表面装着タイプ）であって、産業機器及び民生機器分野における電源回路及びその他の電気回路に利用される平滑用チョークコイルを有する基板表面実装型トロイダルコイルの製造方法を提供することを目的とする。
【０００５】
【課題を解決するための手段】
本発明の基板表面実装型トロイダルコイルの製造方法は、巻線の始端側に引き出し端末をコアの上側に形成してコアに沿って螺旋状に内径に密着整列巻きで巻始め、始端側と略１８０°相対する反対側に巻線空きスペースを２ターン分設けて、引き続きコアに沿って螺旋状に内径に密着整列巻きで巻線の終端側に巻線空きスペースを１ターン分設けて、引き出し端末をコアの下側に形成し、次に巻線の終端側の引き出し端末を延長して巻き終わりの巻線空きスペースに外径側から内径側へ、直径方向に延ばして又は下方方向に折り曲げて反対側の巻線空きスペースに渡らせ、巻線の終端側の引き出し端末とし、さらに、始端側及び終端側の引き出し端末をそれぞれ下方に向くように整形する巻線工程と、
前記工程で巻線が巻かれたトロイダルコイルを引き出し端末が突き出す形で有底円筒状の樹脂ケースに挿入し、そして、引き出し端末を外形端子側に折り曲げ、折り曲げた引き出し端末にクリームハンダを塗布し、さらに、外形端子側の電極端子を内側に折り曲げて前記折り曲げた引き出し端末の上に重ね、熱処理にてハンダを溶かし前記電極端子と前記引き出し端末を接合し、最後に、樹脂ケースの開口に樹脂蓋を装着し接着する組立工程とからなるものである。
【０００６】
【実施例】
以下、本発明の基板表面実装型トロイダルコイル及びその製造方法について、図面に基づいて説明する。
本発明の基板表面実装型トロイダルコイルは、図１(a)平面図及び(b)正面図に示すように、有底円筒状の樹脂ケース１と、該樹脂ケース１の外形端子側２に形成された一対の電極端子３、３とを設け、前記樹脂ケース１の下方開口を覆う樹脂蓋４で封止された容器に形成される。
また、図２のA-A矢視断面図に示すように、前記樹脂ケース１内には、鉄系金属軟磁性圧粉磁心、珪素ー鉄合金系金属軟磁性圧粉磁心又は珪素ーアルミー鉄合金系金属軟磁性圧粉磁心からなるトロイダルコア５と、後述するように該トロイダルコア５に沿って螺旋状に内径に一層整列密着巻きで巻始め、始端側と略１８０°相対する反対側に巻線空きスペースを２ターン分設けて、引き続きコアに沿って螺旋状に内径に一層整列密着巻きで巻線の終端側に巻線空きスペースを１ターン分設けた巻線６とが収納される。
さらに、前記巻線６の始端側と終端側に引き出し端末を設け、該引き出し端末と前記樹脂ケース１の外形端子側２に形成された一対の電極端子３、３とはハンダにより接合される。
前記樹脂ケース１は、外径、高さを小さくするために樹脂ケース１の肉厚を厚さ０．２mm以下とする。
また、トロイダルコア５外径と樹脂ケース１の内径との空隙は、巻線１本分の寸法０．２〜０．４mmとする。
【０００７】
製品部品サイズ構成は、平滑用チョークコイルでインダクタンス１０μH、定格電流１A、２A、５Aタイプである。

【０００８】
次に、定格電流１A、２A、５Aタイプのコア内径／コア外径の比率、コア高さ／樹脂ケース高さの比率は、以下表１、２に示す通り４８．６〜６０％、５５．５〜７６．７％である。
【表１】
コア内径／コア外径の比率

【表２】
コア高さ／樹脂ケース高さの比率

【０００９】
次に、本発明の基板表面実装型トロイダルコイルの製造方法を図面に基づいて、以下に説明する。
まず、最初に、図３(a)平面図及び(b)正面図に示すように、巻線６の始端側に引き出し端末７をコア５の上側に形成してコア５に沿って螺旋状に内径に密着整列巻きで巻始め、始端側と略１８０°相対する反対側に巻線空きスペース８を２ターン分設けて、引き続きコア５に沿って螺旋状に内径に密着整列巻きで巻線６の終端側に巻線空きスペース９を１ターン分設けて、引き出し端末１０をコア５の下側に形成して巻き終わる。
【００１０】
次に、図４(a)平面図及び(b)正面図に示すように、巻線６の終端側の引き出し端末１０を延長して巻き終わりの巻線空きスペース９に外径側から内径側へ、直径方向に延ばして反対側の巻線空きスペース８に渡らせ、巻線６の終端側の引き出し端末１０とする。
巻線６が両方の巻線空きスペース８、９を渡ることで、高さ方向の巻線６の重なりがなくなる。
又は、図５(a)平面図及び(b)正面図に示すように、巻線６の終端側の引き出し端末１０を延長して巻き終わりの巻線空きスペース９に外径側から内径側へ、下方方向に折り曲げて反対側の巻線空きスペース８の下方に渡らせ、巻線６の終端側の引き出し端末１０とする。
巻線６が両方の巻線空きスペース８、９を利用することで、高さ方向の巻線６の重なりがなくなる。
【００１１】
さらに、図６(a)平面図及び(b)正面図に示すように、始端側及び終端側の引き出し端末７、１０をそれぞれ下方に向くように整形する。
又は、図７(a)平面図及び(b)正面図に示すように、始端側の引き出し端末７を下方に向くように整形し、終端側の引き出し端末１０をそのままにする。
このようにして巻線が巻かれたトロイダルコイルが形成される。
【００１２】
次に、図８に示すように、巻線が巻かれたトロイダルコイルは、引き出し端末７、１０が突き出す形で有底円筒状の樹脂ケース１に挿入される。
そして、図９に示すように、引き出し端末７、１０を外形端子側２に折り曲げ、折り曲げた引き出し端末７、１０にクリームハンダ１１を塗布する。
さらに、図１０に示すように、外形端子側２の電極端子３を内側に折り曲げ、前記折り曲げた引き出し端末７、１０の上に重ね、熱処理にてハンダを溶かし電極端子３と引き出し端末７、１０を接合する。
最後に、図１１に示すように、樹脂ケース１の開口に樹脂蓋４を装着し接着する。
このようにして、有底円筒状の樹脂ケース１と、該樹脂ケース１の外形端子側２に形成された一対の電極端子３、３とを設け、前記樹脂ケース１の開口を覆う樹脂蓋４で封止された基板表面実装型トロイダルコイルが製造される。
【００１３】
【効果】
以上述べた如く、本発明の基板表面実装型トロイダルコイルの製造方法によれば、巻線の始端側に引き出し端末をコアの上側に形成してコアに沿って螺旋状に内径に密着整列巻きで巻始め、始端側と略１８０°相対する反対側に巻線空きスペースを２ターン分設けて、さらにコアに沿って螺旋状に内径に密着整列巻きで巻線の終端側に巻線空きスペースを１ターン分設けて、引き出し端末をコアの下側に形成し、次に巻線の終端側の引き出し端末を延長して巻き終わりの巻線空きスペースに外径側から内径側へ、直径方向に延ばして又は下方方向に折り曲げて反対側の巻線空きスペースに渡らせ、巻線の終端側の引き出し端末としたので、トロイダルタイプでしかも他社製品より小型に形成することができる。
【図面の簡単な説明】
【図１】本発明の基板表面実装型トロイダルコイルの(a)平面図、(b)正面図である。
【図２】本発明の基板表面実装型トロイダルコイルのA-A矢視断面図である。
【図３】本発明のトロイダルコイルの巻線工程１の(a)平面図、(b)正面図である。
【図４】本発明のトロイダルコイルの巻線工程２の(a)平面図、(b)正面図である。
【図５】本発明のトロイダルコイルの他の巻線工程２の(a)平面図、(b)正面図である。
【図６】本発明のトロイダルコイルの巻線工程３の(a)平面図、(b)正面図である。
【図７】本発明のトロイダルコイルの他の巻線工程３の(a)平面図、(b)正面図である。
【図８】本発明の基板表面実装型トロイダルコイルの組立工程１の正面図である。
【図９】本発明の基板表面実装型トロイダルコイルの組立工程２の正面図である。
【図１０】本発明の基板表面実装型トロイダルコイルの組立工程３の正面図である。
【図１１】本発明の基板表面実装型トロイダルコイルの組立工程４の正面図である。
【図１２】従来のSMD型コイルの(a)正面図、(b)A-A断面図である。
【符号の説明】
１樹脂ケース
２外形端子側
３電極端子
４樹脂蓋
５トロイダルコア
６巻線
７引き出し端末
８空きスペース
９空きスペース
１０引き出し端末
１１クリームハンダ[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of manufacturing a surface mount toroidal coils having a control coil to be used for the power supply circuit and other electrical circuits in the industrial and consumer fields.
[0002]
[Prior art]
Conventional smoothing choke coils include EI, EE, drum, drum + sleeve, toroidal type, and toroidal with gap.
The size of the shape of the smoothing choke coil varies depending on the inductance and the rated current. Generally, in the case of the same inductance, the shape becomes large when the rated current is large.
The material of the conventional product group is EI, EE, drum, drum + sleeve type is ferrite core, toroidal type is metal (amorphous, iron alloy), and toroidal with gap is amorphous, ferrite core.
Japanese Unexamined Patent Publication No. 11-195533 is known as a conventional publicly known technique.
[0003]
[Patent Literature]
As shown in FIG. 12, the above-mentioned Japanese Patent Application Laid-Open No. 11-195533 discloses an insulating substrate 21 made of glass epoxy resin or the like and having an opening portion 21a for accommodating a cylindrical coil, and a surface-mounting device formed on the insulating substrate 21. Electrode pattern, an adhesive sheet 23 affixed to the lower surface of the insulating substrate 21, a closed magnetic circuit type cylindrical coil 5 having terminals 3b and 3c which are accommodated in the opening 21a and connected to the electrode pattern, and an adhesive sheet 23 The closed magnetic circuit type cylindrical coil 5 is positioned and fixed thereon, and the terminal 3b, 3c of the coil is connected to the electrode pattern formed on the insulating substrate 21 by soldering or fixing means such as thermocompression bonding. There is an SMD type coil sealed with a resin 17 and a manufacturing method thereof.
Thus, in the SMD type (small and substrate surface mounting type), the drum type and the drum + sleeve type were mainstream, and there was no toroidal type.
[0004]
[Problems to be solved by the invention]
Accordingly, the present invention provides a SMD type (surface of the substrate mounting type), the surface mount toroidal coils having a smoothing choke coil utilized in the power supply circuit and other electrical circuits in the industrial and consumer fields An object is to provide a manufacturing method.
[0005]
[Means for Solving the Problems]
The method for manufacturing a substrate surface-mounted toroidal coil according to the present invention includes forming a lead-out terminal on the top end side of the winding on the upper side of the core, and starting winding in close alignment with the inner diameter spirally along the core. Winding space is provided for two turns on the opposite side opposite to 180 °, and then the winding space is spirally wound along the core along the inner diameter, and winding space is provided for one turn on the end side of the winding. Form the terminal under the core, and then extend the terminal at the end of the winding to extend the winding free space at the end of the winding from the outer diameter side to the inner diameter side. A winding process for crossing over the winding space on the opposite side, forming a terminal on the terminal side of the coil, and shaping the terminal terminal and the terminal terminal on the terminal side downward.
Insert the toroidal coil wound with the winding in the above process into the bottomed cylindrical resin case with the drawer terminal protruding, then fold the drawer terminal to the outer terminal side and apply cream solder to the folded drawer terminal Further, the electrode terminal on the outer shape terminal side is folded inward and superimposed on the bent lead terminal, the solder is melted by heat treatment, the electrode terminal and the lead terminal are joined, and finally the resin is opened in the resin case opening. And an assembly process of attaching and bonding a lid.
[0006]
【Example】
Hereinafter, a substrate surface-mounted toroidal coil and a manufacturing method thereof according to the present invention will be described with reference to the drawings.
The substrate surface mount type toroidal coil of the present invention is formed on a bottomed cylindrical resin case 1 and an outer terminal side 2 of the resin case 1 as shown in FIG. 1 (a) plan view and (b) front view. A pair of the

electrode terminals

3 and 3 is provided and formed in a container sealed with a resin lid 4 that covers the lower opening of the resin case 1.
Further, as shown in the AA arrow sectional view of FIG. 2, the resin case 1 includes an iron-based metal soft magnetic powder magnetic core, a silicon-iron alloy metal soft magnetic powder magnetic core, or a silicon-aluminum-iron alloy metal. A toroidal core 5 made of a soft magnetic powder magnetic core, and a spiral winding along the toroidal core 5 along the toroidal core 5 as will be described later, begins to be wound in an aligned and tight winding, and the winding is vacant on the side opposite to the starting end side by about 180 °. A space is provided for two turns, and then a winding 6 is housed in a spiral along the core and further aligned and tightly wound on the inner diameter and provided with a winding empty space for one turn on the terminal end side of the winding.
Further, a lead terminal is provided on the start end side and the end end side of the winding 6, and the lead terminal and the pair of

electrode terminals

3 and 3 formed on the outer terminal side 2 of the resin case 1 are joined by solder.
The resin case 1 has a thickness of 0.2 mm or less in order to reduce the outer diameter and height.
Further, the gap between the outer diameter of the toroidal core 5 and the inner diameter of the resin case 1 is set to a size of 0.2 to 0.4 mm for one winding.
[0007]
The product component size configuration is a smoothing choke coil with an inductance of 10 μH, a rated current of 1A, 2A, and 5A.

[0008]
Next, the ratio of the core inner diameter / core outer diameter and the ratio of the core height / resin case height of the rated currents 1A, 2A, and 5A are 48.6 to 60% as shown in Tables 1 and 2 below. 5-76.7%.
[Table 1]
Ratio of core inner diameter / core outer diameter

[Table 2]
Ratio of core height / resin case height

[0009]
Next, a method for manufacturing a substrate surface-mounted toroidal coil according to the present invention will be described below with reference to the drawings.
First, as shown in FIG. 3A and FIG. 3B, a lead terminal 7 is formed on the upper end side of the core 5 at the start end side of the winding 6 and spiraled along the core 5. Winding is started on the inner diameter by close-alignment winding, and a winding empty space 8 is provided for two turns on the side opposite to the start end side by about 180 °, and then the winding 6 is wound spirally along the core 5 by close-alignment winding on the inner diameter. The winding empty space 9 is provided for one turn on the terminal side of the wire, and the drawing terminal 10 is formed below the core 5 to finish the winding.
[0010]
Next, as shown in FIGS. 4 (a) and (b) front views, the terminal 10 on the terminal end side of the winding 6 is extended so that the winding empty space 9 at the winding end is changed from the outer diameter side to the inner diameter side. The lead terminal 10 on the terminal end side of the winding 6 is made to extend in the diametrical direction and over the winding empty space 8 on the opposite side.
Since the winding 6 crosses both the winding empty spaces 8 and 9, the overlapping of the windings 6 in the height direction is eliminated.
Alternatively, as shown in FIG. 5 (a) plan view and (b) front view, the terminal 10 on the terminal end side of the winding 6 is extended so that the winding free space 9 at the end of winding ends from the outer diameter side to the inner diameter side. The lead terminal 10 on the terminal end side of the winding 6 is formed by bending it downward and extending it below the winding empty space 8 on the opposite side.
Since the winding 6 uses both the winding empty spaces 8 and 9, the overlapping of the windings 6 in the height direction is eliminated.
[0011]
Further, as shown in FIG. 6 (a) plan view and (b) front view, the leading end terminal and the terminal

end drawing terminals

7 and 10 are shaped so as to face downward.
Alternatively, as shown in FIG. 7 (a) plan view and (b) front view, the leading terminal 7 is shaped to face downward, and the terminal terminal 10 is left as it is.
In this way, a toroidal coil around which the winding is wound is formed.
[0012]
Next, as shown in FIG. 8, the toroidal coil wound with the winding is inserted into the bottomed cylindrical resin case 1 in such a manner that the

lead terminals

7 and 10 protrude.
Then, as shown in FIG. 9, the

drawer terminals

7 and 10 are folded to the outer terminal side 2, and the cream solder 11 is applied to the folded

drawer terminals

7 and 10.
Further, as shown in FIG. 10, the electrode terminal 3 on the outer terminal 2 is bent inward, is superimposed on the

bent lead terminals

7, 10, and solder is melted by heat treatment so that the electrode terminals 3 and the

lead terminals

7, 10 are melted. Join.
Finally, as shown in FIG. 11, a resin lid 4 is attached to and bonded to the opening of the resin case 1.
In this way, the bottomed cylindrical resin case 1 and the pair of

electrode terminals

3 and 3 formed on the outer terminal side 2 of the resin case 1 are provided, and the resin lid 4 covers the opening of the resin case 1. A substrate surface-mounting type toroidal coil sealed with is manufactured.
[0013]
【effect】
Above mentioned as, according to the manufacturing method of the surface mount toroidal coils of the present invention, the winding contact regular winding the inner diameter helically along the core drawer terminal at the starting end side is formed on the upper side of the core Winding space is provided for two turns on the opposite side of the starting end side, which is approximately 180 ° from the starting end side, and the winding empty space is provided on the terminal end side of the winding by closely winding the inner diameter spirally along the core. Is provided for one turn, and the lead-out terminal is formed on the lower side of the core. Next, the lead-out terminal at the end of the winding is extended, and the winding empty space at the end of winding is changed from the outer diameter side to the inner diameter side. Since the lead terminal on the terminal end side of the winding is formed by extending to the bottom or bending downward and extending over the winding space on the opposite side, it can be formed in a toroidal type and smaller than other products.
[Brief description of the drawings]
FIG. 1A is a plan view of a substrate surface-mounted toroidal coil according to the present invention, and FIG.
FIG. 2 is a cross-sectional view taken along the line AA of the substrate surface mount type toroidal coil of the present invention.
3A is a plan view and FIG. 3B is a front view of a winding step 1 of a toroidal coil according to the present invention.
4A is a plan view and FIG. 4B is a front view of a toroidal coil winding step 2 according to the present invention.
5A is a plan view of another winding step 2 of the toroidal coil of the present invention, and FIG. 5B is a front view thereof.
6A is a plan view and FIG. 6B is a front view of a winding step 3 of the toroidal coil of the present invention.
7A is a plan view of another winding process 3 of the toroidal coil of the present invention, and FIG. 7B is a front view thereof.
FIG. 8 is a front view of an assembly process 1 of a substrate surface mount type toroidal coil according to the present invention;
FIG. 9 is a front view of an assembly process 2 of a substrate surface-mount type toroidal coil according to the present invention.
FIG. 10 is a front view of an assembling step 3 of the substrate surface-mounted toroidal coil according to the present invention.
FIG. 11 is a front view of an assembly process 4 of a substrate surface-mount type toroidal coil according to the present invention.
FIG. 12A is a front view of a conventional SMD type coil, and FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Resin case 2 External terminal side 3 Electrode terminal 4 Resin cover 5 Toroidal core 6 Winding 7 Drawer terminal 8 Empty space 9 Empty space 10 Drawer terminal 11 Cream solder

Claims

A lead-out terminal is formed on the top end of the winding on the upper side of the core, and winding is started in close contact with the inner diameter in a spiral manner along the core. Next, the winding end space is spirally wound along the core along the core, and a winding empty space is provided for one turn on the terminal end side of the winding, and the lead-out terminal is formed below the core. Extend the terminal end of the end of the wire to the winding empty space at the end of winding from the outer diameter side to the inner diameter side, extend in the diametrical direction, or bend downward and cross over the winding empty space on the opposite side. And a winding step for shaping the leading end side and the terminal end drawing terminal to face downward, respectively,
Insert the toroidal coil wound with the winding in the above process into the bottomed cylindrical resin case with the drawer terminal protruding, then fold the drawer terminal to the outer terminal side and apply cream solder to the folded drawer terminal Further, the electrode terminal on the outer shape terminal side is folded inward and superimposed on the bent lead terminal, the solder is melted by heat treatment, the electrode terminal and the lead terminal are joined, and finally the resin is opened in the resin case opening. A method of manufacturing a substrate surface-mounted toroidal coil, comprising an assembly step of attaching and bonding a lid.