JP4872137B2 - Coil parts - Google Patents

Description

  The present invention relates to a coil component, and more particularly to a coil component coated with a glass layer.

  Conventionally, in order to improve characteristics, a coil component configured by combining a drum core with an outer peripheral core has been publicly known, and as shown in Patent Document 1, the drum core and the outer peripheral core are joined with an adhesive. Yes.

  Examples of the adhesive include an epoxy resin adhesive. In general, since the core manufactured by sintering is porous with fine gaps, the epoxy resin penetrates into the fine gaps and adheres by the so-called anchor effect.

JP 2001-338818 A

  When the above-described adhesive is used, the amount of the adhesive may be insufficient due to the epoxy resin soaking into the gaps in the core. In addition, when the epoxy resin soaks into the gap, the curing agent component in the adhesive may soak in first due to the difference in osmotic pressure. In this case, the adhesive does not sufficiently cure and the necessary adhesive strength is obtained. There was a risk of not being able to. Although the penetration of the adhesive can be suppressed by making the core dense, the adhesive strength due to the anchor effect has been reduced. Since the wettability of the core to the adhesive was not excellent, the adhesive strength was also lowered due to a decrease in the anchor effect.

  Therefore, an object of this invention is to provide the coil components which ensured the adhesive strength.

In order to solve the above-mentioned problems, the present invention provides a first core having a first adhesive surface and a first adhesive surface having an adhesive between the first adhesive surface and the second adhesive surface. A second core bonded to the core, a winding wound around the first core, and at least one of the first core and the second core are attached, and one end and the other end of the winding are respectively connected. And a pair of terminal electrodes, and at least one of the first adhesive surface and the second adhesive surface is provided with a molten and cured glass surface.

  According to such a configuration, the adhesive is bonded to the glass surface. Since the glass surface is smooth and not porous, the penetration of the adhesive is prevented. Moreover, since the glass which comprises a glass surface is generally excellent in the wettability of an adhesive agent, a strong adhesive state can be obtained. Further, since the adhesive is adhered to the glass surface, a stable adhesion state can be obtained regardless of the material of the core.

  In the coil component having the above configuration, the glass surface is preferably configured to include a first glass surface configured as a first adhesive surface and a second glass surface configured as a second adhesive surface.

  According to such a configuration, since the first core and the second core are bonded only by the glass surface, a more stable and strong bonded state can be obtained.

  The first core is connected to the core portion around which the winding is wound, the first flange portion having a plate shape and connected to one end of the core portion, and the other end of the plate portion having the plate shape. The second core is an exterior core disposed around the collar, and the drum core has a first opposed surface facing the exterior core, and the exterior core. It is preferable that a second opposing surface that faces the drum core is defined, and a projecting portion that abuts either one of the first opposing surface and the second opposing surface is provided.

  According to such a configuration, the adhesive is filled in the space formed by the protrusion between the first core and the second core. Although this space is defined by the protrusions, the protrusions can be configured with good dimensional accuracy, so that the accuracy of this space is also increased. By increasing the accuracy of the space filled with the adhesive, the amount of the adhesive necessary for filling does not vary and becomes a stable value, so that a stable adhesive state can be obtained. Moreover, although a magnetic gap is formed by the protrusions, the gap amount is also stabilized, so that the direct current superposition characteristics in the first core and the second core can be stably improved.

  Moreover, it is preferable that a 1st adhesion surface is arrange | positioned at a 1st opposing surface, and a 2nd adhesion surface is arrange | positioned at a 2nd opposing surface.

In addition, the first collar portion is connected to one end of the core portion and is opposed to the second collar portion, a first outer surface that is an end surface of the drum core in the axial direction of the core portion, A first circumferential surface located between the inner surface and the first outer surface is defined, the second inner surface is connected to the other end of the winding core portion and the second inner surface facing the first flange portion; A second outer surface serving as an end surface on the other end side of the drum core in the axial direction of the core portion, and a second peripheral surface positioned between the second inner surface and the second outer surface are defined. A core portion peripheral surface located between the inner surface and the second inner surface is defined, and the drum core has a glass layer applied to the entire surface to form a glass surface, and the first inner surface, the second inner surface, and the core portion peripheral surface It is preferable that the film thickness of this glass layer is thinner than the film thickness of the glass layer of a 1st outer surface, a 1st surrounding surface, a 2nd outer surface, and a 2nd surrounding surface.

  According to such a configuration, a large space in which the winding is wound can be taken, so that the winding amount of the winding can be increased or a winding having a larger diameter can be used.

  The glass layer is preferably applied to the entire surface of either the first core or the second core, or the entire surface of both the first core and the second core.

  According to such a configuration, the strength of the core can be increased and the entire surface of the core can be insulated.

  Moreover, it is preferable that at least one of the first core and the second core is configured with Mn—Zn-based ferrite as a base material.

  According to such a configuration, the characteristics of the coil component can be increased.

  According to the coil component of the present invention, adhesive strength can be ensured.

The disassembled perspective view of the coil components which concern on embodiment of this invention. The perspective view of the coil components which concern on embodiment of this invention. The drum core cross-sectional schematic of the coil components which concern on embodiment of this invention. The bottom perspective view of the coil component concerning an embodiment of the invention. Explanatory drawing which concerns on glass layer formation of the coil components which concern on embodiment of this invention. The perspective view which concerns on the modification of the coil components which concern on embodiment of this invention.

  Hereinafter, a coil component according to an embodiment of the present invention will be described with reference to FIGS. 1 to 5. A coil component 1 shown in FIG. 1 mainly includes a drum core 2, an exterior core 3, a winding 6, and an electrode 7.

  The drum core 2 is made of a magnetic material containing manganese, for example, Mn—Zn-based ferrite, and as shown in FIGS. 1 and 3, a substantially cylindrical core portion 23 and a central axis direction of the core portion 23. It is comprised from the 1st collar part 21 and the 2nd collar part 22 which were provided coaxially at both ends. The 1st collar part 21 and the 2nd collar part 22 are each comprised by the same shape.

  One end of the core portion 23 is connected to the first flange portion 21 and the first inner surface 21A faces the second flange portion 22, and the first end surface on the one end side of the drum core 2 in the axial direction of the core portion 23. An outer surface 21B and a first peripheral surface 21C located between the first inner surface 21A and the first outer surface 21B are defined. 21 C of 1st surrounding surfaces are comprised from a pair of circular arc part 21E and 21E which connect a pair of linear part 21D and 21D and a pair of linear part 21D and 21D. In the first flange portion 21, the first outer surface 21B functions as a suction surface (upper surface) when the coil component 1 is sucked and mounted.

  The other end of the core portion 23 is connected to the second flange portion 22, and the second inner surface 22 </ b> A facing the first flange portion 21 and the other end side end surface of the drum core 2 in the axial direction of the core portion 23. A second outer surface 22B and a second peripheral surface 22C located between the second inner surface 22A and the second outer surface 22B are defined. 22 C of 2nd surrounding surfaces are comprised from a pair of circular arc part 22E and 22E which connect a pair of linear part 22D and 22D and a pair of linear part 22D and 22D. In the second flange portion 22, the second outer surface 22B acts as a mounting surface (lower surface) mounted on a substrate (not shown) when the coil component 1 is sucked and mounted.

  The core portion 23 has a core portion peripheral surface 23A located between the first inner surface 21A and the second inner surface 22A. In the drum core 2, a space 2 a (FIG. 3) for collecting the winding 6 is formed in a portion surrounded by the winding core peripheral surface 23 </ b> A, the first inner surface 21 </ b> A, and the second inner surface 22 </ b> A. Further, a first facing surface facing the outer core 3 is defined from the arc portion 21E of the first flange portion 21 and the arc portion 22E of the second flange portion 22.

  The exterior core 3 is composed of a first divided core 4 and a second divided core 5, and the first divided core 4 and the second divided core 5 have the same shape. Therefore, the following description demonstrates the 1st division | segmentation core 4 as a representative. The first split core 4 is made of the same magnetic material as the drum core 2 and has a first inner surface 4A facing the first peripheral surface 21C and the second peripheral surface 22C. 4 A of 1st inner surfaces are comprised by the circular arc shape, and the circular arc direction length is comprised so that it may become substantially the same as the circumferential direction length of the circular arc parts 21E and 22E.

  In the first inner surface 4A, the first split core 4 in a direction perpendicular to the arc direction, that is, in a state in which the first split core 4 is disposed at the outer peripheral position of the drum core 2, The thickness is configured to be substantially the same as or slightly smaller than the thickness of the drum core 2 (the axial length and the distance from the first outer surface 21B to the second outer surface 22B).

  Further, on the first inner surface 4A, a first protrusion 41 and a second protrusion 42 are provided at positions near both ends in the arc direction, respectively. The first projecting portion 41 and the second projecting portion 42 each extend in a direction (the thickness direction of the first split core 4) that coincides with the axial direction of the drum core 2, and from the first inner surface 4A to the first peripheral surface 21C. And it is comprised so that it may protrude toward 22 C of 2nd surrounding surfaces. Since the 1st projection part 41 and the 2nd projection part 42 can be comprised with sufficient dimensional accuracy, the drum core 2 and exterior core 3 (1st division | segmentation) formed by the 1st projection part 41 and the 2nd projection part 42 are comprised. The dimensional accuracy of the space between the core 4) is also increased. By increasing the dimensional accuracy, the magnetic gap between the drum core 2 and the outer core 3 is stabilized, so that the direct current superimposition characteristics of the coil component 1 can be stably improved.

  As shown in FIG. 1, the second divided core 5 also has a second inner surface 5A having the same shape as the first divided core 4, and the second inner surface 5A has a first protrusion 51 and a second protrusion 52. And are provided. A second facing surface is defined by the first inner surface 4A of the first divided core 4 and the second inner surface 5A of the second divided core 5.

  The drum core 2 and the exterior core 3 having the above-described configuration are both made of a conductive material, but insulation is achieved by coating the surface with an insulating glass layer 8 (FIG. 3). Since the method of applying the glass layer 8 to the drum core 2 and the exterior core 3 is the same, a method of applying the glass layer 8 to the drum core 2 will be described as a representative.

  When the glass layer 8 is coated on the drum core 2, as shown in FIG. 5, a spray nozzle 91 is provided in the central portion, and a plurality of drum cores 2 are accommodated in a barrel 9 that rotates around the spray nozzle 91 as a rotation axis. . The spray nozzle 91 is configured to be able to spray a glass slurry in which fine powder glass, a binder, or the like is suspended.

  In this state, glass slurry is sprayed from the spray nozzle 91 and sprayed onto the drum core 2 for coating. After the glass slurry layer is formed on the drum core 2, dry air of about 70 degrees is put into the barrel 9 to dry the glass slurry layer formed on the drum core 2. Thereby, a layer of glass fine powder is formed on the drum core 2. Thereafter, the drum core 2 is fired, and unnecessary binder components are volatilized and burned to melt (soften) the glass powder, thereby forming the glass layer 8 having a smooth surface.

  In the drum core 2, the core part peripheral surface 23A, the first inner surface 21A, and the second inner surface 22A are surfaces that define a space 2a that is a recess. Further, since the coating method is merely spray coating, the sprayed glass slurry is not sucked and adhered by the drum core 2 itself as in, for example, electrostatic coating. Therefore, compared with the 1st outer surface 21B and the 1st peripheral surface 21C of the 1st collar part 21, and the 2nd outer surface 22B and the 2nd circumferential surface 22C of the 2nd collar part 22, the glass slurry sprayed in the space 2a. Is difficult to adhere. Therefore, as shown in FIG. 3, the thickness of the glass layer 8 in the space 2a (the core portion peripheral surface 23A, the first inner surface 21A, and the second inner surface 22A) is thinner than the first outer surface 21B and the like. Become. Specifically, the average thickness of the glass layer 8 on the first outer surface 21B and the like is about 10 μm, whereas the average thickness of the glass layer 8 on the first inner surface 21A and the second inner surface 22A is about 5 μm. The average thickness of the glass layer 8 on the core peripheral surface 23A is about 3 μm, and the outer peripheral portion of the drum core 2 such as the first outer surface 21B is directed to the core peripheral surface 23A, which is the inner side of the drum core 2. The glass layer 8 is thin.

  Although the winding 6 is accommodated in the space 2a, the space 2a can be made large by thinning the glass layer 8 in the space 2a. Therefore, the number of turns of the winding 6 can be increased, or a large-diameter winding 6 can be used, so that the characteristics of the coil component 1 can be improved.

  Similarly to the drum core 2, the exterior core 3 is baked after being coated with glass slurry in the barrel 9 to form the glass layer 8. Since both the drum core 2 and the exterior core 3 are conductors, short-circuiting is suppressed by covering them with the insulating glass layer 8. Moreover, the strength of the drum core 2 and the exterior core 3 can be increased by being covered with the glass layer 8. Moreover, since the surface (glass surface) of the glass layer 8 of the drum core 2 and the exterior core 3 is formed by melting, it is smooth and hardly becomes porous. Moreover, the glass which comprises this glass layer 8 uses as a base material the material which is excellent in the wettability with respect to the adhesive agent 10 mentioned later.

  The winding 6 is composed of a coated conducting wire in which a conducting wire is coated with an insulating coating such as polyamideimide, and as shown in FIG. 2, the winding core portion peripheral surface 23A (FIG. 1) in the winding core portion 23 (FIG. 1). ) And is accommodated in the space 2a (FIG. 3). Although the glass layer 8 in the space 2a is thinly formed as described above, since the winding 6 is an insulating coating, it is possible to prevent the winding 6 and the drum core 2 from being short-circuited.

  The electrode 7 is formed by applying a silver paste to the surface of the glass layer 8 of the second collar portion 22 in a state where the glass layer 8 is formed on the drum core 2 and then plating with nickel and tin. As shown in FIG. 4, the first electrode 71 is connected to one end of the winding 6 and the second electrode 72 is connected to the other end of the winding 6. The first electrode 71 is disposed across the second outer surface 22B and the one straight portion 22D of the second peripheral surface 22C, and one end of the winding 6 is connected at the position of the one straight portion 22D. The second electrode 72 is disposed across the second outer surface 22B and the other straight portion 22D of the second peripheral surface 22C, and one end of the winding 6 is connected at the position of the other straight portion 22D. By providing the electrode 7 on the surface of the glass layer 8, insulation between the drum core 2 is maintained. The electrode 7 may be formed by bonding a copper metal fitting to the second flange portion 22 after the glass layer 8 is formed.

  As shown in FIGS. 2 and 4, the first split core 4 (exterior core 3) is based on an epoxy resin as shown in FIGS. 2 and 4 in the drum core 2 in a state where the winding 6 is wound and connected to the electrode 7. Bonded with the adhesive 10. At this time, the adhesive 10 uses the surface (glass surface) of the glass layer 8 (FIG. 3) in the arc portions 21E and 22E of the first peripheral surface 21C and the second peripheral surface 22C as the first adhesive surface, and the first inner surface 4A ( The drum core 2 and the first divided core 4 (exterior core 3) are bonded using the surface (glass surface) of the glass layer 8 in FIG. 1) as the second bonding surface. As shown in FIG. 2, the adhesive 10 positioned between the first flange 21 and the first split core 4 is filled so as not to protrude toward the first outer surface 21B.

  The first adhesive surface and the second adhesive surface to which the adhesive 10 is bonded are the surfaces of the glass layer 8 respectively, and the glass layer 8 is not porous, so that the adhesive 10 does not penetrate into the glass layer 8. Since the adhesion of the adhesive 10 to the glass layer 8 is suppressed, an adhesive force due to the anchor effect cannot be obtained excessively, but the wettability of the glass layer 8 to the adhesive 10 is excellent, so that the adhesive strength is lowered. Rather, the drum core 2 and the first divided core 4 (exterior core 3) can be suitably bonded.

  The adhesive 10 is filled in the gap between the drum core 2 and the first split core 4 defined by the first protrusion 41 and the second protrusion 42, but the gap accuracy is high as described above. The variation in the amount of the adhesive 10 necessary for bonding the drum core 2 and the first divided core 4 is reduced. Therefore, the occurrence of uneven adhesion or the like is suppressed, and a stable adhesion state can always be maintained. The second divided core 5 is also bonded to the drum core 2 in the same manner as the first divided core 4.

  The coil component of the present invention is not limited to the above-described embodiment, and various improvements and modifications can be made within the scope described in the claims. For example, although the glass layer 8 is provided over the entire surface of the drum core 2 and the exterior core 3, the present invention is not limited thereto, and the glass layer 8 may be provided at least at a location bonded by the adhesive 10.

  In addition, the adhesive 10 is interposed only on the first peripheral surface 21C in the first flange portion 21, but not limited to this, as shown in FIG. 6, the adhesive 10 may also be provided on the first outer surface 21B. good. In this state, the adhesive 10 is also provided on the upper surface 3B of the exterior core 3 that is flush with the first outer surface 21B. By adopting such a configuration, the bonding area increases, so that the bonding strength can be further increased.

  In the present embodiment, both the first adhesive surface of the drum core 2 and the second adhesive surface of the exterior core 3 are both provided from the surface (glass surface) of the glass layer 8, but at least one is from the glass layer 8. May be provided. Even with such a configuration, the adhesive strength can be increased.

  In the present embodiment, the drum core 2 and the exterior core 3 are molded using Mn—Zn ferrite as a base material. However, even a ceramic core using other materials, for example, Ni—Zn ferrite core or alumina, may be used. Good. The drum core 2 and the outer core 3 may be made of different materials. Even if the base material of the drum core 2 and the exterior core 3 is changed, the first adhesive surface and the second adhesive surface are made the surface of the glass layer (glass surface), so that the adhesive strength is high as in the present embodiment. It can be. Therefore, a stable adhesion state can be obtained regardless of the material of the core.

  In the present embodiment, the exterior core has been described as a split core, but the present invention is not limited to this, and an annular ring core may be used. Further, in the present embodiment, the configuration in which the protruding portion that sets the gap between the outer core and the drum core has been described in the outer core, but the present invention is not limited thereto, and the protruding portion may be provided on the drum core side. Alternatively, protrusions may be provided on both the exterior core and the drum core. Moreover, you may set a gap by the glass layer interposed between an exterior core and a drum core, without providing a projection part.

1 .. Coil parts 2 .. Drum core 2a .. Space 3 .... Exterior core 4 .... First split core 4A ... First inner surface 5 .... Second split core 5A ... Second inner surface 6 ... Winding 7 · · Electrode 8 · · Glass layer 9 · · Barrel 10 · · Adhesive 21 · · First collar 21A · · First inner surface 21B · · First outer surface 21C · · First peripheral surface 21D · · Straight portion 21E · · Arc portion 22 ·· Second flange portion 22A ·· Second inner surface 22B ·· Second outer surface 22C · · Second peripheral surface 22D · · Linear portion 22E · · Arc portion 23 · · Core portion 23A · · Core Part peripheral surface 41 .. First protrusion 42.. Second protrusion 51.. First protrusion 52.. Second protrusion 71... First electrode 72 .. Second electrode 91.

Claims (7)

A first core having a first adhesive surface;
A second core having a second adhesive surface and bonded to the first core with an adhesive interposed between the first adhesive surface and the second adhesive surface;
A winding wound around the first core;
A pair of terminal electrodes attached to at least one of the first core and the second core and having one end and the other end of the winding connected to each other;
A coil component, wherein at least one of the first adhesive surface and the second adhesive surface is composed of a molten and hardened glass surface.   The glass surface is configured to include a first glass surface formed on the first bonding surface and a second glass surface formed on the second bonding surface. The coil component described. The first core has a winding core portion around which the winding is wound, a plate-like first collar portion connected to one end of the winding core portion, and a plate-like end of the winding core portion. A drum core composed of a second collar connected to
The second core is an exterior core disposed around the flange,
The drum core is defined with a first facing surface facing the exterior core, the exterior core is defined with a second facing surface facing the drum core, and either the first facing surface or the second facing surface The coil component according to claim 1, wherein one or both is provided with a protrusion that abuts either one.   The coil component according to claim 3, wherein the first adhesive surface is disposed on the first opposing surface, and the second adhesive surface is disposed on the second opposing surface. One end of the core part is connected to the first collar part, and a first inner surface that faces the second collar part, and a first outer surface that is an end surface on one end side of the drum core in the axial direction of the core part And a first circumferential surface located between the first inner surface and the first outer surface,
The other end of the core is connected to the second flange and a second inner surface facing the first flange and a second end that is the other end of the drum core in the axial direction of the core. An outer surface and a second circumferential surface located between the second inner surface and the second outer surface are defined;
In the core portion, a core portion peripheral surface located between the first inner surface and the second inner surface is defined,
The drum core is coated with a glass layer on the entire surface to form the glass surface, and the film thickness of the glass layer between the first inner surface, the second inner surface, and the winding core peripheral surface is determined by the first outer surface, the first 5. The coil component according to claim 3, wherein the coil component is thinner than a film thickness of the glass layer on the one peripheral surface, the second outer surface, and the second peripheral surface.   The glass layer is provided on the entire surface of one of the first core and the second core, or the entire surface of both the first core and the second core. The coil component according to claim 5.   The at least any one of this 1st core and this 2nd core is comprised using Mn-Zn type ferrite as a base material, The structure of any one of Claim 1 to 6 characterized by the above-mentioned. Coil parts.

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