The present invention relates to a coil component and, more particularly, to a coil component using a drum-shaped core.
A coil component using a drum-shaped core is widely used in electronic devices such as smartphones for the reason that it is smaller in size than a coil component using a toroidal-shaped core and can be mounted on the surface of a circuit board. The drum-shaped core has a winding core part around which wires are wound and a pair of flange parts provided at both axial end portions of the winding core part, and end portions of respective wires are connected respectively to a plurality of terminal electrodes provided on each of the flange parts. Further, there may be a case where a plate-like member is bonded to the upper surface of the drum-shaped core for the purpose of facilitating handling of the coil component at mounting (see JP 09-219318 A). In this case, the wires are positioned between the winding core part and the plate-like member.
However, in the configuration where the plate-like member is bonded to the drum-shaped core, when a displacement occurs in wire winding positions, the wires and plate-like member may interfere with each other. That is, when the wires are densely wound as designed, the wires and the plate-like member do not interfere with each other; however, when the wires are wound in a position different from the one expected by design, or when a space is generated due to failure of dense winding, the last turn of one wire is wound overlapping the previous turn, for example, thus failing to house the last turn between the winding core part and plate-like member.
It is therefore an object of the present invention to prevent interference between the wires and the plate-like member in the coil component using the drum-shaped core.
A coil component according to the present invention includes a drum-shaped core including a winding core part, a first flange part provided at one axial end of the winding core part, and a second flange part provided at other axial end of the winding core part; a plate-like member; a plurality of terminal electrodes provided on each of the first and second flange parts; and a plurality of wires wound around the winding core part such that one end of each wire is connected to any one of the plurality of terminal electrodes provided on the first flange part and other end of each wire is connected to any one of the plurality of terminal electrodes provided on the second flange part. Each of the first and second flange parts has an inner wall surface extending substantially perpendicular to an axial direction of the winding core part and connected to the winding core part and an upper surface extending substantially perpendicular to the inner wall surface. The plate-like member is fixed to the upper surface of each of the first and second flange parts. Each of the first and second flange parts has a first cut part that is a portion at which at least a part of an edge part as a boundary between the inner wall surface and the upper surface is cut off and that can house at least one of the plurality of wires while preventing interference between the wire and the plate-like member.
According to the present invention, the first and second flange parts each have the first cut part, so that even when the winding position of the wires is displaced from a designed position, at least the last turn of the wire can be housed in the first cut part. Thus, it is possible to prevent interference between the wires and the plate-like member due to disordered winding of the wires.
In the present invention, the first cut part may be formed over at least an area covering the entire width of the winding core part so as to be able to house at least one of the plurality of wires while preventing interference between the wire and the plate-like member. This can reliably prevent interference between the wires and the plate-like member.
In the present invention, the first cut part may be formed over an entire width of the inner wall surface and the upper surface in a direction substantially perpendicular to the axial direction. This facilitates the production of the drum-shaped core using a die.
In the present invention, a step surface formed by the first cut part may constitute the same plane with the winding core part. This facilitates the production of the drum-shaped core using a die.
In the present invention, the first and second flange parts may each include a lower surface positioned on the side opposite to the upper surface, and the plurality of terminal electrodes may be formed on the lower surface. This prevents interference between the terminal electrodes and plate-like member, making it possible to simplify the shape of the plate-like member or that of the flange part of the drum-shaped core.
In the present invention, the first and second flange parts may each further have a second cut part at which at least a part of an edge part as the boundary between the inner wall surface and the lower surface is cut off. Thus, even when the winding position of the wires is displaced from a designed position, at least the last turn of the wire can be housed in the second cut part, so that it is possible to prevent the coil component from being mounted on a circuit board in an inclined state.
In the present invention, the second cut part may be formed over an entire width of the inner wall surface and the lower surface in a direction substantially perpendicular to the axial direction. This facilitates the production of the drum-shaped core using a die.
In the present invention, a step surface formed by the second cut part may constitute the same plane with the winding core part. This facilitates the production of the drum-shaped core using a die.
In the present invention, the step surface formed by the first cut part may have a slope. This facilitates the production of the drum-shaped core using a die.
In the present invention, the plurality of wires may include first and fourth wires wound in one direction around the winding core part to constitute a first winding layer and second and third wires wound in the opposite direction around the winding core part through the first winding layer to constitute a second winding layer. The first cut part may be configured to house the second or third wire. With this configuration, the coil component may be used as a pulse transformer, and interference between the upper wires which are easily disorderly wound and the plate-like member can be prevented.
In the present invention, the plate-like member may be made of a magnetic material. With this configuration, a closed magnetic path is formed by the drum-shaped core and plate-like member, thus enhancing inductance.
As described above, according to the present invention, it is possible to prevent interference between the wires and the plate-like member even when the winding position of the wires is displaced from a designed position.
The above and other objects, features and advantages of this invention will become more apparent by reference to the following detailed description of the invention taken in conjunction with the accompanying drawings, wherein:
Preferred embodiments of the present invention will now be explained in detail with reference to the drawings.
The coil component 100 according to the first embodiment is a surface-mount type pulse transformer and has a drum-shaped core 1, a plate-like core 40 bonded to the core 1, and four wires W1 to W4 wound around a winding core part 30 of the core 1 as illustrated in
The cores 1 and 40 are each made of a magnetic material having comparatively high permeability, such as a sintered body of an Ni—Zn based ferrite or an Mn—Zn based ferrite. In general, a magnetic material having high permeability such as the Mn—Zn based ferrite is low in specific resistance and thus has conductivity.
The drum-shaped core 1 integrally has a rod-like winding core part 30 whose axis extends in the x-direction and first and second flange parts 10 and 20 provided at both ends of the winding core part 30 in the x-direction. The first flange part 10 has an inner wall surface 11 and an outer wall surface 12 which constitute the yz plane, a lower surface 13 and an upper surface 14 which constitute the xy plane, and side surfaces 15 and 16 which constitute the xz plane. Similarly, the second flange part 20 has an inner wall surface 21 and an outer wall surface 22 which constitute the yz plane, a lower surface 23 and an upper surface 24 which constitute the xy plane, and side surfaces 25 and 26 which constitute the xz plane.
The coil component 100 is a chip component mounted on the surface of a printed circuit board when used and is mounted with the lower surfaces 13 and 23 of the flange parts 10 and 20 facing the printed circuit board. The plate-like core 40 is fixed to the upper surfaces 14 and of the flange parts 10 and 20 with an adhesive. A closed magnetic loop is formed by the thus configured drum-shaped core 1 and plate-like core 40.
Four terminal electrodes 51 to 54 are arranged in the y-direction on the lower surface 13 of the first flange part 10, and four terminal electrodes 55 to 58 are arranged in the y-direction on the lower surface 23 of the second flange part 20. The terminal electrodes 51 to 54 may be formed over the lower surface 13 and outer wall surface 12, and the terminal electrodes 55 to 58 may be formed over the lower surface 23 and outer wall surface 22. Further, the terminal electrodes 51 to 58 may be formed not only on the lower surfaces 13 and 23, but also on their opposing upper surfaces 14 and 24. The terminal electrodes 51 to may each be a conductive film applied to the corresponding flange part 10 or 20 or may each be a terminal fitting.
As illustrated in
Although not particularly limited, the wire W1 is connected to the terminal electrodes 51 and 56, and the winding direction thereof is, for example, clockwise. The wire W2 is connected to the terminal electrodes 52 and 55, and the winding direction thereof is, for example, counterclockwise. The wire W3 is connected to the terminal electrodes 53 and 58, and the winding direction thereof is, for example, clockwise. The wire W4 is connected to the terminal electrodes 54 and 57, and the winding direction thereof is, for example, counterclockwise. With this configuration, for example, the terminal electrodes 51 and 52 can be used as the primary side input/output terminal of the pulse transformer, terminal electrodes 57 and 58 can be used as the secondary side input/output terminal of the pulse transformer, the terminal electrodes 55 and 56 can be used as the primary center tap of the pulse transformer, and the terminal electrodes 53 and 54 can be used as the secondary center tap of the pulse transformer. The terminal electrodes 55 and 56 constituting the primary center tap may be combined into a single terminal electrode. Similarly, the terminal electrodes 53 and 54 constituting the secondary center tap may be combined into a single terminal electrode.
As illustrated in
As illustrated in
The wires W2 and W3 constituting the second winding layer are wound on the first winding layer, so that the base surface on which they are wound is not flat unlike the case of the wires W1 and W4 constituting the first winding layer. In addition, the winding direction of the wires W2 and W3 constituting the second winding layer is opposite to the winding direction of the wires W1 and W4 constituting the first winding layer, so that the wires W2 and W3 cannot be wound along the valley lines of the first winding layer. Thus, a displacement occurs more easily in the wires W2 and W3 constituting the second winding layer than in the wires W1 and W4 constituting the first winding layer.
However, in the present embodiment, the cut parts C1 and C2 are formed in the flange parts 10 and 20, respectively, so that even when a displacement occurs in the winding positions of the wires W2 and W3 constituting the second winding layer, the displaced wire W2 or W3 is housed in the cut part C1 or C2, respectively, as illustrated in
As described above, in the coil component 100 according to the present embodiment, the cut parts C1 and C2 are formed in the flange parts 10 and 20, respectively, so that even when a displacement occurs in the winding positions of the wires W2 and W3 constituting the second winding layer, interference between the wires W2, W3 and the core 40 can be prevented. In addition, in the present embodiment, the cut part C1 is formed over the entire width of the inner wall surface 11 and upper surface 14 in the y-direction, and the cut part C2 is formed over the entire width of the inner wall surface 21 and upper surface 24 in the y-direction, simplifying the shapes of the flange parts 10 and 20, so that there is no difficulty in producing the core 1 using a die.
As illustrated in
The cut part C3 is a portion at which an edge part as the boundary between the inner wall surface 11 of the first flange part 10 and the lower surface 13 thereof is cut off. Similarly, the cut part C4 is a portion at which an edge part as the boundary between the inner wall surface 21 of the second flange part 20 and the lower surface 23 thereof is cut off. In the present embodiment, the cut part C3 is formed over the entire width of the inner wall surface 11 and lower surface 13 in the y-direction, and the cut part C4 is formed over the entire width of the inner wall surface 21 and lower surface 23 in the y-direction. Further, in the present embodiment, step surfaces 18 and 28 formed respectively by the cut parts C3 and C4 constitute the xy-plane. The difference in dimension in the z-direction between the lower surface (13, 23) and the step surface (18, 28) is larger than the diameter of each of the wires W1 to W4.
With the above configuration, even when a displacement occurs in the winding positions of the wires W2 and W3 constituting the second winding layer, the displaced wire W2 or W3 is housed in the cut part C3 or C4, respectively, as illustrated in
As illustrated in
With this configuration, the same effects as those in the first embodiment can be obtained. Further, the difference in dimension in the z-direction between the upper surface (14, 24) and step surface (17, 27) is increased, so that a disorderly wound wire can be easily housed in the cut part C1 or C2 and, in some cases, two or more wires can be housed in the cut part C1 or C2. In addition, the step surfaces 17 and 27 constitute the same plane as the winding core part 30, making the shape of the drum-shaped core 3 simpler, which in turn further facilitates the production of the core 3 using a die.
As illustrated in
With this configuration, the same effects as those in the third embodiment can be obtained. Further, the difference in dimension in the z-direction between the lower surface (13, 23) and the step surface (18, 28) is increased, so that a disorderly wound wire can be easily housed in the cut part C3 or C4 and, in some cases, two or more wires can be housed in the cut part C3 or C4. In addition, the step surfaces 18 and 28 constitute the same plane as the winding core part 30, making the shape of the drum-shaped core 4 simpler, which in turn further facilitates the production of the core 4 using a die.
In the present embodiment as well, preferably, the cut part (C1 to C4) is formed essentially in the flange part (10 and 20). That is, as illustrated in
As illustrated in
Even with this configuration, the same effects as those in the first embodiment can be obtained. Further, the volume of the core 5 can be ensured to thereby make it possible to obtain high magnetic characteristics.
As illustrated in
Even with this configuration, the same effects as those in the first embodiment can be obtained as long as the wire W2 or W3 can be housed in the cut part C1 or C2, respectively.
As illustrated in
Even with this configuration, the same effects as those in the sixth embodiment can be obtained. Further, the volume of the core 7 can be ensured to thereby make it possible to obtain high magnetic characteristics.
It is apparent that the present invention is not limited to the above embodiments, but may be modified and changed without departing from the scope and spirit of the invention.
For example, although the plate-like core 40 is used in the above embodiments, a plate-like member corresponding to the core 40 need not be a magnetic member, but may be a non-magnetic member.
Number | Date | Country | Kind |
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JP2018-076659 | Apr 2018 | JP | national |
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20150162126 | Kanbe et al. | Jun 2015 | A1 |
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Entry |
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English translation of JP2010165862 (Year: 2010). |
English translation of JP2003077730 (Year: 2003). |
Number | Date | Country | |
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20190318866 A1 | Oct 2019 | US |