JP6932748B2 - Manufacturing method of coil parts - Google Patents

Description

本発明は、コイル部品の製造方法に関し、更に具体的には、導線と端子電極の接合部の形成方法の改良に関するものである。 The present invention relates to a method for manufacturing a coil component, and more specifically to an improvement in a method for forming a joint portion between a conducting wire and a terminal electrode.

部品の用途が拡がり、環境対応の要求が高くなっている。特に、自動車では電子化の動きにより電子部品の採用数は増える一方であり、壊れることのない部品が求められている。従って、コイル部品においても、導線と端子との接合部に高い信頼性が求められている。従来の端子の接合方法としては、例えば、下記特許文献１に示す方法がある。前記特許文献１によれば、端子の挟み部によって絶縁樹脂でできたベースの上下面を挟み込むことにより、挟み部と一体成形された端子の絡げ部をベース上に位置させ、前記ベースの上面にドラム型コアを固着した後、ドラム型コアに巻線を巻き、この巻線のリード部を前記端子の絡げ部に巻き付けた後、リード部と絡げ部とを半田付けしている。 The applications of parts are expanding, and the demand for environmental friendliness is increasing. In particular, in automobiles, the number of electronic parts used is increasing due to the movement toward computerization, and there is a demand for parts that do not break. Therefore, even in coil parts, high reliability is required at the joint between the conducting wire and the terminal. As a conventional method for joining terminals, for example, there is a method shown in Patent Document 1 below. According to Patent Document 1, by sandwiching the upper and lower surfaces of the base made of insulating resin by the pinching portions of the terminals, the entwined portion of the terminals integrally molded with the sandwiching portion is positioned on the base, and the upper surface of the base is formed. After fixing the drum type core to the drum type core, a winding is wound around the drum type core, the lead portion of the winding is wound around the entwined portion of the terminal, and then the lead portion and the entwined portion are soldered.

特開２０００−０２１６５１号公報Japanese Unexamined Patent Publication No. 2000-021651

しかしながら、上述した背景技術の方法では、巻線の径が太くなるほど、巻線に用いられる被膜付の導線の腰の強さが増し、絡げ部に巻き付けることが容易ではなくなる。そして、巻き付けができても、絡げ部との間に隙間を生じてしまい、大きなスペースを要することや密着性が低下するといった、部品の小型化や接続の安定性の点で課題があり、使える被膜付き導線の太さなどの制約となっていた。このように、従来の方法では、太い導線を用いること、更に、その場合に接合部の高い信頼性を得ることが難しかった。 However, in the method of the background technique described above, as the diameter of the winding increases, the strength of the waist of the coated conductor used for the winding increases, and it becomes difficult to wind the winding around the entwined portion. And even if it can be wound, there are problems in terms of miniaturization of parts and stability of connection, such as creating a gap between the entwined part, requiring a large space and reducing the adhesion. There were restrictions such as the thickness of the coated conductor that could be used. As described above, in the conventional method, it is difficult to use a thick conductor and to obtain high reliability of the joint in that case.

本発明は、以上のような点に着目したもので、導線の太さがかかわらず、巻線と端子の接合部の信頼性を高く維持しながら、小型部品にも使用できるコイル部品の製造方法を提供することを、その目的とする。 The present invention focuses on the above points, and is a method for manufacturing a coil component that can be used for small components while maintaining high reliability of the joint between the winding and the terminal regardless of the thickness of the conducting wire. The purpose is to provide.

本発明は、外周に被膜を有する導線を巻回して形成される巻線部と、前記巻線部より外側に引き出され、前記被膜を有する導線と被膜の無い導線により連続的に形成される引出部と、前記引出部より外側に位置し、前記被膜の無い導線の端部に位置する接合部と、該接合部により前記引出部と電気的に導通する端子電極と、を有するコイル部品の製造方法であって、前記端子電極と接続する位置の導線の側面全周の被膜を取り除くことで、端部の被膜が剥離された導線を準備するステップと、前記端部の被膜が剥離された導線を、端子電極となる金属板の接続部に置くステップと、前記金属板の固定部を折り曲げ加工し、金属板上の接続部と固定部との間に前記導線の引出部を挟むステップと、前記導線の端部と固定部の一部に、接合用レーザを接続部側から導線側に向かう方向へ、かつ照射範囲に被膜がある導線部分が入らないように照射して前記接合部を形成するステップとを含み、前記接合部には、空隙を含むことがあり、その空隙の割合は、前記導線の引出部の中央を通り、かつ、前記導線の引出方向と平行な面における接合部の面積に対して、３０％以下であることを特徴とする。 In the present invention, a winding portion formed by winding a conductor having a coating on the outer periphery and a lead drawn outward from the winding portion and continuously formed by the conducting wire having the coating and the conducting wire without the coating. Manufacture of a coil component having a portion, a joint portion located outside the lead portion and located at the end of the uncoated conductor, and a terminal electrode electrically conductive to the lead portion by the joint portion. This is a method of preparing a conductor whose end coating has been peeled off by removing the coating on the entire side surface of the conductor at a position where it is connected to the terminal electrode, and a lead wire whose end coating has been peeled off. In a step of placing the conductor on a connecting portion of a metal plate to be a terminal electrode, and a step of bending the fixing portion of the metal plate and sandwiching a lead-out portion of the conducting wire between the connecting portion and the fixing portion on the metal plate. The joint is formed by irradiating the end of the conductor and a part of the fixed portion with a bonding laser in the direction from the connection side to the conductor side so that the conductor portion having a coating in the irradiation range does not enter. look including the step of, in the joint, it may contain voids, percentage of the voids through the center of the lead-out portion of the wire, and bonded in a plane parallel to the drawing direction of the wire portion It is characterized in that it is 30% or less with respect to the area of.

主要な形態の一つは、前記接合部を、前記導線の被膜端部と接することなく、被膜と離れた位置で形成することを特徴とする。あるいは、前記接合部を、前記導線と前記接続部の一部から形成し、引出部から接合部に向って断面寸法が大きくなるように形成することを特徴とする。 One of the main forms is characterized in that the joint is formed at a position away from the coating without being in contact with the coating end of the conductor. Alternatively, the joint portion is formed from the lead wire and a part of the connection portion, and is formed so that the cross-sectional dimension increases from the drawer portion toward the joint portion.

本発明の前記及び他の目的，特徴，利点は、以下の詳細な説明及び添付図面から明瞭になろう。

The above and other objects, features and advantages of the present invention will be clarified from the following detailed description and accompanying drawings.

本発明によれば、接合部が前記被膜の炭化物の影響を受けることなく、接合強度を得ることができる。また強度が得られる分、前記接合部の長さを短くでき、小型部品に用いることも可能となる。


According to the present invention, the joint strength can be obtained without the joint portion being affected by the carbides of the coating film. In addition, the length of the joint can be shortened as much as the strength is obtained, and it can be used for small parts.

本発明の実施例のコイル部品を示す図であり、(A)は外観斜視図，(B)は前記(A)の接合部を示す平面図，(C)は前記(B)を＃Ａ−＃Ａ線に沿って切断し矢印方向に見た断面図である。It is a figure which shows the coil part of the Example of this invention, (A) is an external perspective view, (B) is a plan view which shows the joint part of (A), (C) is said | It is a cross-sectional view cut along the #A line and viewed in the direction of the arrow. 前記実施例１を示す図であり、(A-1)はドラムコアの平面図，(A-2)はドラムコアの側面図，(B-1)はリングコアの平面図，(B-2)はリングコアの側面図，(C-1)は樹脂ベースの表面側から見た斜視図，(C-2)は樹脂ベースの裏面側を示す平面図である。It is a figure which shows the said Example 1, (A-1) is a plan view of a drum core, (A-2) is a side view of a drum core, (B-1) is a plan view of a ring core, and (B-2) is a ring core. (C-1) is a perspective view seen from the front surface side of the resin base, and (C-2) is a plan view showing the back surface side of the resin base. 前記実施例のコイル部品の製造手順を示す図である。It is a figure which shows the manufacturing procedure of the coil part of the said Example. 前記実施例のコイル部品の製造手順を示す図である。It is a figure which shows the manufacturing procedure of the coil part of the said Example. 導線端部と端子の接合部における被膜剥離の長さ，接合用のレーザ照射範囲及び接合部の長さを示す平面図である。It is a top view which shows the length of the coating peeling at the joint part of a conductor end part and a terminal part, the laser irradiation range for joining, and the length of a joint part.

以下、本発明を実施するための最良の形態を、実施例に基づいて詳細に説明する。 Hereinafter, the best mode for carrying out the present invention will be described in detail based on examples.

最初に、図１〜図５を参照しながら本発明の実施例を説明する。本発明は、導線の外周を覆う被膜を有する被膜付き導線を用い、被膜付き導線をコアに巻回し、被膜付き導線の端部を端子電極に接合する接合部を有するコイル部品である。図１(A)は、被膜付き導線を巻回されるドラムコアと、被膜付き導線を巻回したドラムコアを貫通孔に収納するリングコアと、更に２つのコアの接着と端子電極を固定する樹脂ベースから構成されるコイル部品である。図１(A)は外観斜視図，図１(B)は(A)の接合部を示す平面図，図１(C)は(B)を＃Ａ−＃Ａ線に沿って切断し矢印方向に見た断面図である。図２(A-1)は、本実施例のドラムコアの平面図，図２(A-2)はドラムコアの側面図，図２(B-1)は本実施例のリングコアの平面図，図２(B-2)はリングコアを矢印Ｆ２方向から見た側面図，図２(C-1)は樹脂ベースを表面側から見た斜視図，図２(C-2)は樹脂ベース裏面側を示す平面図である。図３及び図４は、本実施例のコイル部品の製造手順を示す図，図５は、導線端部と端子の接合部における被膜剥離の長さ，接合時のレーザ照射範囲及び接合部の長さを示す平面図である。 First, an embodiment of the present invention will be described with reference to FIGS. 1 to 5. The present invention is a coil component having a coated conductor having a coating covering the outer periphery of the conducting wire, winding the coated conducting wire around a core, and joining the end of the coated conducting wire to a terminal electrode. FIG. 1A shows a drum core around which a coated conductor is wound, a ring core for accommodating a drum core around which a coated conductor is wound in a through hole, and a resin base for adhering two cores and fixing terminal electrodes. It is a coil component that is composed. FIG. 1 (A) is an external perspective view, FIG. 1 (B) is a plan view showing the joint portion of (A), and FIG. It is a cross-sectional view seen in. FIG. 2 (A-1) is a plan view of the drum core of this embodiment, FIG. 2 (A-2) is a side view of the drum core, and FIG. 2 (B-1) is a plan view of the ring core of this embodiment. (B-2) is a side view of the ring core viewed from the direction of arrow F2, FIG. 2 (C-1) is a perspective view of the resin base viewed from the front surface side, and FIG. 2 (C-2) is a back surface view of the resin base. It is a plan view. 3 and 4 are views showing the manufacturing procedure of the coil component of this embodiment, and FIG. 5 shows the length of coating peeling at the joint between the conductor end and the terminal, the laser irradiation range at the time of joining, and the length of the joint. It is a top view which shows.

図１(A)及び図３に示すように、本実施例のコイル部品１０は、ドラムコア２０が、リングコア３０の貫通孔３２に収納されており、これらの間、すなわち、ドラムコア２０の鍔部の外周と、リングコア２０の貫通孔３２の内周の間のギャップＧに、２種類の固定部６０Ａ，６０Ｂ，６２Ａ，６２Ｂが設けられた構造となっている。また、ドラムコア２０の他方の鍔部２６と接着される樹脂ベース７０には、ドラムコア２０に巻回する巻線４０から引き出された端部と接続する端子電極５０Ａ，５０Ｂが設けられている。 As shown in FIGS. 1A and 3, in the coil component 10 of this embodiment, the drum core 20 is housed in the through hole 32 of the ring core 30, and between them, that is, the flange portion of the drum core 20. The structure is such that two types of fixing portions 60A, 60B, 62A, and 62B are provided in the gap G between the outer circumference and the inner circumference of the through hole 32 of the ring core 20. Further, the resin base 70 to be adhered to the other flange portion 26 of the drum core 20 is provided with terminal electrodes 50A and 50B connected to the end portion drawn from the winding 40 wound around the drum core 20.

図４(C)に概略を示すように、第２の固定部６０Ａ，６０Ｂは、ドラムコア２０の鍔部２４の中心Ｃを挟んで対向するように２箇所に設けられている。そして、第２の固定部６０Ａ，６０Ｂを設けた部分を覆うように、図４(D)に示すように、第１の固定部６２Ａ，６２Ｂが弧状に設けられている。第１の固定部６２Ａ，６２Ｂは、第２の固定部６０Ａ，６０Ｂの外側を覆っていればよく、例えば、全周にリング状に設けてもよい。本実施例では、第２の固定部の硬度が、第１の固定部の硬度より高いものを用いている。 As outlined in FIG. 4C, the second fixing portions 60A and 60B are provided at two locations so as to face each other with the center C of the flange portion 24 of the drum core 20 interposed therebetween. Then, as shown in FIG. 4D, the first fixing portions 62A and 62B are provided in an arc shape so as to cover the portions where the second fixing portions 60A and 60B are provided. The first fixing portions 62A and 62B may cover the outside of the second fixing portions 60A and 60B, and may be provided in a ring shape on the entire circumference, for example. In this embodiment, the hardness of the second fixed portion is higher than the hardness of the first fixed portion.

次に、コイル部品１０を構成する各部について、詳細に説明する。図２(A-1)及び(A-2)に示すように、コアの一部を構成するドラムコア２０は、巻線４０が巻回される巻軸２２の両端に、一対の鍔部２４，２６を備えている。本実施例では、巻軸２２及び鍔部２４，２６は、巻軸２２の軸方向と直交する断面形状が、略円形となっている。鍔部２４，２６の表面中央部には、凹部２５，２７が設けられている。巻線４０は、導線４２の外周を絶縁性の被膜４４で覆ったものである。導線４２としては例えば、Ｃｕが用いられ、被膜４４としては、耐熱温度が１２５℃〜１８０℃程度の樹脂製のものが用いられる。 Next, each part constituting the coil component 10 will be described in detail. As shown in FIGS. 2 (A-1) and 2 (A-2), the drum core 20 forming a part of the core has a pair of collars 24 at both ends of the winding shaft 22 around which the winding 40 is wound. It has 26. In this embodiment, the winding shaft 22 and the flange portions 24, 26 have a substantially circular cross-sectional shape orthogonal to the axial direction of the winding shaft 22. Recesses 25 and 27 are provided in the central portion of the surface of the flange portions 24 and 26. The winding 40 is formed by covering the outer circumference of the conducting wire 42 with an insulating coating 44. For example, Cu is used as the conducting wire 42, and as the coating film 44, one made of resin having a heat resistant temperature of about 125 ° C. to 180 ° C. is used.

リングコア３０は、図２(B-1)及び(B-2)に示すように、断面略円形の貫通孔３２を有する中空体であって、本実施例では、外形形状が略円形となっている。すなわち、リングコア３０は、上面３０Ａ，底面３０Ｂ，外周面３０Ｃからなる略円筒状である。リングコア３０の内周の寸法はドラムコア２０の外周の寸法より大きく、貫通孔３２にギャップＧを伴って、ドラムコア２０が収納される。リングコア３０の底面３０Ｂ側には、ドラムコア２０に巻回した巻線４０から導線４２を引き出すための溝３８Ａ，３８Ｂが形成されている。また、リングコア３０の上面３０Ａ側には、第１の固定部６２Ａ，６２Ｂとなる接着剤の厚みを増すための溝３６Ａ，３６Ｂが形成されている。 As shown in FIGS. 2 (B-1) and 2 (B-2), the ring core 30 is a hollow body having a through hole 32 having a substantially circular cross section, and in this embodiment, the outer shape is substantially circular. There is. That is, the ring core 30 has a substantially cylindrical shape including an upper surface 30A, a lower surface 30B, and an outer peripheral surface 30C. The inner circumference of the ring core 30 is larger than the outer circumference of the drum core 20, and the drum core 20 is housed in the through hole 32 with a gap G. Grooves 38A and 38B for pulling out the conducting wire 42 from the winding 40 wound around the drum core 20 are formed on the bottom surface 30B side of the ring core 30. Further, on the upper surface 30A side of the ring core 30, grooves 36A and 36B for increasing the thickness of the adhesive serving as the first fixing portions 62A and 62B are formed.

次に、樹脂ベース７０について説明する。樹脂ベース７０は、ドラムコア２０の一方の鍔部（本実施例では、鍔部２６）を装着するとともに、巻線４０の導線４２と電気的に導通する一対の板状の金属である端子電極５０Ａ，５０Ｂが設けられたものである。樹脂ベース７０は、図２(C-1)及び(C-2)に示すように、上面７０Ａと底面７０Ｂ間に所定の厚みを有し、側面７２Ａ〜７２Ｄを有する正方形の板状体の対角する角を２箇所切り落とした形状となっている。図示の例では、側面７２Ａと側面７２Ｂの間に側面７４Ａを形成し、側面７２Ｃと側面７２Ｄの間に側面７４Ｂを形成している。端子電極５０Ａ，５０Ｂは、コアの接着面と反対の実装面側に配置されている。端子電極５０Ａ，５０Ｂは、例えば、Ｎｉ／Ｓｎめっきを施した０．１５ｍｍ厚みのＣｕ板により形成される。Ｎｉ／Ｓｎめっきは、完成品として回路に実装される基板側のみに施すとしても良い。 Next, the resin base 70 will be described. The resin base 70 is equipped with one flange portion (flange portion 26 in this embodiment) of the drum core 20, and is a pair of plate-shaped metal terminal electrodes 50A that are electrically conductive with the lead wire 42 of the winding 40. , 50B is provided. As shown in FIGS. 2 (C-1) and 2 (C-2), the resin base 70 is a pair of square plate-like bodies having a predetermined thickness between the upper surface 70A and the bottom surface 70B and having side surfaces 72A to 72D. It has a shape with two corners cut off. In the illustrated example, the side surface 74A is formed between the side surface 72A and the side surface 72B, and the side surface 74B is formed between the side surface 72C and the side surface 72D. The terminal electrodes 50A and 50B are arranged on the mounting surface side opposite to the adhesive surface of the core. The terminal electrodes 50A and 50B are formed of, for example, a 0.15 mm thick Cu plate plated with Ni / Sn. Ni / Sn plating may be applied only to the substrate side mounted on the circuit as a finished product.

側面７４Ａ，７４Ｂからは、接合用の接続部５２Ａ，５２Ｂが引き出されている。該接続部５２Ａ，５２Ｂは、樹脂ベース７０内において、端子電極５０Ａ，５０Ｂの一部とそれぞれ一体化されたものであり、電気的につながっている。すなわち、樹脂ベース７０の一部を面取りして側面７４Ａ，７４Ｂを設けることによって、接合用のスペースが形成されている。接続部５２Ａ，５２Ｂの先端には、図２(C-1)及び(C-2)に示すように、接続部５２Ａ，５２Ｂの延長方向と直交するＬ字形の固定部５４Ａ，５４Ｂが一体のものとして設けられている。固定部５４Ａ，５４Ｂは、図３(D)及び(E)に示すように、巻線４０の引出部４６Ａ，４６Ｂを、接続部５２Ａ，５２Ｂとの間に挟むように折り返される。固定部５４Ａ，５４Ｂは、折り曲げやすいように、接続部５２Ａ，５２Ｂの半分程度の幅に形成されている。また、樹脂ベース７０の上面７０Ａには、中央に突起７６が設けられ、ドラムコア３０の鍔部２６の凹部２７を位置合わせして取り付けられている。 Connecting portions 52A and 52B for joining are pulled out from the side surfaces 74A and 74B. The connecting portions 52A and 52B are integrated with a part of the terminal electrodes 50A and 50B in the resin base 70, respectively, and are electrically connected to each other. That is, a space for joining is formed by chamfering a part of the resin base 70 to provide the side surfaces 74A and 74B. As shown in FIGS. 2 (C-1) and 2 (C-2), L-shaped fixing portions 54A and 54B orthogonal to the extension direction of the connecting portions 52A and 52B are integrated with the tips of the connecting portions 52A and 52B. It is provided as a thing. As shown in FIGS. 3D and 3E, the fixing portions 54A and 54B are folded back so as to sandwich the drawing portions 46A and 46B of the winding 40 with the connecting portions 52A and 52B. The fixing portions 54A and 54B are formed to have a width of about half that of the connecting portions 52A and 52B so that they can be easily bent. Further, a protrusion 76 is provided in the center of the upper surface 70A of the resin base 70, and the recess 27 of the flange portion 26 of the drum core 30 is aligned and attached.

接続部５２Ａ，５２Ｂ上に巻線４０の端部を引き出し、引出部４６Ａ，４６Ｂを固定部５４Ａ，５４Ｂと挟む。接続部５２Ａ，５２Ｂは、用いる導線４２の太さより幅が広く、約３倍以内とする。このような範囲とし、被膜端部４５より外側のみ、これらをレーザで溶融させることにより接合部５６Ａ，５６Ｂが形成され、巻線４０の導線端部４７Ａ，４７Ｂが、端子電極５０Ａ，５０Ｂの接続部５２Ａ，５２に接続される。すなわち、導線端部４７Ａ，４７Ｂが、端子電極５０Ａ，５０Ｂと電気的に接続される。接合部５６Ａ，５６Ｂは、図１(C)に示すように、空隙（ないし気泡）５８を含んでいる。空隙５８は、巻線４０の引出部４６Ｂの中央を通り、かつ、導線４２の引出部４６Ｂと平行な面（図１(C)に＃Ｂ−＃Ｂで示す断面）における接合部５６Ｂの面積に対して、１０％以下である。 The end of the winding 40 is pulled out on the connecting portions 52A and 52B, and the drawer portions 46A and 46B are sandwiched between the fixing portions 54A and 54B. The width of the connecting portions 52A and 52B is wider than the thickness of the conducting wire 42 to be used, and is within about 3 times. In such a range, joints 56A and 56B are formed by melting them with a laser only outside the coating end 45, and the conductor ends 47A and 47B of the winding 40 connect the terminal electrodes 50A and 50B. It is connected to units 52A and 52. That is, the conductor end portions 47A and 47B are electrically connected to the terminal electrodes 50A and 50B. The joints 56A and 56B include voids (or bubbles) 58, as shown in FIG. 1 (C). The gap 58 passes through the center of the lead-out portion 46B of the winding 40, and the area of the joint portion 56B on the plane parallel to the lead-out portion 46B of the conducting wire 42 (cross section shown by # B- # B in FIG. 1 (C)). It is 10% or less with respect to.

次に、図３〜図５も参照して、本実施例のコイル部品１０の製造方法の一例を説明する。まず、図３(A)に示すように、上述したドラムコア２０とリングコア３０と樹脂ベース７０を準備する。上述したように、樹脂ベース７０には、あらかじめ電極板が埋め込まれ、実装面側に端子電極５０Ａ，５０Ｂが露出し、側面７４Ａ，７４Ｂから接続部５２Ａ，５２Ｂが引き出されている。次に、図３(B)に示すように、ドラムコア２０の巻軸２２に、巻線４０を、例えば、被膜４４を持つ断面が円形である丸線を用い、一方側から巻軸２２に沿って導線を重ねるようにして巻回する。巻線４０は、巻軸２２の周りに巻回し、巻軸２２から外側に向かい、ドラムコア２０より外側に両引出部４６Ａ，４６Ｂを引き出す。該引出部４６Ａ，４６Ｂは、図３(B)に示すように、端子電極５０Ａ，５Ｂとの接続位置に合うようにフォーミングする。 Next, an example of the manufacturing method of the coil component 10 of this embodiment will be described with reference to FIGS. 3 to 5. First, as shown in FIG. 3A, the drum core 20, the ring core 30, and the resin base 70 described above are prepared. As described above, the electrode plate is embedded in the resin base 70 in advance, the terminal electrodes 50A and 50B are exposed on the mounting surface side, and the connecting portions 52A and 52B are pulled out from the side surfaces 74A and 74B. Next, as shown in FIG. 3B, a winding 40 is used for the winding shaft 22 of the drum core 20, for example, a round wire having a coating 44 and a circular cross section is used, and the winding shaft 22 is aligned from one side. And wind it so that the conductors overlap. The winding 40 is wound around the winding shaft 22, goes outward from the winding shaft 22, and pulls out both drawer portions 46A and 46B to the outside of the drum core 20. As shown in FIG. 3B, the drawer portions 46A and 46B are formed so as to match the connection positions with the terminal electrodes 50A and 5B.

ここでは、両引出部４６Ａ，４６Ｂは、ドラムコア２０の一方の鍔部２６の内側に沿うように高さを揃え、ドラムコア３０から、周方向外側に向けて、それぞれに導線端部４７Ａ，４７Ｂ（引出部４６Ａ，４６Ｂ）が反対方向に向かうようにフォーミングしている。すなわち、一方の導線端部４７Ａ側から他方の導線端部４７Ｂ側を見ると、これらの導線端部４７Ａ，４７Ｂ（及び引出部４６Ａ，４６Ｂ）がほぼ一直線上にある。このように、引出部４６Ａ，４６Ｂが一直線上にあると、次工程以降の被膜剥離を精度よくでき、接合の安定性も良くなる。 Here, both the drawer portions 46A and 46B have the same height along the inside of one flange portion 26 of the drum core 20, and the conductor end portions 47A and 47B (lead wire ends 47A and 47B, respectively, from the drum core 30 toward the outside in the circumferential direction). The drawer portions 46A and 46B) are formed so as to face in opposite directions. That is, when the other conductor end portion 47B side is viewed from the one conductor end portion 47A side, these conductor end portions 47A, 47B (and the lead wire ends 46A, 46B) are substantially in a straight line. As described above, when the drawer portions 46A and 46B are in a straight line, the coating film can be peeled off accurately in the next and subsequent steps, and the joining stability is also improved.

次に、図３(C)に示すように、巻線４０の引き出された引出部４６Ａ，４６Ｂから、端子電極５０Ａ，５０Ｂと接続する位置の被膜４４を剥離する。被膜剥離は、例えば、グリーンレーザを巻線４０の引出部４６Ａ，４６Ｂの端部を含むように、引出部４６Ａ，４６Ｂの側面方向から照射したのち、巻線したドラムコア２０を１８０度反転して再度照射を行う。このように、一方の側面側と１８０度反転した側面側の２方向からグリーンレーザを照射することになり、この部分の引出部４６Ａ，４６Ｂの側面全周の被膜４４はほぼ残らず取り除くことができる。ここでのグリーンレーザは、被膜４４を昇華させるようにエネルギー調整を行うことで、被膜４４の炭化などを起こすことなく、寸法精度良く剥離することができる。このとき、剥離後の被膜４４の端部４５が、後の接合時に用いるレーザの照射範囲に含まれないように、図５(A)に示すように、導線４２の端部４７Ｂから剥離する距離ＬＡを決めて行う。このように、１８０度角度の異なる２方向からレーザ照射を行うことで、巻線の引出部４６Ａ，４６Ｂの端部側の導線４２のほぼ全周の被膜４４を取ることができる。 Next, as shown in FIG. 3C, the coating 44 at the position where the winding 40 is connected to the terminal electrodes 50A and 50B is peeled off from the drawn out portions 46A and 46B of the winding 40. In the coating peeling, for example, the green laser is irradiated from the side surface direction of the drawers 46A and 46B so as to include the ends of the drawers 46A and 46B of the winding 40, and then the wound drum core 20 is inverted 180 degrees. Irradiate again. In this way, the green laser is irradiated from two directions, one side surface side and the side surface side inverted 180 degrees, and the coating 44 on the entire side surface of the drawer portions 46A and 46B in this portion can be removed almost completely. can. The green laser here can be peeled off with high dimensional accuracy without causing carbonization of the coating film 44 by adjusting the energy so as to sublimate the coating film 44. At this time, as shown in FIG. 5A, the distance from the end portion 47B of the conducting wire 42 so that the end portion 45 of the coating film 44 after peeling is not included in the irradiation range of the laser used at the time of later joining. LA is decided and done. By irradiating the laser from two directions having different angles of 180 degrees in this way, it is possible to remove the coating 44 on substantially the entire circumference of the conductor 42 on the end side of the lead-out portions 46A and 46B of the winding.

以上のようにして巻線４０が巻回され、引出部４６Ａ，４６Ｂから被膜４４が剥離されたドラムコア２０を、図３(D)に示すように、鍔部２６の表面２６Ａが樹脂ベース７０の上面７０Ａ側を向くように置く。鍔部２６の表面２６Ａと樹脂ベース７０の上面７０Ａの間には、熱硬化性接着剤を塗布しておく。このとき、上面７０Ａの中央部の突起７６と、鍔部２６の中央の凹部２７の位置を合わせるとともに、巻線４０の引出部４６Ａ，４６Ｂと、樹脂ベース７０の接合用の接続部５２Ａ，５２Ｂの位置が合うようにする（図３(D)及び図５(A)）。そして、樹脂ベース７０上にドラムコア２０を置いたら、ドラムコア２０に加重を掛けながら硬化させる。 As shown in FIG. 3D, the surface 26A of the flange portion 26 of the drum core 20 in which the winding 40 is wound and the coating 44 is peeled off from the drawer portions 46A and 46B is the resin base 70. Place it so that the upper surface 70A side faces. A thermosetting adhesive is applied between the surface 26A of the collar portion 26 and the upper surface 70A of the resin base 70. At this time, the protrusion 76 at the center of the upper surface 70A and the recess 27 at the center of the collar 26 are aligned, and the connecting portions 52A and 52B for joining the drawer portions 46A and 46B of the winding 40 and the resin base 70. (Fig. 3 (D) and Fig. 5 (A)). Then, when the drum core 20 is placed on the resin base 70, the drum core 20 is cured while being weighted.

続いて、図３(E)及び図５(B)に示すように、固定部５４Ａ，５４Ｂを折り曲げ加工し、該固定部５４Ａ，５４Ｂと接続部５２Ａ，５２Ｂとの間に、巻線４０の引出部４６Ａ，４６Ｂを挟む。そして、導線端部４７Ａ，４７Ｂと固定部５４Ａ，５４Ｂの一部に接合用のレーザを照射して接合部５６Ａ，５６Ｂを形成することにより、導線４２と接続部５２Ａ，５２Ｂが接合し、導線４２と端子電極５０Ａ，５０Ｂの電気的な接続を行う。レーザは、例えば、ＹＡＧレーザを用い、接続部５２Ａ，５２Ｂから導線４２に向ってから照射する。図４(A)では、背面方向からＹＡＧレーザを照射することになる。特に、太い導線を用いる場合は、ＹＡＧレーザのエネルギーを高くする必要があるが、このような場合でも背面方向からの照射を行うことで、巻線４０や引出部４６Ａ，４６ＢなどにＹＡＧレーザの反射の影響を受けなくすることができる。 Subsequently, as shown in FIGS. 3 (E) and 5 (B), the fixing portions 54A and 54B are bent, and the winding 40 is formed between the fixing portions 54A and 54B and the connecting portions 52A and 52B. The drawer portions 46A and 46B are sandwiched. Then, by irradiating a part of the conductor end portions 47A and 47B and the fixed portions 54A and 54B with a laser for joining to form the joining portions 56A and 56B, the conducting wire 42 and the connecting portions 52A and 52B are joined and the conducting wire is formed. The 42 and the terminal electrodes 50A and 50B are electrically connected. The laser uses, for example, a YAG laser, and irradiates the laser from the connecting portions 52A and 52B toward the conducting wire 42. In FIG. 4A, the YAG laser is irradiated from the back direction. In particular, when using a thick conductor, it is necessary to increase the energy of the YAG laser, but even in such a case, by irradiating from the back direction, the winding 40, the extraction portions 46A, 46B, etc. of the YAG laser It can be made unaffected by reflection.

接合は、図５(B)に示すように、被膜剥離した導線４２の引出部４６Ａ，４６Ｂの端部４７Ａ，４７Ｂと、折り曲げた固定部５４Ａ，５４Ｂの一部が、接合用のレーザ照射範囲ＬＢにおさまるようにする。すなわち、接合用のレーザ照射範囲ＬＢは、被膜４４がない範囲とする。なお、接合用のレーザ照射範囲ＬＢの設定は、ＹＡＧレーザのスポットの中心からの距離ｒ（図５(B)参照）で示される。この照射範囲ＬＢに被膜４４が存在しないことで、被膜４４などが反射することがなくなり、エネルギーを効率よく吸収させることができる。 In the joining, as shown in FIG. 5 (B), the ends 47A and 47B of the lead wires 46A and 46B whose coatings have been peeled off and a part of the bent fixing portions 54A and 54B are in the laser irradiation range for joining. Try to fit in the LB. That is, the laser irradiation range LB for bonding is a range without the coating 44. The setting of the laser irradiation range LB for bonding is indicated by the distance r (see FIG. 5B) from the center of the spot of the YAG laser. Since the coating 44 is not present in the irradiation range LB, the coating 44 and the like are not reflected, and energy can be efficiently absorbed.

なお、被膜剥離の長さは、導線端部４７Ａ，４７Ｂから被膜４４の残っている被膜端部４５までの長さ（図５(A)のＬＡ参照）を指し、ＹＡＧレーザの照射範囲（図５(B)のＬＢ）は、被膜端部４５と接するか、または被膜端部４５と接しない位置に設定し、照射範囲と被膜端部４５との間に距離を取るように行っている。この結果、接合部５６Ａ，５６Ｂは、被膜端部４５と接することなく、被膜と離れた位置で形成される。接合部５６Ａ，５６Ｂの長さ（図５(C)のＬＣ。ただし、接合部５６Ｂ側を図示し、接合部５６Ａ側は省略している。）は、引出部４６Ａ，４６Ｂから導線４２の断面寸法の変化する部分から接合部５６Ａ，５６Ｂの先端までの長さとした。接合部５６Ａ，５６Ｂは、導線４２と接続部５４Ａ，５４Ｂの一部から形成され、引出部４６Ａ，４６Ｂから接合部５６Ａ，５６Ｂに向って断面寸法が大きくなっている。ＹＡＧレーザの照射範囲ＬＢから被膜端部４５までの距離を十分確保することで、接合時の熱による被膜の分解を抑制でき、接合部５６Ａ，５６Ｂの形成に影響することがなくなる。このため、接合部５６Ａ，５６Ｂの大きさを小さくできる。この大きさは、長さとしてみることもでき、長さが短ければ、接合に必要なスペースを小さくでき、小型の部品にも用いることができる。また、本実施例においては、端子電極５０Ａ，５０Ｂから樹脂ベース７０に伝わる熱を低くでき、樹脂部分の変形や劣化を防ぐことになる。更には、導線４２の被膜４４へのダメージが抑えられ、巻線部分のショート不良などを防止できる。なお、本実施例では、被膜端部４５とＹＡＧレーザ照射範囲ＬＢとの間に、−０．５ｍｍの距離をとっているが、これ以上の距離を確保しても効果は同様である。なお、ここでは、被膜端部４５が、ＹＡＧレーザの照射範囲ＬＢに含まれる場合の長さをプラスとしており、含まれない場合はマイナスとしている。従って、マイナスの場合は、被膜端部４５とＹＡＧレーザ照射範囲ＬＢとの間に距離が確保されていることを意味し、ＹＡＧレーザの照射範囲ＬＢと被膜端部４５との距離を被膜端部位置とする。 The length of the film peeling refers to the length from the lead wire ends 47A and 47B to the film end 45 where the film 44 remains (see LA in FIG. 5 (A)), and is the irradiation range of the YAG laser (FIG. LB) of 5 (B) is set at a position where it is in contact with the coating end portion 45 or not in contact with the coating end portion 45, and a distance is provided between the irradiation range and the coating end portion 45. As a result, the joint portions 56A and 56B are formed at positions separated from the coating film without being in contact with the coating film end portion 45. The lengths of the joints 56A and 56B (LC in FIG. 5C. However, the joint 56B side is shown and the joint 56A side is omitted) are the cross sections of the conductors 42 from the drawers 46A and 46B. The length was set from the portion where the dimensions change to the tips of the joints 56A and 56B. The joint portions 56A and 56B are formed of the conducting wire 42 and a part of the connecting portions 54A and 54B, and the cross-sectional dimensions increase from the drawer portions 46A and 46B toward the joint portions 56A and 56B. By ensuring a sufficient distance from the irradiation range LB of the YAG laser to the coating end portion 45, decomposition of the coating film due to heat during bonding can be suppressed, and the formation of the bonding portions 56A and 56B is not affected. Therefore, the size of the joint portions 56A and 56B can be reduced. This size can also be seen as a length, and if the length is short, the space required for joining can be reduced, and it can be used for small parts. Further, in this embodiment, the heat transferred from the terminal electrodes 50A and 50B to the resin base 70 can be reduced, and the resin portion can be prevented from being deformed or deteriorated. Furthermore, damage to the coating 44 of the conducting wire 42 can be suppressed, and short-circuit defects in the winding portion can be prevented. In this embodiment, a distance of −0.5 mm is taken between the coating end portion 45 and the YAG laser irradiation range LB, but the effect is the same even if a distance longer than this is secured. Here, the length when the coating end portion 45 is included in the irradiation range LB of the YAG laser is positive, and when it is not included, it is negative. Therefore, if it is negative, it means that a distance is secured between the coating end portion 45 and the YAG laser irradiation range LB, and the distance between the YAG laser irradiation range LB and the coating end portion 45 is defined as the coating end portion. Position.

このように、ＹＡＧレーザの照射範囲ＬＢに被膜４４が存在しなければ、被膜４４の炭化物の影響を受けることもなく、高い接合強度を得ることができる。そして、必要な強度が得られることで、接合部５６Ａ，５６Ｂ自体の大きさを小さくできる。また、接合部５６Ａ，５６Ｂには、溶解段階で空隙５８を（図１(C)参照）を含むことがあるが、少なくとも被膜４４のガス化の影響は受けることがないため、空隙５８の割合を一定以下に少なくできる。このため、接合部５６Ａ，５６Ｂの大きさを小さくでき、長さとしても短くなる。これらにより、接合部５６Ａ，５６Ｂの長さは小さくしつつ、接合部５６Ａ，５６Ｂの機械的強度を確保することができ、省スペース化につなげることができる。また、本実施例では、導線と端子電極に同じ材質の金属を用いる。これにより、接合時の溶解をほぼ同時に行うことができ、接合部５６Ａ，５６Ｂ以外の周囲の部分への影響を抑えることができる。なお、端子電極については、Ｎｉ／Ｓｎめっきなどを施すこともあるが、この場合でも、Ｎｉ／Ｓｎめっきの接合への影響は小さく、この部分を除いた端子電極が導線と同じ材質であれば、同様に接続することができる。 As described above, if the coating 44 is not present in the irradiation range LB of the YAG laser, high bonding strength can be obtained without being affected by the carbides of the coating 44. Then, by obtaining the required strength, the size of the joint portions 56A and 56B themselves can be reduced. Further, the joint portions 56A and 56B may include voids 58 (see FIG. 1C) at the dissolution stage, but at least they are not affected by gasification of the coating 44, so that the proportion of voids 58 is not affected. Can be reduced below a certain level. Therefore, the size of the joint portions 56A and 56B can be reduced, and the length can be shortened. As a result, the mechanical strength of the joints 56A and 56B can be ensured while reducing the lengths of the joints 56A and 56B, which can lead to space saving. Further, in this embodiment, a metal of the same material is used for the conductor wire and the terminal electrode. As a result, melting at the time of joining can be performed almost at the same time, and the influence on the surrounding parts other than the joining portions 56A and 56B can be suppressed. The terminal electrodes may be plated with Ni / Sn, but even in this case, the effect on the bonding of Ni / Sn plating is small, and the terminal electrodes excluding this part are made of the same material as the conducting wire. , Can be connected in the same way.

以上のようにして接合部５６Ａ，５６Ｂを形成したら（図４(B)）、次に、図４(C)に示すように、リングコア３０の貫通孔３２にドラムコア２０が収納されるように、リングコア３０を樹脂ベース７０上に配置する。リングコア３０と樹脂ベース７０の間には、熱硬化性樹脂を塗布しておく。そして、画像認識により、ドラムコア２０とリングコア３０の位置調整を行う。この状態で、図４(C)に示すように、ドラムコア２０の上面側、すなわち、実装面と反対側（本実施例では、鍔部２４の上面２４Ａ側）からディスペンサを用い、ドラムコア２０の鍔部２４の外周面とリングコア３０の内周面との間にＵＶ接着剤を２点塗布し、ＵＶランプで硬化させる。 After forming the joints 56A and 56B as described above (FIG. 4 (B)), then, as shown in FIG. 4 (C), the drum core 20 is housed in the through hole 32 of the ring core 30. The ring core 30 is arranged on the resin base 70. A thermosetting resin is applied between the ring core 30 and the resin base 70. Then, the positions of the drum core 20 and the ring core 30 are adjusted by image recognition. In this state, as shown in FIG. 4C, a dispenser is used from the upper surface side of the drum core 20, that is, the side opposite to the mounting surface (in this embodiment, the upper surface 24A side of the collar portion 24), and the collar of the drum core 20 is used. Two UV adhesives are applied between the outer peripheral surface of the portion 24 and the inner peripheral surface of the ring core 30, and cured with a UV lamp.

塗布して硬化させたＵＶ接着剤が、第２の固定部６０Ａ，６０Ｂとなる。第２の固定部６０Ａ，６０Ｂは、ドラムコア２０とリングコア３０を位置決めした位置に固定する。そのため、以後の工程間や、環境試験等による位置の変動を抑制できる。また、図示の例では、複数（２箇所)配置し、ドラムコア２０の中心Ｃに対して対抗した位置にあるため、リングコア３０に掛かる応力も均等になる。 The UV adhesive applied and cured becomes the second fixing portions 60A and 60B. The second fixing portions 60A and 60B fix the drum core 20 and the ring core 30 at the positioned positions. Therefore, it is possible to suppress the fluctuation of the position between the subsequent processes and due to the environmental test and the like. Further, in the illustrated example, since a plurality of (two places) are arranged and are located at positions opposite to the center C of the drum core 20, the stress applied to the ring core 30 is also equal.

最後に、図４(D)に示すように、ドラムコア２０とリングコア３０間のギャップＧに、第２の固定部６０Ａ，６０Ｂの上面（外側）を覆うように、熱硬化性接着剤をディスペンサを用いて塗布し、１５０℃で硬化させる。硬化後の熱硬化性接着剤は、第１の固定部６２Ａ，６２Ｂとなる。また、この熱硬化工程により、ドラムコア２０及びリングコア３０と樹脂ベース７０の間に塗布された熱硬化性接着剤も硬化し、ドラムコア２０及びリングコア３０と、樹脂ベース７０が接着される。 Finally, as shown in FIG. 4 (D), a thermosetting adhesive is dispensed into the gap G between the drum core 20 and the ring core 30 so as to cover the upper surface (outside) of the second fixing portions 60A and 60B. Apply using and cure at 150 ° C. The thermosetting adhesive after curing becomes the first fixing portions 62A and 62B. Further, by this thermosetting step, the thermosetting adhesive applied between the drum core 20 and the ring core 30 and the resin base 70 is also cured, and the drum core 20 and the ring core 30 and the resin base 70 are adhered to each other.

このように、第１の固定部６２Ａ，６２Ｂが、第２の固定部６０Ａ，６０Ｂを覆うことで、第２の固定部６０Ａ，６０Ｂとは重ならず、ドラムコア２０の外周面と接する部分では、第１の固定部６２Ａ，６２Ｂの高さ方向の厚みを確保できる。また、第１の固定部６２Ａ，６２Ｂとドラムコア２０の外周面と接する部分の長さを長くとることで、この厚みを確保した部分を長くでき、剥離などの欠陥を抑制できる。このため、第１の固定部６２とドラムコア２０の外周面と接触している部分の長さの割合が、ドラムコア２０の外周面の長さに対して６０％以上存在しているほうがよい。 In this way, the first fixing portions 62A and 62B cover the second fixing portions 60A and 60B so that they do not overlap with the second fixing portions 60A and 60B and are in contact with the outer peripheral surface of the drum core 20. , The thickness of the first fixing portions 62A and 62B in the height direction can be secured. Further, by increasing the length of the portion in contact between the first fixing portions 62A and 62B and the outer peripheral surface of the drum core 20, the portion having this thickness can be lengthened, and defects such as peeling can be suppressed. Therefore, it is preferable that the ratio of the length of the portion in contact between the first fixing portion 62 and the outer peripheral surface of the drum core 20 is 60% or more with respect to the length of the outer peripheral surface of the drum core 20.

なお、第１の固定部６２Ａ，６２Ｂと第２の固定部６０Ａ，６０Ｂの重なっている部分については、第２の固定部６０Ａ，６０Ｂとドラムコア２０の外周面と接している部分の長さを、第１の固定部６２とドラムコア２０の外周面と接触している部分の長さに含む。本実施例では２種類の接着剤を用いているが、第２の固定部６０Ａ，６０Ｂとなる接着剤は、硬化後の硬度の高いものを用い、第１の固定部６２Ａ，６２Ｂとなる接着剤（熱硬化性接着剤）としては、硬化後の線膨張係数の低いものを用いる。 Regarding the overlapping portion of the first fixing portions 62A and 62B and the second fixing portions 60A and 60B, the length of the portion in contact between the second fixing portions 60A and 60B and the outer peripheral surface of the drum core 20 is set. , Is included in the length of the portion in contact between the first fixing portion 62 and the outer peripheral surface of the drum core 20. In this embodiment, two types of adhesives are used, but as the adhesives to be the second fixing portions 60A and 60B, those having high hardness after curing are used, and the adhesives to be the first fixing portions 62A and 62B are used. As the agent (thermosetting adhesive), one having a low linear expansion coefficient after curing is used.

＜試作例＞・・・次に、本実施例の試作例について説明する。以下の表１に示す条件で、比較例１，２及び試作例１〜８のコイル部品を製作し、空隙の割合（％）と強度ｍｉｎ値（Ｎ）について確認を行った。コイル部品は１２．５×１２．５×６ｍｍの寸法の巻線型インダクタとし、磁性体であるドラムコア２０及びリングコア３０としては、Ｎｉ−Ｚｎフェライトを用いた。また、巻線４０としては、ポリアミドイミド被膜付きのφ０．４ｍｍの導線を用い（導線自体はＣｕ）、巻数は１０．５とした。 <Prototype example> ... Next, a prototype example of this embodiment will be described. Coil parts of Comparative Examples 1 and 2 and Prototype Examples 1 to 8 were manufactured under the conditions shown in Table 1 below, and the percentage of voids (%) and the strength min value (N) were confirmed. The coil component was a winding inductor having dimensions of 12.5 × 12.5 × 6 mm, and Ni—Zn ferrite was used as the magnetic drum core 20 and ring core 30. As the winding 40, a wire having a diameter of 0.4 mm with a polyamide-imide coating was used (the wire itself is Cu), and the number of turns was 10.5.

また、第２の固定部６０Ａ，６０Ｂには短時間で硬化が可能な接着剤として、硬度としてショアＤの４０から６５であるＵＶ接着剤を用い、第１の固定部６２Ａ，６２Ｂ、および樹脂ベース７０と２つのコアの接着には熱硬化性接着剤を用い、硬度としてショアＤの３０、または４０であるエポキシ樹脂の接着剤を用いた。樹脂ベース７０としては、１５０℃以上の耐熱性のエポキシ樹脂からなる外形寸法（最大部分）１２．５×１２．５ｍｍで厚みが１ｍｍのものを用いた。また、端子電極５０Ａ，５０Ｂとしては、Ｎｉ／Ｓｎめっきが施された厚み０．１５ｍｍのＣｕ板を、樹脂ベース７０に埋め込んだものを用いた。接合に用いる接合用のレーザは、グリーンレーザ（波長５３２ｎｍ）とした。 Further, as the adhesive capable of curing in a short time, UV adhesive having a hardness of 40 to 65 of Shore D is used for the second fixing portions 60A and 60B, and the first fixing portions 62A and 62B and the resin are used. A thermosetting adhesive was used to bond the base 70 and the two cores, and an epoxy resin adhesive having a hardness of 30 or 40 of Shore D was used. As the resin base 70, a resin base 70 having an external dimension (maximum portion) of 12.5 × 12.5 mm and a thickness of 1 mm made of a heat-resistant epoxy resin at 150 ° C. or higher was used. As the terminal electrodes 50A and 50B, a Cu plate having a thickness of 0.15 mm plated with Ni / Sn was embedded in the resin base 70. The laser for bonding used for bonding was a green laser (wavelength 532 nm).

なお、被膜長さは、ＹＡＧレーザの照射範囲ＬＢに含まれる場合の長さをプラス、含まれない場合の長さをマイナスとして、被膜４４の端部４５との位置関係を求める。被膜４４の端部４５は、被膜４４の有無による色の違いにより判断する。また、接合部長さは、引出部４６Ａ，４６Ｂから導線４２の断面寸法の変化する部分から接合部５６Ａ，５６Ｂの先端までの長さとした。接合部５６Ａ，５６Ｂは、引出部４６Ａ，４６Ｂから接合部５６Ａ，５６Ｂに向って断面寸法が大きくなることから容易に判断できる。 As for the film length, the positional relationship with the end portion 45 of the film 44 is determined by setting the length when it is included in the irradiation range LB of the YAG laser as a plus and the length when it is not included as a minus. The end portion 45 of the coating 44 is determined by the difference in color depending on the presence or absence of the coating 44. The length of the joint was set to be the length from the drawers 46A and 46B to the tip of the joint 56A and 56B from the portion where the cross-sectional dimension of the conductor 42 changes. The joint portions 56A and 56B can be easily determined from the fact that the cross-sectional dimensions increase from the drawer portions 46A and 46B toward the joint portions 56A and 56B.

次に、空隙５８は、接合部５６Ａ，５６Ｂを、導線４２の引出部４６Ａ，４６Ｂの中央を通り、かつ、導線４２の引出方向と平行な面のＳＥＭ観察による断面写真を元に画像処理を行い、画像のコントラストの濃淡から、濃い部分を空隙５８とし、淡い部分を空隙５８ではない部分とし、接合部５６Ａ，５６Ｂの断面積に対する空隙５８の割合を求めた。空隙５８の大きさは５０倍の倍率に拡大し、画像処理により面積から円に置き換え、この円の直径に相当する大きさで１０μｍ以上のものを選択し、この面積の合計を空隙５８の面積とした。また、接合部の強度評価は、引出部を接合部から内側方向に引っ張り、接合部の破断する強度を測定した。測定は比較例、試作例ともにｎ＝２０でそれぞれの最小値（ｍｉｎ値）を求めた。なお、内側方向とは、リングコアの側面を外側とし、外側からドラムコアに向って見る方向を指す。 Next, the gap 58 is image-processed based on a cross-sectional photograph of a surface of the joints 56A and 56B passing through the center of the lead wires 46A and 46B and parallel to the lead wire 42 withdrawal direction by SEM observation. From the contrast of the image, the dark portion was defined as the void 58, the light portion was defined as the portion other than the void 58, and the ratio of the void 58 to the cross-sectional area of the joint portions 56A and 56B was determined. The size of the gap 58 is enlarged to a magnification of 50 times, the area is replaced with a circle by image processing, a size corresponding to the diameter of this circle of 10 μm or more is selected, and the total of this area is the area of the gap 58. And said. Further, in the strength evaluation of the joint portion, the pull-out portion was pulled inward from the joint portion, and the breaking strength of the joint portion was measured. In both the comparative example and the prototype example, the minimum value (min value) of each was determined at n = 20. The inward direction refers to a direction in which the side surface of the ring core is the outside and the direction is viewed from the outside toward the drum core.

表１に示した比較例及び試作例の結果から、以下のことが確認された。なお、比較例１と試作例１〜４は線径がφ０．６ｍｍであり、比較例２と試作例５〜８は線径がφ０．２ｍｍであるが、比較例１及び試作例１〜４と、比較例２及び試作例５〜８は、端子の材質と被膜端部位置は対応させた。
比較例１は、φ０．６ｍｍの導線４２を用い、端子電極５０Ａ，５０Ｂとして、導線４２と同じ材質のＣｕを用い、被膜端部位置が０．３ｍｍ（被膜端部４５がＹＡＧレーザ照射範囲ＬＢに含まれる）としたものである。結果をみると、被膜剥離した被膜無し部分が先に溶けて、被膜有りの部分は黒い変色の痕跡が残る。これは、被膜４４の炭化によるものであり、このような部分があると、この部分を切っ掛けに剥離しやすいことで、十分な強度は得られず、これが強度ばらつきが生じる原因となる。このため、強度の最小値を確保するため、結果として、全体としての長さは長くなる。 From the results of the comparative example and the prototype example shown in Table 1, the following was confirmed. Comparative Example 1 and Prototype Examples 1 to 4 have a wire diameter of φ0.6 mm, and Comparative Example 2 and Prototype Examples 5 to 8 have a wire diameter of φ0.2 mm, but Comparative Example 1 and Prototype Examples 1 to 4 have a wire diameter of φ0.2 mm. In Comparative Example 2 and Prototype Examples 5 to 8, the terminal material and the coating end position corresponded to each other.
In Comparative Example 1, a conducting wire 42 having a diameter of 0.6 mm is used, Cu of the same material as the conducting wire 42 is used as the terminal electrodes 50A and 50B, and the coating end portion position is 0.3 mm (the coating end portion 45 is the YAG laser irradiation range LB). Included in). Looking at the results, the part without the film that had peeled off the film melted first, and the part with the film left a trace of black discoloration. This is due to the carbonization of the coating film 44, and if there is such a portion, it is easy to peel off from this portion as a trigger, so that sufficient strength cannot be obtained, which causes variation in strength. Therefore, in order to secure the minimum value of the strength, as a result, the length as a whole becomes long.

試作例１は、φ０．６ｍｍの導線４２を用い、端子電極５０Ａ，５０Ｂとして、導線４２と同じ材質のＣｕを用い、被膜端部位置が０．０ｍｍ（被膜端部４５がＹＡＧレーザ照射範囲に入らないギリギリの位置）としたものである。試作例１によれば、被膜４４の端部４５が接合部５６Ａ，５６Ｂと干渉しない範囲で接合を行うことで、安定した接合が可能となる。このため、接合部の長さを短くでき、それでも十分な強度が得られている。また、接合に必要なパワーを従来より半減することができ、被膜４４へのダメージを抑え、巻線部分への影響はない。 In Prototype Example 1, a conducting wire 42 having a diameter of 0.6 mm is used, Cu of the same material as the conducting wire 42 is used as the terminal electrodes 50A and 50B, and the coating end portion position is 0.0 mm (the coating end portion 45 is in the YAG laser irradiation range). (Position of the last minute that does not enter). According to Prototype Example 1, stable bonding is possible by performing bonding within a range in which the end portion 45 of the coating film 44 does not interfere with the bonding portions 56A and 56B. Therefore, the length of the joint can be shortened, and sufficient strength is still obtained. In addition, the power required for joining can be halved compared to the conventional method, damage to the coating 44 is suppressed, and there is no effect on the winding portion.

試作例２は、φ０．６ｍｍの導線を用い、端子電極５０Ａ，５０Ｂとして、導線４２と同じ材質のＣｕを用い、被膜端部位置が−０．２ｍｍ（被膜端部４５がＹＡＧレーザ照射範囲ＬＢから０．２ｍｍ離れている）としたものである。試作例２によれば、接合部の長さを短くしても安定性がよく、十分な強度が得られている。試作例３は、被膜端部位置が−０．５ｍｍである（被膜端部４５がレーザ照射範囲ＬＢから０．５ｍｍ離れている）ほかは、試作例２と同様である。試作例３によれば、被膜端部４５をＹＡＧレーザ照射範囲ＬＢからさらに離すことにより、空隙５８の割合が減って、接合部の強度を高く維持しつつ、接合部の長さを短くすることができる。なお、−０．２ｍｍと−０．５ｍｍの結果を比較すると、空隙の割合以外には大きな差がないことから、φ０．６ｍｍの導線４２を用いた場合であっても、被膜端部４５は、ＹＡＧレーザ照射範囲ＬＢから０．５ｍｍ離れていれば十分と考えられ、これ以上離しても有効な差は生じないと考えられる。 In Prototype Example 2, a conducting wire having a diameter of 0.6 mm is used, Cu of the same material as the conducting wire 42 is used as the terminal electrodes 50A and 50B, and the coating end portion position is -0.2 mm (the coating end portion 45 is the YAG laser irradiation range LB). It is 0.2 mm away from). According to Prototype Example 2, stability is good even if the length of the joint is shortened, and sufficient strength is obtained. Prototype Example 3 is the same as Prototype Example 2 except that the film end portion position is −0.5 mm (the coating end portion 45 is separated from the laser irradiation range LB by 0.5 mm). According to Prototype Example 3, by further separating the coating end portion 45 from the YAG laser irradiation range LB, the proportion of voids 58 is reduced, the strength of the joint portion is maintained high, and the length of the joint portion is shortened. Can be done. Comparing the results of -0.2 mm and -0.5 mm, there is no big difference other than the ratio of voids. Therefore, even when the wire 42 of φ0.6 mm is used, the coating end portion 45 is , It is considered that a distance of 0.5 mm from the YAG laser irradiation range LB is sufficient, and it is considered that an effective difference does not occur even if the distance is longer than this.

試作例４は、端子電極５０Ａ，５０Ｂとして、導線４２とは異なる材質のリン青銅を用いたものであり、その他は試作例３と同様に作成した。試作例４では、接合部５６Ａ，５６Ｂの形状が不安定になった。これは、リン青銅が先に溶けてしまい、（導線４２はＣｕ）を用い、導線４２が後から溶けるため、わずかであるが接合時のレーザを照射する時間を要することになる。このため、時間を長くかける分、溶融する量が多くなり、試作例３と比べると接合部の長さは長くなる。 In Prototype Example 4, phosphor bronze, which is a material different from that of the conducting wire 42, was used as the terminal electrodes 50A and 50B, and the others were produced in the same manner as in Prototype Example 3. In Prototype Example 4, the shapes of the joints 56A and 56B became unstable. This is because the phosphor bronze melts first, and (the conductor 42 is Cu) is used, and the conductor 42 melts later, so that it takes a little time to irradiate the laser at the time of joining. Therefore, the longer the time is, the larger the amount of melting is, and the length of the joint is longer than that of Prototype Example 3.

比較例２及び試作例５〜８は、導線４２をφ０．２ｍｍにしたほかは、比較例１及び試作例１〜４と同じであり、同様の傾向を示す。なお、細い導線４２の場合には、導線４２も溶けやすくなるため接合に必要なエネルギーは低くてよいことになる。この場合、端子は低いエネルギーで溶けることが望ましく、試作例８に示すように、一つの方法としてリン青銅を用いることで、リン青銅を先に溶かすことができる。これは、細い導線４２では、被膜４４の厚みが薄い場合に用い、熱による被膜ダメージを受けにくくすることにつながる。 Comparative Example 2 and Prototype Examples 5 to 8 are the same as Comparative Example 1 and Prototype Examples 1 to 4 except that the conducting wire 42 is φ0.2 mm, and show the same tendency. In the case of the thin conductor 42, the conductor 42 is also easily melted, so that the energy required for joining may be low. In this case, it is desirable that the terminals are melted with low energy, and as shown in Prototype Example 8, phosphor bronze can be melted first by using phosphor bronze as one method. This is used when the thickness of the coating 44 is thin in the thin conducting wire 42, and it leads to making it difficult to receive coating damage due to heat.

このように、実施例１によれば、次のような効果がある。
(1)被膜付き導線を巻回して形成した巻線部４０と、導線４２の端部にある接合部５６Ａ，５６Ｂと、該接合部５６Ａ，５６Ｂにより導線４２と電気的に接続する端子電極５０Ａ，５０Ｂを有するコイル部品１０において、導線４０の被膜４４と接合部５６Ａ，５６Ｂが接していないため、導通を確実にとることができる。また、強度を得られる分、接合部の長さを短くできるため、省スペース化を図ることも可能である。
(2)接合部５６Ａ，５６Ｂが空隙（ないし気泡）５８を含み、該空隙５８が、導線４２の引出部４６Ａ，４６Ｂの中央を通り、かつ、導線４２の引出方向と平行な面における接合部５６Ａ，５６Ｂの断面積に対して１０％以下とした。このため、空隙５８の存在を抑えることで、強度を高くすることができ、更に接合部の長さを短くすることができる。また、体積を小さくできるため、無駄なスペースを使うことなく、小型の部品にも用いることができる。 As described above, according to the first embodiment, there are the following effects.
(1) A winding portion 40 formed by winding a coated conductor wire, joint portions 56A and 56B at the end of the conductor wire 42, and a terminal electrode 50A electrically connected to the conductor wire 42 by the joint portions 56A and 56B. In the coil component 10 having, 50B, since the coating 44 of the conducting wire 40 and the joints 56A and 56B are not in contact with each other, continuity can be ensured. In addition, since the length of the joint can be shortened as much as the strength can be obtained, it is possible to save space.
(2) The joints 56A and 56B include gaps (or bubbles) 58, and the gaps 58 pass through the center of the lead wires 46A and 46B of the conductor 42 and are parallel to the lead direction of the conductor 42. It was set to 10% or less with respect to the cross-sectional area of 56A and 56B. Therefore, by suppressing the presence of the void 58, the strength can be increased and the length of the joint can be further shortened. Moreover, since the volume can be reduced, it can be used for small parts without wasting space.

(3)導線４２及び端子電極５０Ａ，５０Ｂ（及び接続部５２Ａ，５２Ｂ）に、Ｃｕを用いることで太い導線であっても接続しやすくなる。これは、引出部５２Ａ，５２Ｂと導線５２の接合時のレーザ照射による熱の吸収率、温度変化を同じにすることができ、同じタイミングでそれぞれを溶融させることによるものであり、また形状の安定性にもつながる。
(4)導線４２の被膜４４の耐熱温度を１２５℃〜１８０℃としたので、高温の対応が可能となる。これは、接合部５６Ａ，５６Ｂの熱による被膜４４のダメージを受けにくくし、引出部４６Ａ，４６Ｂおよび巻線４０の絶縁劣化を防止できることによる。 (3) By using Cu for the conductor 42 and the terminal electrodes 50A and 50B (and the connecting portions 52A and 52B), even a thick conductor can be easily connected. This is because the heat absorption rate and temperature change due to laser irradiation at the time of joining the lead wires 52A and 52B and the conductor 52 can be made the same, and each of them is melted at the same timing, and the shape is stable. It also leads to sex.
(4) Since the heat resistant temperature of the coating 44 of the conducting wire 42 is set to 125 ° C. to 180 ° C., it is possible to cope with a high temperature. This is because the coating 44 is less likely to be damaged by the heat of the joints 56A and 56B, and the insulation deterioration of the drawers 46A and 46B and the winding 40 can be prevented.

なお、本発明は、上述した実施例に限定されるものではなく、本発明の要旨を逸脱しない範囲内において種々変更を加え得ることができる。例えば、以下のものも含まれる。
(1)前記実施例で示した形状，寸法は一例であり、必要に応じて適宜変更してよい。例えば、前記実施例では、リングコア３０の外形断面形状を円形としたが、八角形や四角形等であってもよく、また、角に回転しない程度のＲをつけた形状としてもよい。
(2)前記実施例で示した被膜剥離の範囲も一例であり、導線の太さや接合に用いる接合用のレーザの照射範囲や出力に応じて、同様の効果を奏する範囲内で適宜変更可能である。被膜剥離する長さは、被膜４４の端部４５が、その後の導線と端子電極の引出部との接合部と干渉しない位置であればよい。また、このときの接合に用いる接合用のレーザを照射するパワーは、導線にはダメージを与えない範囲で設定すればよい。
(3)前記実施例で示したリングコア３０からの巻線４０の引き出し構造も一例であり、同様の効果を奏する範囲内で適宜設計変更可能である。
(4)前記実施例では、導線４２と端子電極５０を同じ材質で形成することとしたが、これも一例であり、導線の太さによっては、上述した試作例８のように、端子電極として導線より溶けやすい金属を用いてもよい。 The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the gist of the present invention. For example, the following are also included.
(1) The shapes and dimensions shown in the above examples are examples, and may be appropriately changed as necessary. For example, in the above embodiment, the outer cross-sectional shape of the ring core 30 is circular, but it may be an octagon, a quadrangle, or the like, or a shape having an radius that does not rotate at the corner.
(2) The range of film peeling shown in the above embodiment is also an example, and can be appropriately changed within a range that produces the same effect according to the thickness of the conducting wire and the irradiation range and output of the laser for joining used for joining. be. The length at which the coating film is peeled off may be such that the end portion 45 of the coating film 44 does not interfere with the subsequent joint portion between the conducting wire and the protruding portion of the terminal electrode. Further, the power for irradiating the bonding laser used for bonding at this time may be set within a range that does not damage the conducting wire.
(3) The pull-out structure of the winding 40 from the ring core 30 shown in the above embodiment is also an example, and the design can be appropriately changed within a range in which the same effect can be obtained.
(4) In the above embodiment, the conductor 42 and the terminal electrode 50 are made of the same material, but this is also an example, and depending on the thickness of the conductor, as the terminal electrode as in the prototype 8 described above. A metal that is more soluble than the conductor may be used.

(5)前記実施例で示した端子電極５０Ａ，５０Ｂの形状や、樹脂ベース７０を用いた巻線４０の引出部４６Ａ，４６Ｂとの接合形態も一例であり、同様の効果を奏する範囲内で適宜設計変更可能である。
(6)前記実施例では、２つの第２の固定部６０Ａ，６０Ｂを設けることとしたが、これも一例であり、第２の固定部は２つ以上であれば、その数や配置は適宜変更可能である。
(7)前記実施例では示した樹脂ベース７０も一例であり、同様の効果を奏する範囲で、材料や形状等を適宜変更してよい。
(8)前記実施例では、第２の固定部６０Ａ，６０Ｂの上面を完全に覆うように第１の固定部６２Ａ，６２Ｂを設けることとしたが、これも一例であり、必ずしも第２の固定部の全体を覆う必要はなく、一部を覆うような形態であってもよい。少なくとも第２の固定部６０Ａ，６０Ｂは第１の固定部６２Ａ，６２Ｂのいずれかに接していればよい。いずれの形態であっても、第１及び第２の固定部が部品から脱落するようなことがない。 (5) The shapes of the terminal electrodes 50A and 50B shown in the above embodiment and the joining form of the winding 40 using the resin base 70 with the drawer portions 46A and 46B are also examples, and are within the range in which the same effect is obtained. The design can be changed as appropriate.
(6) In the above embodiment, two second fixing portions 60A and 60B are provided, but this is also an example. If there are two or more second fixing portions, the number and arrangement thereof are appropriate. It can be changed.
(7) The resin base 70 shown in the above embodiment is also an example, and the material, shape, and the like may be appropriately changed within the range in which the same effect is obtained.
(8) In the above embodiment, the first fixing portions 62A and 62B are provided so as to completely cover the upper surfaces of the second fixing portions 60A and 60B, but this is also an example and is not necessarily the second fixing. It is not necessary to cover the whole part, and it may be a form that covers a part. At least the second fixing portions 60A and 60B may be in contact with any of the first fixing portions 62A and 62B. In either form, the first and second fixing portions do not fall off from the parts.

本発明によれば、被膜付き導線を巻回した巻線部と、前記導線の引出部の端部に位置する接合部と、該接合部により前記導線と電気的に導通する端子電極と、を有するコイル部品において、前記被膜と前記接合部が離れている。このため、被膜の炭化物の影響を受けることなく、接合強度を得ることができる。また、強度が得られる分、接合部の長さを短くできるため、小型部品向けのコイル部品の用途に適用できる。特に、耐温度や耐衝撃性に優れることから、自動車や産業機械の分野向けのコイル部品の用途として好適である。 According to the present invention, a winding portion around which a coated conductor wire is wound, a joint portion located at an end portion of a lead portion of the conductor wire, and a terminal electrode electrically conductive to the conductor wire by the joint portion are provided. In the coil component to have, the coating film and the joint portion are separated from each other. Therefore, the bonding strength can be obtained without being affected by the carbides of the coating film. In addition, since the length of the joint can be shortened as much as the strength is obtained, it can be applied to the application of coil parts for small parts. In particular, since it is excellent in temperature resistance and impact resistance, it is suitable as an application for coil parts for the fields of automobiles and industrial machines.

１０：コイル部品
２０：ドラムコア
２２：巻軸
２４，２６：鍔部
２４Ａ，２６Ａ：表面
２５，２７：凹部
３０：リングコア
３０Ａ：上面
３０Ｂ：底面
３０Ｃ：外周面
３０Ｄ：内周面
３２：貫通孔
３６Ａ，３６Ｂ，３８Ａ，３８Ｂ：溝
４０：巻線
４２：導線
４４：被膜
４５：被膜端部
４６Ａ，４６Ｂ：引出部
４７Ａ，４７Ｂ：導線端部
５０Ａ，５０Ｂ：端子電極
５２Ａ，５２Ｂ：接続部
５４Ａ，５４Ｂ：固定部
５６Ａ，５６Ｂ：接合部
５８：空隙
６０Ａ，６０Ｂ：第２の固定部
６２Ａ，６２Ｂ：第１の固定部
７０：樹脂ベース
７０Ａ：上面
７０Ｂ：底面
７２Ａ〜７２Ｄ：側面
７４Ａ，７４Ｂ：側面
７６：突起
Ｃ：ドラムコアの中心
ＬＡ：被膜剥離の長さ
ＬＢ：接合用のレーザ照射範囲
ＬＣ：接合部長さ
Ｇ：ギャップ 10: Coil parts 20: Drum core 22: Winding shaft 24, 26: Brim portion 24A, 26A: Surface 25, 27: Recessed portion 30: Ring core 30A: Top surface 30B: Bottom surface 30C: Outer peripheral surface 30D: Inner peripheral surface 32: Through hole 36A , 36B, 38A, 38B: Groove 40: Winding 42: Conductor 44: Coating 45: Coating end 46A, 46B: Drawer 47A, 47B: Conductor end 50A, 50B: Terminal electrode 52A, 52B: Connection 54A, 54B: Fixing part 56A, 56B: Joint part 58: Air gap 60A, 60B: Second fixing part 62A, 62B: First fixing part 70: Resin base 70A: Top surface 70B: Bottom surface 72A to 72D: Side surface 74A, 74B: Side surface 76: Protrusion C: Center of drum core LA: Length of film peeling LB: Laser irradiation range for bonding LC: Joint length G: Gap

Claims (3)

外周に被膜を有する導線を巻回して形成される巻線部と、
前記巻線部より外側に引き出され、前記被膜を有する導線と被膜の無い導線により連続的に形成される引出部と、
前記引出部より外側に位置し、前記被膜の無い導線の端部に位置する接合部と、
該接合部により前記引出部と電気的に導通する端子電極と、
を有するコイル部品の製造方法であって、
前記端子電極と接続する位置の導線の側面全周の被膜を取り除くことで、端部の被膜が剥離された導線を準備するステップと、
前記端部の被膜が剥離された導線を、端子電極となる金属板の接続部に置くステップと、
前記金属板の固定部を折り曲げ加工し、金属板上の接続部と固定部との間に前記導線の引出部を挟むステップと、
前記導線の端部と固定部の一部に、接合用レーザを接続部側から導線側に向かう方向へ、かつ照射範囲に被膜がある導線部分が入らないように照射して前記接合部を形成するステップと、
を含み、
前記接合部には、空隙を含むことがあり、その空隙の割合は、前記導線の引出部の中央を通り、かつ、前記導線の引出方向と平行な面における接合部の面積に対して、３０％以下であることを特徴とするコイル部品の製造方法。 A winding part formed by winding a conducting wire having a coating on the outer circumference,
A lead portion that is pulled out from the winding portion and is continuously formed by a conductor having a coating and a conducting wire without a coating,
A joint located outside the lead and at the end of the uncoated conductor,
A terminal electrode that electrically conducts with the lead-out portion through the joint portion,
It is a manufacturing method of coil parts having
A step of preparing a conductor whose end coating has been peeled off by removing the coating on the entire side surface of the conductor at the position where it is connected to the terminal electrode.
The step of placing the lead wire from which the coating on the end portion has been peeled off at the connection portion of the metal plate to be the terminal electrode, and
A step of bending the fixing portion of the metal plate and sandwiching the lead-out portion of the conducting wire between the connecting portion and the fixing portion on the metal plate.
The joint portion is formed by irradiating the end portion and a part of the fixed portion of the conductor wire with a bonding laser in the direction from the connection portion side to the conductor wire side so that the conductor portion having a coating film does not enter the irradiation range. Steps to do and
Only including,
The joint may include voids, the proportion of which is 30 relative to the area of the junction in a plane that passes through the center of the lead wire leadout and is parallel to the lead wire leadout direction. % Or less, a method for manufacturing a coil component. 前記接合部を、前記導線の被膜端部と接することなく、被膜と離れた位置で形成することを特徴とする請求項１記載の製造方法。 The manufacturing method according to claim 1, wherein the joint portion is formed at a position away from the coating film without being in contact with the coating end portion of the conducting wire. 前記接合部を、前記導線と前記接続部の一部から形成し、引出部から接合部に向って断面寸法が大きくなるように形成することを特徴とする請求項１又は２記載の製造方法。 The manufacturing method according to claim 1 or 2, wherein the joint portion is formed from the lead wire and a part of the connection portion, and is formed so that the cross-sectional dimension increases from the drawer portion toward the joint portion.

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