Method of manufacturing coil component

• US 10,454,235 B2
• Filed: 09/25/2017
• Issued: 10/22/2019
• Est. Priority Date: 09/30/2016
• Status: Active Grant

• Current Assignee: Murata Manufacturing Co Limited
• Original Assignee: Murata Manufacturing Co Limited
• Inventors: Murakami, Takashi, Igarashi, Akio, Onishi, Koji
• Primary Examiner(s): Nguyen, Donghai D
• Application Number:
  US15/714,375
• Publication Number:
  US 20180097327A1
• Time in Patent Office: 757 Days
• Field of Search: 29605, 29843, 29876
• CPC Class Codes: H01F 17/043 with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)
• CPC Class Codes: H01F 2017/0093 Common mode choke coil
• CPC Class Codes: H01F 27/2828 Construction of conductive connections, of leads
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 5/04 Arrangements of electric connections to coils, e.g. leads
• CPC Class Codes: H01R 43/0221 Laser welding H01R43/0228 takes precedence
• CPC Class Codes: H01R 43/0228 without preliminary removing of insulation before soldering or welding
• CPC Class Codes: H01R 43/20 for assembling or disassembling contact members with insulating base, case or sleeve

Abstract

A metal terminal where a connecting portion has a receiving portion which receives a wire and a contact segment which extends from the receiving portion by way of a bending scheduled portion is prepared. By applying heat and pressure in a state where the wire is placed on the receiving portion for temporarily fixing the wire, the wire is adhered to the receiving portion using a molten or softened insulating resin coating as an adhesive agent. Next, the connecting portion is bent by way of the bending scheduled portion such that the contact segment faces the receiving portion by way of the wire and the contact segment is brought into contact with the wire. Next, by irradiating a laser beam to a portion of the metal terminal, the wire and the metal terminal are welded to each other.

Claims

1. A method of manufacturing a coil component which includes:

a wire having a conductive wire portion made of a conductor and an insulating resin coating which covers a peripheral surface of the conductive wire portion; and

a metal terminal having a connecting portion which is electrically connected to the conductive wire portion,

the method comprising;

preparing the metal terminal wherein the connecting portion of the metal terminal has a receiving portion which receives the wire and a contact segment extending from the receiving portion via a bending scheduled portion;

a thermocompression bonding step of applying heat and pressure in a state where the wire is placed on the receiving portion, and adhering the wire to the receiving portion by melting or softening the insulating resin coating for use as an adhesive agent;

a contacting step of bending the connecting portion at the bending scheduled portion such that the contact segment faces the receiving portion via the wire and the contact segment is brought into contact with the wire; and

welding the wire and the metal terminal to each other by irradiating a laser beam to a portion of the metal terminal such that the entire receiving portion in the thickness direction and the entire contact segment in the thickness direction are integrally formed with each other at respective distal end portions of the receiving portion and the contact segment, and the whole periphery of the end portion of the wire is covered by a melted ball.

2. The method of manufacturing a coil component according to claim 1, wherein the thermocompression bonding step includes a step of exposing the conductive wire portion from the insulating resin coating by removing a portion of the insulating resin coating located on a side opposite to a receiving portion side.

3. The method of manufacturing a coil component according to claim 1 further comprising exposing the conductive wire portion from the insulating resin coating by irradiating a laser beam to the wire after the thermocompression bonding step is performed.

4. The method of manufacturing a coil component according to claim 2, wherein, in the contacting step, the contact segment is brought into contact with the conductive wire portion exposed from the insulating resin coating.

5. The method of manufacturing a coil component according to claim 1, wherein the contacting step includes a step of clamping the receiving portion and the contact segment of the metal terminal so as to bring the receiving portion and the contact segment into a close contact state.

6. The method of manufacturing a coil component according to claim 1, wherein, in the welding step, a laser beam is irradiated to a surface of the contact segment on a side opposite to a surface of the contact segment which is adhered to the wire.