JPH09219324A - Wire wheel component and manufacturing method thereof - Google Patents

Abstract

(57) Abstract: A miniaturization of a wire wheel component having a coil block in which a coil pattern of a copper foil is formed on a laminated substrate,
We aim to reduce the thickness and improve reliability, and to streamline the manufacturing process. SOLUTION: A coil pattern 26 formed of a copper plate
Are laminated with an insulating sheet adhesive 12 interposed therebetween, and a coil block 21 having a hollow portion 13 at the center thereof, and the hollow portion and both sides thereof so as to be sandwiched from both sides of the coil block 21. EE type or E provided between
The I-shaped core 23 and one or both ends of the coil block 21 not covered by the core 23 are provided in the thickness direction so as to be connected to the coil pattern 26 of the coil block 21. A wire ring component composed of a terminal portion.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wire ring component such as a transformer and a choke coil which is mounted on a printed wiring board by surface mounting or the like, and a method for manufacturing the same, and in particular, a coil pattern made of copper foil is formed on a laminated substrate. The present invention relates to a small wire wheel component having a coil block and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, electronic circuit devices using printed wiring boards have been widely put into practical use in response to demands for downsizing, thinning, and cost reduction. In addition, various printed wiring boards have been developed in order to achieve high density, high functionality, and high reliability, and the progress is remarkable. As this printed wiring board, for example, a paper-based copper-clad laminate, a glass-based copper-clad laminate, an aluminum-based copper-clad laminate, a ceramic-based printed board, etc. are used. The stretched laminated board is often used mainly in digital circuits of OA equipment. Therefore, the current flowing through the wiring is a minute current as a digital signal, and further thinning and high density of the copper foil are being studied.

As a component mounted on a printed wiring board,
In addition to active and passive elements such as semiconductor components, resistors and capacitors, there is a demand for miniaturization and thinning of coil components such as transformers, choke coils and inductors. As the conventional most general structure of this coil component, as shown in a sectional view in FIG. 10, a conductive wire is wound around a resin bobbin 1 to form a winding 2, and a core 3 is fitted from above and below. It is a plug-in type. The bobbin 1 is provided with a wiring lead terminal 4 to which the lead wire of the winding 2 is connected.

Recently, there has also been used a wire wheel component using a coil block in which a coil pattern is formed on a glass base material or the like with a copper foil and laminated to form a multilayer substrate. As with the printed wiring board, this coil block can be produced in a large number to improve productivity, and a bobbinless wire wheel component can be obtained to rationalize the manufacturing process. As shown in FIG. 11, this coil component is obtained by inserting a coil block 6 into a ferrite core 5 and connecting a rod-shaped pin terminal 7 to the side edge of the coil block 6 by soldering.
It is a very thin wire wheel component called a seat transformer, and is an effective shape for low-profile electronic circuit devices.
Further, instead of the above-mentioned pin terminal 7, there is also one in which a metallized electrode 8 is provided on the side end surface of the coil block 6 as shown in FIG.

Details of the wire wheel component will be described with reference to FIGS. FIG. 11A is a perspective view showing a completed state of assembly, and FIG. 11B is a perspective view of an intermediate stage of assembly (the pin terminal 7 is omitted). As shown in a sectional view in FIG. 13, the coil block 6 has a coil pattern 10 made of copper foil as shown in FIG. 14 formed on both surfaces of a base substrate 9 made of, for example, a glass base material by an etching method.
The coil patterns 10 on both surfaces are connected to each other by through holes 11 which are plated as necessary, and the base substrate 9 is formed into an insulating sheet adhesive 12 made of the same material as the base substrate 9. It is formed by laminating and press-bonding a plurality of sheets. Reference numeral 16 is a fitting hole for the pin terminal 7.

A hollow portion 13 is provided at the center of the coil block 6, and the central leg 14 of the EE type core 5 is inserted into the hollow portion 13, and the outer legs 15 on both sides of the central leg 14 are provided on the coil block 6. They are united with each other on the outside and integrated with the coil block 6. Terminal portions of the coil pattern 10 formed on the base substrate 9 are provided at the side ends on both sides of the coil block 6 which are not covered with the core 5, as shown in the perspective views of FIGS. A plurality of pin terminals 7 or metallized electrodes 8 for connecting and mounting to a printed wiring board (not shown) are provided and configured as a coil component. In this prior art example, the core 5 has EE
Although a mold is used, it is of course possible to use an EI type core.

[0007]

However, in the conventional glass-based copper-clad laminate described above, a relatively large current,
For example, when used under 5 A or more, when a thin copper foil having a thickness of 0.10 mm or less is used, there is a problem in characteristics such as conduction loss. For this reason, the wire wheel components used in high-current circuits have attempted to solve this problem by using multiple layers of copper foil with the same coil pattern in parallel and increasing the cross-sectional area. Since the base substrate 9 or the insulating sheet-like adhesive 12 that forms the insulating layer is always sandwiched between the foil and the foil, the coil block 6
There was a problem that the thickness of the wire becomes thicker and the wire wheel component itself becomes taller.

Further, since the electric power converted by the wire wheel component, for example, a transformer is generally an alternating current, a skin effect at that frequency is considered at a certain frequency. That is, the thickness of the copper foil must be within a range that does not cause conduction loss due to the skin effect of the alternating current. There is a demand to improve these characteristics and to realize an electronic component as a miniaturized, thinned, and low-priced wire wheel component. The present invention is particularly applicable to a wire wheel component used under a large current,
(EN) Provided are a coil component and a manufacturing method thereof, which can be reduced in size, reduced in thickness, and reduced in price, and which can also solve the problem of conduction loss.

[0009]

A coil member according to the present invention is a coil having a plurality of coil patterns formed of a copper plate laminated with an insulating sheet adhesive and having a hollow portion at the center thereof. A block, an EE type or EI type core provided between the hollow portion and both sides thereof so as to be sandwiched from both sides of the coil block, and one of an end portion of the coil block which is not covered by the core, or Both are composed of a terminal portion provided in the thickness direction so as to be connected to the coil pattern of the coil block.

In the method for manufacturing a wire wheel component according to the present invention, a collective coil pattern having a plurality of coil patterns formed of a copper plate and a collective coil pattern of the same kind or a different kind from the collective coil pattern are formed into an insulating sheet shape. Laminating with an adhesive and integrating them to create a multi-piece coil block aggregate substrate, and then inserting a terminal into which the pin terminals are connected to the terminal portions of each coil pattern by router processing or the like on the coil block aggregate substrate. After the holes are arranged and the inner surface of the terminal fitting hole is metal-plated, the coil block aggregate substrate is subjected to a router process or the like to leave a connecting portion between the unit coil blocks, and substantially the center of each coil pattern. A hollow portion into which the central leg of the core is inserted and a dividing groove, and the pin end is inserted into the metal-plated terminal fitting hole of the coil block assembly substrate. The fitted, soldered, a single coil block detach connecting portion of the unit coil block each other, and forms with the EE type or EI type core to the coil block mounted fixed.

[0011]

DETAILED DESCRIPTION OF THE INVENTION The present invention will be described with reference to FIGS. FIG. 1 is a perspective view of an intermediate stage of assembly of a wire wheel component of the present invention, in which a coil block 21 having a terminal fitting hole 22 is mounted and fixed so as to be sandwiched by EI type cores 23a and 23b to form a wire wheel component. It is what makes me. In addition, 2
Reference numerals 4 and 25 are the central leg and the outer leg of the E-shaped core 23a. As shown in the exploded perspective view of the coil block 21 of FIG. 2 and the side view of the coil block 21 of FIG. 3, the coil block 21 of the wire wheel component has the same or different type of coil formed of a copper plate. The pattern 26 is formed by laminating and pressing a plurality of the patterns 26 with the insulating sheet adhesive 12 sandwiched therebetween. The coil patterns 26 of the three copper plates shown in FIG. 2 are all formed in different patterns.
Through the terminal fitting hole 22 provided through the coil block 21 as shown in FIG.
It is connected and fixed to the printed wiring board by pin terminals provided on the.

As shown in the sectional view of FIG. 4, the terminal fitting hole 22 has a plating 25 made of copper or the like on its inner surface 28. Further, lands 29 formed by copper plating are formed on the upper and lower outer sides of the coil block 21 of the terminal fitting hole 22 to ensure soldering connection to a pin terminal or the like.
As a terminal for connecting the coil pattern 26, as shown in FIG. 11, the terminal portion 27 of the coil pattern 26 is exposed on the side end surface of the coil block 21, and the terminal portion 27 is included in the coil block 21. It may be provided as a strip-shaped metallized electrode in the thickness direction.

Although the thickness of the coil pattern 26 made of the copper plate varies depending on the use, it can be applied to an AC circuit having a current capacity of about 5 A by using, for example, a thickness of about 0.30 mm. In this case, the thickness of the insulating sheet adhesive 12 is the same as that of the conventional example.
The thickness corresponding to the embedding amount may be maintained by maintaining the distance between the two to about 0.1 mm, which is appropriately determined by the coil pattern to be formed.

The coil block 2 of the wire wheel component according to the present invention
1 has the coil pattern 26 made of a copper plate thicker than the copper foil as described above, so that the conventional base substrate 9 can be omitted and the number of insulating sheet adhesives 12 can be reduced. It will be possible. for that reason,
As shown in FIG. 5, the conventional coil pattern 1 of FIG.
Comparing the case in which 0 is connected in three layers in parallel to form the coil block 6 having three turns and the case where the coil block 26 according to the present invention in FIG. 5B forms the coil block 21 having three turns. Then, the thickness of the coil block 21 according to the present invention is about 30 times smaller than that of the conventional coil block 6.
It becomes possible to make it thinner. Also, the coil pattern 2
The copper plate on which 6 is formed has a pattern formed,
It is desirable to have a strength that does not bend when one side (one end) is supported. For example, in the case of a normal copper plate, the lower limit is about 0.2 mm. Therefore, the thickness of the copper plate is appropriately selected depending on the current capacity.
By using the copper plate having such a thickness, it is possible to obtain the intended coil component without causing conduction loss due to the skin effect of the alternating current.

Next, the manufacturing process of the coil block 21 will be described. As shown in FIG. 6A, the copper plate 31 is pre-etched or press-molded with a die to form the collective coil pattern 32 of FIG. 6B in which a plurality of identical coil patterns 26 are formed. The collective coil pattern 32 is provided with a connecting portion 33 so that the coil patterns 26 are not separated. Next, as shown in FIG. 7A, a required amount of the insulating sheet adhesive 12 is sandwiched between a plurality of patterns of the same type or different types of the collective coil pattern 32, and this is repeated for a predetermined number of sheets. Are stacked, aligned and subjected to pressure press working, and integrated to form a coil block aggregate substrate 34 of FIG. 7B.

At the time of this integration, the sheet-shaped adhesive 12 is surely embedded between the aggregated coil patterns 32, so the amount and material of the adhesive should be taken into consideration. For example, it may be necessary to increase the resin content of the sheet adhesive 12 to fill the step difference of the pattern or to supply only the resin component in advance by another method. Next, as shown in FIG. 8A, in the coil block assembly substrate 34, the terminal fitting hole 22 of the coil block assembly substrate 37 is processed by a router or the like, and then the inner surface 28 of the hole is metal-plated to make the terminal fitting hole 22.
And Next, in order to divide into the respective coil blocks 21, the division groove 36 in which the connecting portion 35 is left at a position corresponding to the connecting portion 35 of the coil pattern 26, and the hollow portion 13 into which the central leg 24 of the E-shaped core 23a is inserted. By processing with a router or the like, a divisible coil block aggregate substrate 37 is manufactured.

Next, after the pin terminals 7 are fitted and soldered in the terminal fitting holes 22 in which the inner surfaces 28 of the holes are plated with metal, the coil block assembly board 37 is divided manually or by using a jig. Then, as a single coil block 21, as shown in FIG. 8B, an EI type core 23 is mounted and fixed in the same manner as in the conventional example to obtain a wire wheel component. In addition, the coil block aggregate substrate 37 described above is
Although an example in which the pin terminal 7 is fitted into the terminal fitting hole 22 and soldered and then divided into the single coil block 21, the outer leg 25 of the E-shaped core 23a can be inserted.
With the layout of the collective coil pattern 32, the layout is such that the split grooves 36 on the side edges of the coil block collective substrate 37 where the terminal fitting holes 22 are not provided are expanded.
The EI core 23 in the state of the coil block aggregate substrate 37
(Or EE type core) may be assembled. With such an assembly, the automation rate can be further increased and the work efficiency can be further improved.

When the terminal portion of the coil block 21 is formed as the metallized metallized electrode 8, the coil block assembly substrate 34 is processed by a router or the like as shown in FIG. First, the terminal forming hole 40 is provided so that the terminal portion 27 of the coil pattern 26 is exposed at the side end surface thereof when the unit coil block 21 surrounded by the dividing lines 38 and 39 shown by the chain line is cut.
Next, the terminal forming hole 40 of the coil block assembly substrate 34.
Metallic plating is performed in the thickness direction including the terminal portion 27 of the coil pattern exposed at the. At this time, in order to surely make a solder connection to a circuit pattern of a printed wiring board (not shown), plating may be performed so as to form an L-shaped or U-shaped metallized electrode including this portion. desirable. Next, the hollow portion 13 (shown by a chain line in FIG. 9) into which the central leg 24 of the core 23a is inserted is provided at a substantially central portion of each coil pattern 26. Next, the coil block assembly substrate 37
Is cut at the dividing points indicated by the dividing lines 38 and 39 by router processing or the like to obtain a single coil block 21 on which the strip-shaped metallized electrodes 8 (shown in FIG. 12) are formed. Next, as shown in FIG. 12, the EI type core 21 is mounted and fixed so that the metallized electrode 8 is exposed on the side surface to form a coil component.

[0019]

As described above, the coil pattern is formed by the copper plate itself, instead of the coil pattern in which the copper foil is printed on the base substrate, and the coil pattern formed by the copper plate is inserted through the insulating sheet adhesive. By using a laminated coil block, it is possible to reduce the dimension in the thickness direction of a wire wheel component used in a circuit having a relatively large current capacity, and it is possible to provide a thin wire wheel component. Therefore, it is possible to meet the demand for thinning and miniaturization of components mounted on the printed wiring board. Also,
By adopting a coil block in which a copper plate of 0.2 mm or more is patterned and used in the form of a coil, the thickness of the copper plate is set to a range that does not cause conduction loss due to the skin effect of the alternating current. This has the effect of reducing conduction loss when used under a large current (5 A or more).

[Brief description of drawings]

FIG. 1 is a structural diagram of a wire wheel component according to the present invention.

FIG. 2 is a perspective view showing a relationship between a coil pattern and a terminal of the wire wheel component of the present invention.

FIG. 3 is a side view illustrating a configuration of a coil block according to the present invention.

FIG. 4 is a side view illustrating a structure of a terminal fitting hole of the coil block according to the present invention.

FIG. 5 is a side view of a coil block in a wire wheel component according to the present invention and a coil block in a conventional wire wheel component for comparing the thicknesses of the two.

FIG. 6 is a plan view of a copper plate and a collective coil pattern, showing a part of the manufacturing process of the wire wheel component of the present invention.

FIG. 7 is a perspective view of a coil block aggregate substrate and a laminated state of an aggregate coil pattern and a sheet-like adhesive, showing a part of the manufacturing process of the coil component of the present invention.

FIG. 8 is a plan view of a processed coil block aggregate substrate and a perspective view of an assembly structure of the coil assembly, showing a part of the manufacturing process of the coil assembly of the present invention.

FIG. 9 is a plan view illustrating a processed state of the coil block aggregate substrate in the manufacturing process of the coil component of the present invention.

FIG. 10 is a structural diagram showing an example of a conventional wire wheel component.

FIG. 11 is a structural diagram showing an example of a wire wheel component using a conventional coil block.

FIG. 12 is a structural diagram showing another example of a wire wheel component using a conventional coil block.

FIG. 13 is a cross-sectional view illustrating the structure of a conventional coil block.

FIG. 14 is a top view showing an example of a coil pattern of a coil block.

[Explanation of symbols]

 1 Bobbin 2 Winding 3 Core 4 Lead Terminal 5 EE Type Core 6,21 Coil Block 7 Pin Terminal 8 Metallized Electrode 9 Base Substrate 10,26 Coil Pattern 11 Through Hole 12 Insulating Sheet Adhesive 13 Hollow Part 14, 24 Central leg 15,25 Outer leg 16,22 Terminal fitting hole 23 EI type core 27 Terminal part 28 Hole inner surface 29 Land 31 Copper plate 32 Collecting coil pattern 33,35 Connecting part 34,37 Coil block collecting board 36 Dividing groove 38,39 Dividing Wire 40 Terminal forming hole

Claims (6)

[Claims] 1. A coil block formed by stacking a plurality of coil patterns made of a copper plate via an insulating sheet adhesive and having a hollow portion in the center thereof, and sandwiching the coil block from both sides of the coil block. An EE-type or EI-type core provided between the hollow portion and both sides thereof and one or both of end portions of the coil block which are not covered with the core are connected to a coil pattern of the coil block. And a terminal part provided in the thickness direction thereof. 2. The wire wheel component according to claim 1, wherein the terminal portion is formed as a pin terminal provided at a side edge portion of the coil block so as to penetrate the coil block. 3. The wire wheel component according to claim 1, wherein the terminal portion is formed on the side end surface of the coil block in the thickness direction as an electrode made of strip-shaped metal plating. 4. A collective coil pattern having a plurality of coil patterns formed of a copper plate, and a collective coil pattern of the same kind or different kind as the collective coil pattern are laminated via an insulating sheet adhesive to be integrated. To produce a multi-piece coil block assembly board, and by forming a terminal fitting hole to which a pin terminal is connected to the terminal portion of each coil pattern by router processing or the like on the coil block assembly board, After metal plating is applied to the inner surface of the insertion hole, the coil block assembly board is left with a connecting portion between the unit coil blocks by router processing or the like, and the central leg of the core is inserted substantially in the center of each coil pattern. A hollow portion and a dividing groove are provided, the pin terminal is fitted into the metal-plated terminal fitting hole of the coil block assembly substrate, and soldered, A manufacturing method of a wire wheel component, wherein a connecting portion between unit coil blocks is separated to form a single coil block, and an EE type or EI type core is attached and fixed to the coil block. 5. A collective coil pattern having a plurality of coil patterns formed of a copper plate, and a collective coil pattern of the same kind or different kind as the collective coil pattern are laminated via an insulating sheet adhesive to be integrated. To produce a multi-piece coil block assembly board, and by forming a terminal fitting hole to which a pin terminal is connected to the terminal portion of each coil pattern by router processing or the like on the coil block assembly board, After metal plating is applied to the inner surface of the insertion hole, the coil block assembly board is left with a connecting portion between the unit coil blocks by router processing or the like, and the central leg of the core is inserted substantially in the center of each coil pattern. A hollow portion and a wide dividing groove into which the outer leg of the core can be inserted, and the hollow portion of the coil block assembly substrate before separating the connecting portion. After mounting fixing the EE type or EI type core pre dividing grooves, Senwa component manufacturing method of forming by disconnecting the connecting portion of the coil block set substrate. 6. A collective coil pattern having a plurality of coil patterns formed of a copper plate and a collective coil pattern of the same type or a different type from the collective coil pattern are laminated via an insulating sheet adhesive to be integrated. To form a multi-piece coil block assembly substrate, and a terminal forming hole is provided by router processing or the like so that the terminal portion of each coil pattern of the unit coil block is exposed on the side end surface thereof. After forming a metallized electrode by strip-shaped metal plating in the thickness direction including the terminal portion of each coil pattern exposed on the side end surface, by router processing or the like at substantially the center of each coil pattern of the coil block aggregate substrate, A hollow part for inserting the central leg of the core is provided, and the coil block aggregate substrate is connected to the unit coil blocks by router processing or the like. A single coil block by cutting, Senwa component manufacturing method of forming by the EE type or EI type core to the coil block mounted fixed.