Coil component and method for producing same

Patent metadata

Field	Value
Publication number	US-9984809-B2
Application number	US-201515117081-A
Country	US
Kind code	B2
Filing date	Mar 9, 2015
Priority date	Mar 14, 2014
Publication date	May 29, 2018
Grant date	May 29, 2018

Abstract

A coil component according to the present invention includes: a magnetic core made of a mixture of a powdery magnetic material and a binding agent and obtained by press forming the mixture; a coil element embedded in the magnetic core and having an end portion protruding from the magnetic core; and a holding member configured to hold the end portion of the coil element. The holding member has a first slit and a second slit which faces the first slit. The end portion of the coil element and the holding member are welded together in an area between the first slit and the second slit.

First claim

The invention claimed is:

1. A coil component comprising:
a magnetic core made of a mixture of a powdery magnetic material and a binding agent and obtained by press forming the mixture;
a coil element formed by winding a conductive wire, embedded in the magnetic core and having an end portion protruding from the magnetic core; and
a holding member configured to hold the end portion of the coil element, the holding member having a side face, wherein:
the holding member has a recess portion, at the side face, protruding toward a center of the magnetic core,
the holding member has, in the side face, a first slit and a second slit which faces the first slit,
the end portion of the coil element is welded to the recess portion of the holding member and the holding member are welded together in an area between the first slit and the second slit, and
the recess portion has a convex surface facing the magnetic core and a concave surface opposite to the convex surface, and the end portion of the coil element is welded to the concave surface.

2. The coil component according to claim 1 , wherein the first slit and the second slit each have a proximal-side width near an area where the end portion of the coil element protrudes from the magnetic core and a distal-side width far from the area, the proximal-side width being greater in dimension than the distal-side width.

3. The coil component according to claim 1 , wherein the holding member has a third slit positioned in an area to which the end portion of the coil element is directed to extend.

4. The coil component according to claim 1 , wherein the holding member has a fourth slit connecting the first slit with the second slit.

5. A method for producing a coil component, the method comprising:
a coil portion forming step of spirally winding a conductive wire to form a coil element;
a welding step of welding an end portion of the coil element to a holding member made of a processed metal;
a magnetic core forming step of embedding the coil element in a mixture of a magnetic material and a binding agent and press forming the mixture to form a magnetic core;
after the welding step, a terminal forming step of bending the holding member to form a terminal,
wherein the holding member has a recess portion, a first slit and a second slit which faces the first slit,
the end portion of the coil element and the holding member are welded together to the recess portion at an area between the first slit and the second slit,
the recess portion has a convex surface facing the magnetic core and a concave surface opposite to the convex surface, and
the end portion of the coil element is welded to the concave surface in the welding step.

6. The method for producing a coil component according to claim 5 , wherein
the first slit and the second slit each have a proximal-side width near an area where the end portion of the coil element protrudes from the magnetic core and a distal-side width far from the area, the proximal-side width being greater in dimension than the distal-side width, and
the holding member and the end portion of the coil element are applied with a soldering dip.

7. The method for producing a coil component according to claim 5 , wherein the step-formed portion of the holding member has a third slit positioned in an area to which the end portion of the coil element is directed to extend.

8. The method for producing a coil component according to claim 5 , wherein the step-formed portion of the holding member has a fourth slit connecting the first slit with the second slit.

Assignees

• Panasonic Ip Man Co Ltd

Inventors

• Wakamori Ikuya
• Ohtsubo Mutsuyasu
• Satou Manabu

Classifications

• H01F2017/048

  with encapsulating core, e.g. made of resin and magnetic powder · CPC title

• H01F41/10

  Connecting leads to windings (making electric connections in general H01R43/00) · CPC title

• H01F27/29

  Terminals; Tapping arrangements {for signal inductances} · CPC title

• H01F17/041

  Means for preventing rotation or displacement of the core · CPC title

• H01F17/04 Primary

  with magnetic core · CPC title