Coil device capable of performing a wire connection

• US 10,170,234 B2
• Filed: 01/21/2016
• Issued: 01/01/2019
• Est. Priority Date: 01/22/2015
• Status: Active Grant

• Current Assignee: TDK Corporation
• Original Assignee: TDK Corporation
• Inventors: Iwata, Hiroyuki, Takagi, Nobuo, Abe, Hiroyuki, Shimura, Koji
• Primary Examiner(s): Enad, Elvin G
• Assistant Examiner(s): Barnes, Malcolm
• Application Number:
  US15/003,602
• Publication Number:
  US 20160217919A1
• Time in Patent Office: 1,076 Days
• CPC Class Codes: H01F 17/045 with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
• CPC Class Codes: H01F 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support

Abstract

A coil device includes a magnetic core and terminal electrodes. The terminal electrodes include attachment pieces, wire connection rising pieces, connection pieces, and fillet forming pieces. The wire connection rising pieces are integrally risen from one ends in a longitudinal direction of the attachment pieces along a side surface in the X-axis direction of a flange. The connection pieces are integrally formed with upper end sides of the wire connection rising pieces and have welded balls connected to lead parts of a wire by laser welding. The fillet forming pieces are integrally risen from one ends in a lateral direction crossing the longitudinal direction of the attachment pieces along a side surface in the Y-axis direction of the flange. Laser shielding members are arranged between the welded balls and the flange of a magnetic core.

Claims

1. A coil device comprising:

a magnetic core having a winding core wound by a wire to form a coil;

a first flange and a second flange having a substantially planar shape and integrally formed at both ends in the winding axis direction of the winding core; and

a terminal electrode attached on an outer end surface of the first flange formed at an end in a winding axis direction of the winding core, wherein the terminal electrode comprises;

an attachment piece contacted with the outer end surface of the first flange;

a wire connection rising piece integrally risen from one end in a longitudinal direction of the attachment piece along a side surface in a first axis direction of the first flange; and

a connection piece formed integrally with an upper end side of the wire connection rising piece and having a welded ball connected to a lead part of the wire by laser welding, and wherein

a laser shielding member is arranged between the welded ball and the magnetic core,

the side surface in the first axis direction of the first flange includes;

a rising piece facing plane facing the wire connection rising piece in such a manner as to be contactable with the wire connection rising piece to position the connection piece; and

a terminal space concave part caved inside from the rising piece facing plane to form a space between the terminal space concave part and the wire connection rising piece,

the shielding member is formed integrally with the wire connection rising piece of the terminal electrode,

the shielding member is held in space between the welded ball and the terminal space concave part of the magnetic core,

the first flange has notches dented more largely than the second flange so that an outer shape size of the first flange is smaller than that of the second flange,

the rising piece facing plane and the terminal space concave part are formed on the notches, and

the wire connection rising piece is located inside the notches.

2. The coil device as set forth in claim 1, wherein

a lead connection part consisting of the welded ball is formed within a range of a thickness of the first flange.

3. The coil device as set forth in claim 1, wherein

an exterior resin surrounds the winding core wound by the wire.

4. The coil device as set forth in claim 1, wherein

a temporary lock piece for temporarily locking the lead part of the wire is formed integrally with the upper end side of the wire connection rising piece and separately from the connection piece.

5. The coil device as set forth in claim 1, wherein

the shielding member is formed integrally with the wire connection rising piece to shield the magnetic core from being irradiated by a laser beam irradiated for connecting a tip of the lead part of the wire and the connection piece from a direction crossing the side surface in the first axis direction toward the connection piece and the tip of the lead part of the wire.

13. The coil device as set forth in claim 1, wherein

a tip in the second axis direction of the shielding piece is bent in the first axis direction toward the terminal space concave part, and is substantially flush with one of the side surfaces in the second axis direction of the first flange.

14. The coil device as set forth in claim 1, wherein the wire connection rising piece located inside the notches and formed on the first flange is hidden by corners of the second flange in a view from the winding axis direction.

6. A coil device comprising:

a magnetic core having a winding core wound by a wire to form a coil;

a first flange and a second flange having a substantially planar shape and integrally formed at both ends in a winding axis direction of the winding core; and

a terminal electrode attached on an outer end surface of the first flange formed at an end in the winding axis direction of the winding core, wherein the terminal electrode comprises;

an attachment piece contacted with the outer end surface of the first flange;

a wire connection rising piece integrally risen from one end in a longitudinal direction of the attachment piece along a side surface in a first axis direction of the first flange;

a connection piece formed integrally with an upper end side of the wire connection rising piece and connected with a lead part of the wire; and

a fillet forming piece integrally risen from one end in a lateral direction crossing the longitudinal direction of the attachment piece along a side surface in a second axis direction of the first flange, and wherein

the lead part of the wire is connected with the connection piece at a temperature equal to or higher than a melting temperature of a solder fillet to be formed on the fillet forming piece,

the first flange has notches dented more largely than the second flange so that an outer shape size of the first flange is smaller than that of the second flange,

the side surface in the first axis direction of the first flange includes;

a rising piece facing plane facing the wire connection rising piece to position the connection piece; and

a terminal space concave part caved inside from the rising piece facing plane to form a space between the terminal space concave part and the wire connection rising piece,

the rising piece facing plane and the terminal space concave part are formed on the notches, and

the wire connection rising piece is located inside the notches.

7. The coil device as set forth in claim 6, wherein

a lead connection part having the lead part of the wire connected with the connection piece is formed within a range of a thickness of the first flange.

8. The coil device as set forth in claim 6, wherein

an exterior resin surrounds the winding core wound by the wire.

9. The coil device as set forth in claim 6, wherein

the fillet forming piece rises lower than a thickness in the winding axis direction of the first flange.

10. The coil device as set forth in claim 6, wherein

an engagement concave part engaged with the fillet forming piece is formed on the side surface in the second axis direction of the first flange.

11. The coil device as set forth in claim 6, wherein

a temporary lock piece for temporarily locking the lead part of the wire is formed integrally with the upper end side of the wire connection rising piece and separately from the connection piece.

12. The coil device as set forth in claim 6, wherein

the shielding member is formed integrally with the wire connection rising piece to shield the magnetic core from being irradiated by a laser beam irradiated for connecting a tip of the lead part of the wire and the connection piece from a direction crossing the side surface in the first axis direction toward the connection piece and the tip of the lead part of the wire.

15. The coil device as set forth in claim 6, wherein the wire connection rising piece located inside the notches and formed on the first flange is hidden by corners of the second flange in a view from the winding axis direction.