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JP2016058419A - Surface mounting inductor and method of manufacturing the same - Google Patents

Surface mounting inductor and method of manufacturing the same Download PDF

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Publication number
JP2016058419A
JP2016058419A JP2014180929A JP2014180929A JP2016058419A JP 2016058419 A JP2016058419 A JP 2016058419A JP 2014180929 A JP2014180929 A JP 2014180929A JP 2014180929 A JP2014180929 A JP 2014180929A JP 2016058419 A JP2016058419 A JP 2016058419A
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Prior art keywords
coil
molded body
winding
lead
mount inductor
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Japanese (ja)
Inventor
千寿 境
Senju Sakai
千寿 境
緑川　智樹
Tomoki Midorikawa
智樹 緑川
昌明 戸塚
Masaaki Totsuka
昌明 戸塚
佐々森　邦夫
Kunio Sasamori
邦夫 佐々森
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Toko Inc
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Toko Inc
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Priority to JP2014180929A priority Critical patent/JP2016058419A/en
Priority to PCT/JP2015/075103 priority patent/WO2016035862A1/en
Publication of JP2016058419A publication Critical patent/JP2016058419A/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/10—Connecting leads to windings

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)

Abstract

PROBLEM TO BE SOLVED: To provide a surface mounting inductor the shape of which can be made thin while reducing variation of resistance value, and to provide a method of manufacturing the same.SOLUTION: A surface mounting inductor includes a coil 11 formed by winding a conductor, and a molding 12 using resin and a sealing material containing a magnetic material, and incorporating the coil. The coil 11 is formed by winding a conductor having a circular profile, a conductor having a square profile, or a rectangular conductor having an aspect ratio of profile of 1:2 or less. The lead-out end 11B of the coil is formed by crushing the conductor so that the major axis is 1.5 times or more of the diameter of the conductor. The lead-out end 11B of the coil 11 is exposed to the end face of the molding 12 so that the major axis direction is parallel with the end face of the molding 12.SELECTED DRAWING: Figure 1

Description

本発明は、導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用いて形成されてコイルを内蔵する成形体とを備えた表面実装インダクタ及びその製造方法に関する。   The present invention relates to a surface-mount inductor including a coil formed by winding a conductive wire, and a molded body that is formed using a sealing material including a resin and a magnetic material and incorporates the coil, and a method for manufacturing the same.

従来の表面実装インダクタに、図４に示す様に、断面が平角形状の導線を巻回してコイル４１を形成し、このコイル４１を磁性粉末と樹脂を含む封止材で形成された成形体４２内に埋設し、コイル４１を成形体４２の表面に形成された外部端子４３に接続したものがある（例えば、特許文献１を参照。）。この表面実装インダクタは、導線を巻回して形成したコイル４１を、磁性粉末と樹脂を含む封止材で平板形状の周縁部に柱状凸部を有する形状に形成されたタブレットに載置し、コイル４１の引き出し端部をタブレットの柱状凸部の外側側面に沿わせた状態で、コイル４１の引き出し端部が成型金型の内壁面とタブレットの柱状凸部の外側側面との間に挟まれるようにコイル４１とタブレットを成型金型に配置し、この金型を用い、圧縮成形法もしくは圧粉成形法によりコイル４１を内蔵する成形体４２が形成される。   As shown in FIG. 4, a coil 41 is formed on a conventional surface-mount inductor by winding a conducting wire having a flat cross section, and the coil 41 is formed of a sealing material containing magnetic powder and resin. There is one in which the coil 41 is embedded in and connected to an external terminal 43 formed on the surface of the molded body 42 (see, for example, Patent Document 1). In this surface mount inductor, a coil 41 formed by winding a conducting wire is placed on a tablet formed in a shape having a columnar convex portion on a flat peripheral edge portion with a sealing material containing magnetic powder and resin, and the coil The drawer end of the coil 41 is sandwiched between the inner wall surface of the molding die and the outer side surface of the columnar convex portion of the tablet in a state where the drawer end portion of 41 is aligned with the outer side surface of the columnar convex portion of the tablet. The coil 41 and the tablet are placed in a molding die, and a molded body 42 containing the coil 41 is formed by using this die by a compression molding method or a powder molding method.

特開２０１０−２４５４７３号公報JP 2010-245473 A

近年、この種の表面実装インダクタが用いられる電子機器では小型化、高機能化の技術革新が著しく、この種の表面実装インダクタにおいても小型化、高機能化が望まれている。この様な状況の中、従来の表面実装インダクタにおいて、形状を薄型にしようとした場合、コイルの形状も薄型にする必要がある。しかしながら、従来の表面実装インダクタは、断面が平角形状の導線を巻回してコイルを形成しているため、コイルの形状を単純に薄くすると導線の線幅が狭くなり、成形体の表面に露出するコイルの引き出し端部の露出面積が小さくなる傾向にある。成形体の表面に露出するコイルの引き出し端部の露出面積が小さくなった場合、コイルの引き出し端部と外部端子との接合面積も小さくなり、抵抗値のバラツキが大きくなる。   In recent years, electronic devices using this type of surface-mount inductor have undergone remarkable technological innovations for miniaturization and high functionality, and this type of surface-mount inductor is also desired to be small and highly functional. In such a situation, in the conventional surface mount inductor, when trying to make the shape thin, it is necessary to make the coil shape thin. However, since the conventional surface mount inductor is formed by winding a conducting wire having a rectangular cross section, the wire width of the conducting wire is narrowed and exposed to the surface of the molded body if the coil shape is simply made thin. The exposed area of the coil drawing end tends to be small. When the exposed area of the coil drawing end exposed on the surface of the molded body is reduced, the bonding area between the coil drawing end and the external terminal is also reduced, and the variation in resistance value is increased.

本発明は、形状を薄型にできると共に、抵抗値のバラツキを低減することができる表面実装インダクタ及びその製造方法を提供することを目的とする。   It is an object of the present invention to provide a surface-mount inductor and a method for manufacturing the same that can reduce the shape and reduce variations in resistance value.

本発明は、導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、コイルを内蔵する成形体を備えた表面実装インダクタにおいて、コイルは断面が円形状の導線を巻回して形成され、コイルの引き出し端部が導線を押しつぶして形成され、引き出し端部の長径が導線の直径の１．５倍以上有し、コイルの引き出し端部は、その長径方向が成形体の端面と平行になる様に成形体表面に露出する。
また、本発明は、導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、コイルを内蔵する成形体を備えた表面実装インダクタにおいて、コイルは断面が真四角の導線を巻回して形成され、コイルの引き出し端部が導線を押しつぶして形成され、引き出し端部の長径が導線の太さの１．５倍以上有し、コイルの引き出し端部は、その長径方向が成形体の端面と平行になる様に成形体表面に露出する。
さらに、本発明は、導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、コイルを内蔵する成形体を備えた表面実装インダクタにおいて、コイルは断面の縦横の比率が１：２以下の平角状の導線を巻回して形成され、コイルの引き出し端部が導線を押しつぶして形成され、引き出し端部の長径が導線の太さの１．５倍以上有し、コイルの引き出し端部は、その長径方向が成形体の端面と平行になる様に成形体の端面に露出する。
またさらに、本発明は、導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、コイルを内蔵する成形体を備えた表面実装インダクタの製造方法において、導線を巻回してコイルを形成する工程、コイルの引き出し端部をその長径が導線の太さの１．５倍以上有する様に押しつぶす工程及び、引き出し端部がその長径方向が成形体の端面と平行に露出する様にコイルを成形体内に埋設する工程を備える。 The present invention relates to a surface mount inductor including a coil formed by winding a conductive wire and a sealing material including a resin and a magnetic material, and including a molded body with a built-in coil. The lead-out end portion of the coil is formed by crushing the conductor, the major diameter of the lead-out end portion is 1.5 times or more the diameter of the lead wire, and the major axis direction of the lead-out end portion of the coil is It is exposed on the surface of the molded body so as to be parallel to the end face.
The present invention also relates to a surface mount inductor including a coil formed by winding a conductive wire and a sealing material including a resin and a magnetic material, and a molded body incorporating the coil. The lead end of the coil is formed by crushing the conductive wire, the long diameter of the lead end is 1.5 times the thickness of the lead, and the long end direction of the lead end of the coil is It is exposed on the surface of the molded body so as to be parallel to the end face of the molded body.
Further, according to the present invention, in a surface mount inductor including a coil formed by winding a conductive wire and a sealing material including a resin and a magnetic material and including a molded body incorporating the coil, the coil has a cross-sectional aspect ratio. 1: 2 or less is formed by winding a rectangular conductive wire, the lead end portion of the coil is formed by crushing the lead wire, the long diameter of the lead end portion is 1.5 times the thickness of the lead wire, The drawer end is exposed on the end surface of the molded body so that the major axis direction thereof is parallel to the end surface of the molded body.
Furthermore, the present invention relates to a method of manufacturing a surface mount inductor comprising a coil formed by winding a conductive wire and a sealing material containing a resin and a magnetic material, and including a molded body incorporating the coil. Forming the coil, crushing the coil drawing end so that its long diameter is 1.5 times the thickness of the conductor, and the drawing end is exposed in parallel with the end face of the molded body. In the same manner, a step of embedding the coil in the molded body is provided.

本発明は、導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、コイルを内蔵する成形体を備えた表面実装インダクタにおいて、コイルは断面が円形状の導線を巻回して形成され、コイルの引き出し端部が導線を押しつぶして形成され、引き出し端部の長径が導線の直径の１．５倍以上有し、コイルの引き出し端部は、その長径方向が成形体の端面と平行になる様に成形体表面に露出するので、形状を薄型にできると共に、抵抗値のバラツキを低減することができる。
また、本発明は、導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、コイルを内蔵する成形体を備えた表面実装インダクタにおいて、コイルは断面が真四角の導線を巻回して形成され、コイルの引き出し端部が導線を押しつぶして形成され、引き出し端部の長径が導線の太さの１．５倍以上有し、コイルの引き出し端部は、その長径方向が成形体の端面と平行になる様に成形体表面に露出するので、形状を薄型にできると共に、抵抗値のバラツキを低減することができる。
さらに、本発明は、導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、コイルを内蔵する成形体を備えた表面実装インダクタにおいて、コイルは断面の縦横の比率が１：２以下の平角状の導線を巻回して形成され、コイルの引き出し端部が導線を押しつぶして形成され、引き出し端部の長径が導線の太さの１．５倍以上有し、コイルの引き出し端部は、その長径方向が成形体の端面と平行になる様に成形体の端面に露出するので、形状を薄型にできると共に、抵抗値のバラツキを低減することができる。
またさらに、本発明は、導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、コイルを内蔵する成形体を備えた表面実装インダクタの製造方法において、導線を巻回してコイルを形成する工程、コイルの引き出し端部をその長径が導線の太さの１．５倍以上有する様に押しつぶす工程及び、引き出し端部がその長径方向が成形体の端面と平行に露出する様にコイルを成形体内に埋設する工程を備えるので、形状を薄型にできると共に、抵抗値のバラツキを低減することができる。 The present invention relates to a surface mount inductor including a coil formed by winding a conductive wire and a sealing material including a resin and a magnetic material, and including a molded body with a built-in coil. The lead-out end portion of the coil is formed by crushing the conductor, the major diameter of the lead-out end portion is 1.5 times or more the diameter of the lead wire, and the major axis direction of the lead-out end portion of the coil is Since it is exposed on the surface of the molded body so as to be parallel to the end face, the shape can be reduced and the variation in resistance value can be reduced.
The present invention also relates to a surface mount inductor including a coil formed by winding a conductive wire and a sealing material including a resin and a magnetic material, and a molded body incorporating the coil. The lead end of the coil is formed by crushing the conductive wire, the long diameter of the lead end is 1.5 times the thickness of the lead, and the long end direction of the lead end of the coil is Since it is exposed on the surface of the molded body so as to be parallel to the end face of the molded body, the shape can be reduced and the variation in resistance value can be reduced.
Further, according to the present invention, in a surface mount inductor including a coil formed by winding a conductive wire and a sealing material including a resin and a magnetic material and including a molded body incorporating the coil, the coil has a cross-sectional aspect ratio. 1: 2 or less is formed by winding a rectangular conductive wire, the lead end portion of the coil is formed by crushing the lead wire, the long diameter of the lead end portion is 1.5 times the thickness of the lead wire, Since the leading end portion is exposed on the end surface of the molded body so that the major axis direction thereof is parallel to the end surface of the molded body, the shape can be reduced and the variation in resistance value can be reduced.
Furthermore, the present invention relates to a method of manufacturing a surface mount inductor comprising a coil formed by winding a conductive wire and a sealing material containing a resin and a magnetic material, and including a molded body incorporating the coil. Forming the coil, crushing the coil drawing end so that its long diameter is 1.5 times the thickness of the conductor, and the drawing end is exposed in parallel with the end face of the molded body. Thus, since the step of embedding the coil in the molded body is provided, the shape can be reduced and the variation in the resistance value can be reduced.

本発明の表面実装インダクタの第１の実施例を示す断面図である。It is sectional drawing which shows the 1st Example of the surface mount inductor of this invention. 本発明の表面実装インダクタの第２の実施例を示す断面図である。It is sectional drawing which shows the 2nd Example of the surface mount inductor of this invention. 本発明の表面実装インダクタの第３の実施例を示す断面図である。It is sectional drawing which shows the 3rd Example of the surface mount inductor of this invention. 従来の表面実装インダクタの断面図である。It is sectional drawing of the conventional surface mount inductor.

本発明の表面実装インダクタは、導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、コイルを内蔵する成形体を備える。コイルは、断面が円形状の導線を巻回して形成されたり、断面が真四角の導線を巻回して形成されたり、断面の縦横の比率が１：２以下の平角状の導線を巻回して形成されたりする。このコイルの引き出し端部は、引き出し端部の長径が導線の太さの１．５倍以上有する様に、押しつぶして形成される。そして、コイルの引き出し端部は、その長径方向が成形体の端面と平行になる様に成形体表面に露出する。
従って、本発明の表面実装インダクタは、引き出し端部の線幅を狭くすることなく、コイルの高さを従来のものよりも低くできる。 The surface-mount inductor according to the present invention includes a coil formed by winding a conductive wire, and a molded body containing the coil, using a sealing material including a resin and a magnetic material. The coil is formed by winding a conductive wire having a circular cross section, or formed by winding a conductive wire having a square cross section, or by winding a flat conductive wire having a cross-sectional ratio of 1: 2 or less. Or formed. The leading end of the coil is formed by crushing so that the major axis of the leading end is 1.5 times the thickness of the conducting wire. And the drawer | drawing-out edge part of a coil is exposed to the molded object surface so that the major axis direction may become parallel to the end surface of a molded object.
Therefore, the surface mount inductor of the present invention can make the height of the coil lower than the conventional one without narrowing the line width of the lead end.

以下、本発明の表面実装インダクタの実施例を図１乃至図３を参照して説明する。
図１は、本発明の表面実装インダクタの第１の実施例を示す断面図である。
図１において、１１はコイル、１２は成形体である。
コイル１１は、断面が円形状で、表面が絶縁体で被覆された導線をその両端部が外周に位置するように渦巻き状に２段の外外巻きに巻回した巻回部１１Ａと、巻回部１１Ａから引き出され、巻回部１１Ａを挟んで対向する１対の引き出し端部１１Ｂを備えた空芯コイルが形成される。引き出し端部１１Ｂは、その長径Ａ２が巻回部１１Ａを構成する部分の導線の直径Ａ１の１．５倍以上有する様に押しつぶして形成される。
成形体１２は、樹脂と磁性材料を含む封止材を用いてコイル１１を内蔵する様に形成される。封止材としては、磁性材料として例えば鉄系の金属磁性粉末を、樹脂として例えばエポキシ樹脂をそれぞれ用い、これらを混合したものが用いられる。成形体１２の端面にはコイル１１の引き出し端部１１Ｂの表面が露出する。この時、コイル１１の引き出し端部１１Ｂは、その長径方向が成形体１２の端面と平行になる様に成形体１２の表面に露出する。また、この成形体１２の表面には、１対の外部端子１３が形成される。
そして、成形体１２の端面にそれぞれ露出したコイル１１の引き出し端部１１Ｂが外部端子１３に接続されることにより、コイル１１が１対の外部端子１３間に接続される。 Embodiments of the surface mount inductor according to the present invention will be described below with reference to FIGS.
FIG. 1 is a sectional view showing a first embodiment of a surface mount inductor according to the present invention.
In FIG. 1, 11 is a coil and 12 is a molded body.
The coil 11 has a winding section 11A in which a conductor having a circular cross section and a surface covered with an insulator is wound in two outer and outer windings in a spiral shape so that both ends thereof are positioned on the outer periphery. An air-core coil is formed that includes a pair of lead-out end portions 11B that are drawn from the turn portion 11A and face each other with the winding portion 11A interposed therebetween. The lead-out end portion 11B is formed by crushing so that the major axis A2 has 1.5 times or more the diameter A1 of the conducting wire of the portion constituting the winding portion 11A.
The molded body 12 is formed so as to incorporate the coil 11 using a sealing material containing a resin and a magnetic material. As the sealing material, for example, an iron-based metal magnetic powder is used as a magnetic material, and an epoxy resin is used as a resin, and a mixture thereof is used. The surface of the lead-out end portion 11B of the coil 11 is exposed at the end surface of the molded body 12. At this time, the leading end portion 11 </ b> B of the coil 11 is exposed on the surface of the molded body 12 such that the major axis direction thereof is parallel to the end surface of the molded body 12. A pair of external terminals 13 are formed on the surface of the molded body 12.
Then, the coil 11 is connected between the pair of external terminals 13 by connecting the leading end portion 11 </ b> B of the coil 11 exposed at the end face of the molded body 12 to the external terminal 13.

この様な表面実装インダクタは以下の様にして製造される。まず、断面が円形状で、表面が絶縁体で被覆された導線をその両端部が外周に位置するように渦巻き状に２段の外外巻きに巻回して巻回部１１Ａを形成した後、導線の両端を巻回部１１Ａの外周からそれぞれ巻回部１１Ａを挟んで対向する様に引き出して引き出し端部１１Ｂを形成して空芯のコイル１１が形成される。
次に、コイル１１の引き出し端部１１Ｂが、その長径Ａ２が巻回部１１Ａを構成する部分の導線の直径Ａ１の１．５倍以上有する様に押しつぶされる。
続いて、樹脂と磁性材料を含む封止材を用い、圧縮成形法や圧粉成形法にて、コイル１１を内蔵する成形体１２が形成される。この時、コイル１１は、引き出し端部１１Ｂの長径方向が成形体の端面と平行に露出する様に成形体１２内に埋設される。
この様に形成された成形体１２は、端面に露出したコイル１１の引き出し端部１１Ｂの絶縁被膜を剥離する処理と、バレル研磨処理が施される。この絶縁被覆を剥離する処理と、バレル研磨処理は、同時に行うこともできる。そして、この成形体１２の表面に外部端子１３が形成され、コイル１１の引き出し端部１１Ｂと外部端子１３が接続される。 Such a surface mount inductor is manufactured as follows. First, after forming a winding part 11A by winding a conductive wire having a circular cross section and having a surface covered with an insulator in a spiral shape so that both ends thereof are positioned on the outer periphery and wound in two outer and outer windings, Both ends of the conducting wire are drawn out from the outer periphery of the winding part 11A so as to face each other with the winding part 11A interposed therebetween, and a lead-out end part 11B is formed to form the air core coil 11.
Next, the lead-out end portion 11B of the coil 11 is crushed so that the major axis A2 has 1.5 times or more the diameter A1 of the conducting wire of the portion constituting the winding portion 11A.
Subsequently, a molded body 12 containing the coil 11 is formed by a compression molding method or a compacting method using a sealing material including a resin and a magnetic material. At this time, the coil 11 is embedded in the molded body 12 so that the major axis direction of the lead-out end portion 11B is exposed in parallel with the end surface of the molded body.
The molded body 12 formed in this way is subjected to a treatment for peeling off the insulating film on the lead-out end portion 11B of the coil 11 exposed on the end face and a barrel polishing treatment. The process of peeling off the insulating coating and the barrel polishing process can be performed simultaneously. And the external terminal 13 is formed in the surface of this molded object 12, and the drawer | drawing-out edge part 11B of the coil 11 and the external terminal 13 are connected.

図２は、本発明の表面実装インダクタの第２の実施例を示す断面図である。
コイル２１は、断面が真四角で、表面が絶縁体で被覆された導線をその両端部が外周に位置するように渦巻き状に２段の外外巻きに巻回した巻回部２１Ａと、巻回部２１Ａから引き出され、巻回部２１Ａを挟んで対向する１対の引き出し端部２１Ｂを備えた空芯コイルが形成される。引き出し端部２１Ｂは、その長径Ｂ２が巻回部２１Ａを構成する部分の導線の太さＢ１の１．５倍以上有する様に押しつぶして形成される。
成形体２２は、樹脂と磁性材料を含む封止材を用いてコイル２１を内蔵する様に形成される。封止材としては、磁性材料として例えば鉄系の金属磁性粉末を、樹脂として例えばエポキシ樹脂をそれぞれ用い、これらを混合したものが用いられる。成形体２２の端面にはコイル２１の引き出し端部２１Ｂの表面が露出する。この時、コイル２１の引き出し端部２１Ｂは、その長径方向が成形体２２の端面と平行になる様に成形体２２の表面に露出する。また、この成形体２２の表面には、１対の外部端子２３が形成される。
そして、成形体２２の端面にそれぞれ露出したコイル２１の引き出し端部２１Ｂが外部端子２３に接続されることにより、コイル２１が１対の外部端子２３間に接続される。 FIG. 2 is a cross-sectional view showing a second embodiment of the surface mount inductor of the present invention.
The coil 21 has a winding section 21A in which a conductor having a square cross section and a surface covered with an insulator is wound in two spiral outer windings so that both ends thereof are positioned on the outer periphery. An air-core coil that is drawn out from the turn part 21A and includes a pair of lead-out end parts 21B facing each other with the winding part 21A interposed therebetween is formed. The leading end portion 21B is formed by crushing so that the major axis B2 is 1.5 times or more the thickness B1 of the conductive wire of the portion constituting the winding portion 21A.
The molded body 22 is formed so as to incorporate the coil 21 using a sealing material including a resin and a magnetic material. As the sealing material, for example, an iron-based metal magnetic powder is used as a magnetic material, and an epoxy resin is used as a resin, and a mixture thereof is used. The surface of the lead-out end portion 21B of the coil 21 is exposed at the end surface of the molded body 22. At this time, the leading end portion 21 </ b> B of the coil 21 is exposed on the surface of the molded body 22 such that the major axis direction thereof is parallel to the end surface of the molded body 22. A pair of external terminals 23 are formed on the surface of the molded body 22.
The coil 21 is connected between the pair of external terminals 23 by connecting the drawn end portions 21 </ b> B of the coils 21 exposed at the end surfaces of the molded body 22 to the external terminals 23.

この様な表面実装インダクタは以下の様にして製造される。まず、断面が真四角で、表面が絶縁体で被覆された導線をその両端部が外周に位置するように渦巻き状に２段の外外巻きに巻回して巻回部２１Ａを形成した後、導線の両端を巻回部２１Ａの外周からそれぞれ巻回部２１Ａを挟んで対向する様に引き出して引き出し端部２１Ｂを形成してコイル２１が形成される。
次に、コイル２１の引き出し端部２１Ｂが、その長径Ｂ２が巻回部２１Ａを構成する部分の導線の太さＢ１の１．５倍以上有する様に押しつぶされる。
続いて、樹脂と磁性材料を含む封止材を用い、圧縮成形法や圧粉成形法にて、コイル２１を内蔵する成形体２２が形成される。この時、コイル２１は、引き出し端部２１Ｂの長径方向が成形体の端面と平行に露出する様に成形体２２内に埋設される。
この様に形成された成形体２２は、端面に露出したコイル２１の引き出し端部２１Ｂの絶縁被膜を剥離する処理と、バレル研磨処理が施される。この絶縁被覆を剥離する処理と、バレル研磨処理は、同時に行うこともできる。そして、この成形体２２の表面に外部端子２３が形成され、コイル２１の引き出し端部２１Ｂと外部端子２３が接続される。 Such a surface mount inductor is manufactured as follows. First, after forming a winding part 21A by winding a conductive wire whose cross section is a square and whose surface is coated with an insulator in a spiral shape so that both ends thereof are located on the outer periphery, and wound in two outer and outer windings, The coil 21 is formed by pulling out both ends of the conducting wire from the outer periphery of the winding portion 21A so as to face each other with the winding portion 21A interposed therebetween, thereby forming a lead-out end portion 21B.
Next, the leading end portion 21B of the coil 21 is crushed so that the major axis B2 is 1.5 times or more the conductor thickness B1 of the portion constituting the winding portion 21A.
Subsequently, a molded body 22 containing the coil 21 is formed by a compression molding method or a compacting method using a sealing material containing a resin and a magnetic material. At this time, the coil 21 is embedded in the molded body 22 so that the major axis direction of the lead-out end portion 21B is exposed in parallel with the end surface of the molded body.
The molded body 22 formed in this way is subjected to a treatment for peeling off the insulating coating on the lead-out end portion 21B of the coil 21 exposed on the end face and a barrel polishing treatment. The process of peeling off the insulating coating and the barrel polishing process can be performed simultaneously. External terminals 23 are formed on the surface of the molded body 22, and the lead-out end 21 </ b> B of the coil 21 and the external terminals 23 are connected.

図３は、本発明の表面実装インダクタの第３の実施例を示す断面図である。
コイル３１は、断面の縦横の比率が１：２以下で、表面が絶縁体で被覆された平角状の導線をその両端部が外周に位置するように、導線の断面の横方向、すなわち導線の幅方向が巻軸と水平な状態で渦巻き状に２段の外外巻きに巻回した巻回部３１Ａと、巻回部３１Ａから引き出され、巻回部３１Ａを挟んで対向する１対の引き出し端部３１Ｂを備えた空芯コイルが形成される。引き出し端部３１Ｂは、その長径Ｃ２が巻回部３１Ａを構成する部分の導線の太さＣ１の１．５倍以上有する様に押しつぶして形成される。
成形体３２は、樹脂と磁性材料を含む封止材を用いてコイル３１を内蔵する様に形成される。封止材としては、磁性材料として例えば鉄系の金属磁性粉末を、樹脂として例えばエポキシ樹脂をそれぞれ用い、これらを混合したものが用いられる。成形体３２の端面にはコイル３１の引き出し端部３１Ｂの表面が露出する。この時、コイル３１の引き出し端部３１Ｂは、その長径方向が成形体３２の端面と平行になる様に成形体３２の表面に露出する。また、この成形体３２の表面には、１対の外部端子３３が形成される。
そして、成形体３２の端面にそれぞれ露出したコイル３１の引き出し端部３１Ｂが外部端子３３に接続されることにより、コイル３１が１対の外部端子３３間に接続される。 FIG. 3 is a cross-sectional view showing a third embodiment of the surface mount inductor of the present invention.
The coil 31 has a cross-sectional ratio of 1: 2 or less and a rectangular conductor wire whose surface is covered with an insulator, so that both ends thereof are positioned on the outer periphery, that is, in the transverse direction of the conductor wire, that is, A winding part 31A wound in a two-stage outer and outer winding in a spiral shape with the width direction being parallel to the winding axis, and a pair of drawers that are drawn from the winding part 31A and opposed across the winding part 31A An air-core coil provided with the end 31B is formed. The leading end portion 31B is formed by crushing so that the major axis C2 is 1.5 times or more the thickness C1 of the conductive wire of the portion constituting the winding portion 31A.
The molded body 32 is formed so as to incorporate the coil 31 using a sealing material including a resin and a magnetic material. As the sealing material, for example, an iron-based metal magnetic powder is used as a magnetic material, and an epoxy resin is used as a resin, and a mixture thereof is used. On the end surface of the molded body 32, the surface of the lead-out end portion 31B of the coil 31 is exposed. At this time, the leading end portion 31B of the coil 31 is exposed on the surface of the molded body 32 so that the major axis direction thereof is parallel to the end surface of the molded body 32. A pair of external terminals 33 are formed on the surface of the molded body 32.
The coil 31 is connected between the pair of external terminals 33 by connecting the lead end portions 31 </ b> B of the coils 31 exposed at the end surfaces of the molded body 32 to the external terminals 33.

この様な表面実装インダクタは以下の様にして製造される。まず、断面の縦横の比率が１：２以下で、表面が絶縁体で被覆された平角状の導線をその両端部が外周に位置するように、導線の断面の横方向、すなわち導線の幅方向が巻軸と水平な状態で渦巻き状に２段の外外巻きに巻回した巻回部３１Ａを形成した後、導線の両端を巻回部３１Ａの外周からそれぞれ巻回部３１Ａを挟んで対向する様に引き出して引き出し端部３１Ｂを形成してコイル３１が形成される。
次に、コイル３１の引き出し端部３１Ｂが、その長径Ｃ２が巻回部３１Ａを構成する部分の導線の太さＣ１の１．５倍以上有する様に押しつぶされる。
続いて、樹脂と磁性材料を含む封止材を用い、圧縮成形法や圧粉成形法にて、コイル３１を内蔵する成形体３２が形成される。この時、コイル３１は、引き出し端部３１Ｂの長径方向が成形体の端面と平行に露出する様に成形体３２内に埋設される。
この様に形成された成形体３２は、端面に露出したコイル３１の引き出し端部３１Ｂの絶縁被膜を剥離する処理と、バレル研磨処理が施される。この絶縁被覆を剥離する処理と、バレル研磨処理は、同時に行うこともできる。そして、この成形体３２の表面に外部端子３３が形成され、コイル３１の引き出し端部３１Ｂと外部端子３３が接続される。 Such a surface mount inductor is manufactured as follows. First, the horizontal direction of the cross section of the conducting wire, that is, the width direction of the conducting wire, so that the both ends of the rectangular conducting wire whose cross-sectional ratio is 1: 2 or less and whose surface is coated with an insulator are located on the outer periphery. After forming the winding part 31A that is wound in two spirals in a state of being parallel to the winding axis, the opposite ends of the conductor are opposed to the winding part 31A from the outer periphery of the winding part 31A. In this way, the coil 31 is formed by forming the drawer end 31B.
Next, the leading end portion 31B of the coil 31 is crushed so that the major axis C2 has 1.5 times or more the thickness C1 of the conducting wire of the portion constituting the winding portion 31A.
Subsequently, a molded body 32 containing the coil 31 is formed by a compression molding method or a compacting method using a sealing material including a resin and a magnetic material. At this time, the coil 31 is embedded in the molded body 32 such that the major axis direction of the lead-out end portion 31B is exposed in parallel with the end surface of the molded body.
The molded body 32 formed in this way is subjected to a treatment for peeling off the insulating coating on the lead-out end portion 31B of the coil 31 exposed on the end face and a barrel polishing treatment. The process of peeling off the insulating coating and the barrel polishing process can be performed simultaneously. The external terminal 33 is formed on the surface of the molded body 32, and the lead-out end 31B of the coil 31 and the external terminal 33 are connected.

以上、本発明の表面実装インダクタ及びその製造方法の実施例を述べたが、本発明はこの実施例に限られるものではない。例えば、封止材は、磁性材料として鉄系の金属磁性粉末を、樹脂としてエポキシ樹脂を用いたが、磁性材料として他の組成の金属磁性粉末、その表面がガラス等の絶縁体で被覆された金属磁性粉末、表面を改質した金属磁性粉末、フェライト粉末等を用いても良い。また、樹脂として、ポリイミド樹脂やフェノール樹脂などの熱硬化性樹脂や、ポリエチレン樹脂やポリアミド樹脂などの熱可塑性樹脂を用いても良い。さらに、導線の両端を巻回部の外周からそれぞれ巻回部を挟んで対向する様に引き出して引き出し端部を形成しているが、導線の両端を巻回部の外周の同じ側面から引き出して引き出し端部を形成しても良い。   As mentioned above, although the Example of the surface mount inductor of this invention and its manufacturing method was described, this invention is not limited to this Example. For example, the sealing material used was an iron-based metal magnetic powder as the magnetic material, and an epoxy resin as the resin. However, the magnetic material was a metal magnetic powder of another composition, and its surface was coated with an insulator such as glass. Metal magnetic powder, surface-modified metal magnetic powder, ferrite powder, and the like may be used. Further, as the resin, a thermosetting resin such as a polyimide resin or a phenol resin, or a thermoplastic resin such as a polyethylene resin or a polyamide resin may be used. Furthermore, the both ends of the conducting wire are drawn out from the outer periphery of the winding part so as to face each other with the winding part sandwiched therebetween, and the drawing end part is formed, but both ends of the conducting wire are drawn out from the same side of the outer periphery of the winding part. A drawer end may be formed.

１１ コイル
１２ 成形体 11 Coil 12 Molded body

Claims (7)

導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、該コイルを内蔵する成形体を備えた表面実装インダクタにおいて、
該コイルは断面が円形状の導線を巻回して形成され、該コイルの引き出し端部が該導線を押しつぶして形成され、該引き出し端部の長径が該導線の直径の１．５倍以上有し、
該コイルの引き出し端部は、その長径方向が該成形体の端面と平行になる様に該成形体の端面に露出したことを特徴とする表面実装インダクタ。 In a surface mount inductor including a coil formed by winding a conductive wire and a sealing material including a resin and a magnetic material, and a molded body incorporating the coil,
The coil is formed by winding a conducting wire having a circular cross section, and the leading end of the coil is formed by crushing the conducting wire, and the major diameter of the leading end is 1.5 times or more the diameter of the conducting wire. ,
A surface-mount inductor, wherein a lead-out end portion of the coil is exposed at an end surface of the molded body so that a major axis direction thereof is parallel to the end surface of the molded body. 導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、該コイルを内蔵する成形体を備えた表面実装インダクタにおいて、
該コイルは断面が真四角の導線を巻回して形成され、該コイルの引き出し端部が該導線を押しつぶして形成され、該引き出し端部の長径が該導線の太さの１．５倍以上有し、
該コイルの引き出し端部は、その長径方向が該成形体の端面と平行になる様に該成形体端面に露出したことを特徴とする表面実装インダクタ。 In a surface mount inductor including a coil formed by winding a conductive wire and a sealing material including a resin and a magnetic material, and a molded body incorporating the coil,
The coil is formed by winding a conducting wire having a square cross section, and the leading end of the coil is formed by crushing the conducting wire, and the major diameter of the leading end is 1.5 times the thickness of the conducting wire. And
A surface-mount inductor, wherein a lead-out end portion of the coil is exposed at an end surface of the molded body so that a major axis direction thereof is parallel to the end surface of the molded body. 導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、該コイルを内蔵する成形体を備えた表面実装インダクタにおいて、
該コイルは断面の縦横の比率が１：２以下の平角状の導線を巻回して形成され、該コイルの引き出し端部が該導線を押しつぶして形成され、該引き出し端部の長径が該導線の太さの１．５倍以上有し、
該コイルの引き出し端部は、その長径方向が該成形体の端面と平行になる様に該成形体の端面に露出したことを特徴とする表面実装インダクタ。 In a surface mount inductor including a coil formed by winding a conductive wire and a sealing material including a resin and a magnetic material, and a molded body incorporating the coil,
The coil is formed by winding a rectangular conductive wire having a cross-sectional aspect ratio of 1: 2 or less, and a lead end of the coil is formed by crushing the lead, and a major axis of the lead end is equal to that of the lead. Have more than 1.5 times the thickness,
A surface-mount inductor, wherein a lead-out end portion of the coil is exposed at an end surface of the molded body so that a major axis direction thereof is parallel to the end surface of the molded body. 導線を巻回して形成したコイルと、樹脂と磁性材料を含む封止材を用い、該コイルを内蔵する成形体を備えた表面実装インダクタの製造方法において、
導線を巻回してコイルを形成する工程、該コイルの引き出し端部をその長径が該導線の太さの１．５倍以上有する様に押しつぶす工程及び、該引き出し端部がその長径方向が該成形体の端面と平行に露出する様に該コイルを該成形体内に埋設する工程を備えることを特徴とする表面実装インダクタの製造方法。 In a method of manufacturing a surface-mount inductor using a coil formed by winding a conductive wire and a sealing material containing a resin and a magnetic material, and a molded body incorporating the coil,
A step of forming a coil by winding a conducting wire, a step of crushing the leading end of the coil so that the major axis has a length of 1.5 times or more of the thickness of the conducting wire, and the leading end of the coil in the major axis direction A method for manufacturing a surface mount inductor, comprising: a step of embedding the coil in the molded body so as to be exposed in parallel with an end face of the body. 前記導線は断面が円形状のものが用いられた請求項４に記載の表面実装インダクタの製造方法。   The method for manufacturing a surface mount inductor according to claim 4, wherein the conductor has a circular cross section. 前記導線は断面が真四角のものが用いられた請求項４に記載の表面実装インダクタの製造方法。   The method for manufacturing a surface mount inductor according to claim 4, wherein the conductor has a square cross section. 前記導線は断面の縦横の比率が１：２以下の平角状のものが用いられた請求項４に記載の表面実装インダクタの製造方法。   5. The method of manufacturing a surface-mount inductor according to claim 4, wherein the conducting wire has a rectangular shape with a cross-sectional aspect ratio of 1: 2 or less.
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