Method of producing a coil component

• US 9,177,720 B2
• Filed: 12/09/2013
• Issued: 11/03/2015
• Est. Priority Date: 04/27/2010
• Status: Active Grant

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: Yamada, Satoru, Hatayama, Yoshiyuki
• Primary Examiner(s): Kim, Paul D
• Application Number:
  US14/100,725
• Publication Number:
  US 20140090235A1
• Time in Patent Office: 694 Days
• Field of Search: 295/921, 296/021, 296/032.3, 296/05, 296/06, 336/65, 336/83, 336 90- 96, 336/192, 336/200, 336206-208, 336/232, 336/323
• US Class Current: 1/1
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 41/10 Connecting leads to windings making electric connections in general H01R43/00
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

A coil component includes a core formed by a magnetic material, a coil embedded in the core, a part of a terminal portion of the coil protruded from a side surface of the core, and a tabular terminal, a part thereof protruded from the side surface of the core and partly connected with the protruded part of the terminal portion of the coil. The protruded part of the terminal portion of the coil and the protruded part of the tabular terminal are respectively bent toward the bottom surface side of the core along the side surface of the core, and the protruded and bent part o the terminal portion of the coil is arranged between the protruded and bent part of the tabular terminal and the core.

Claims

1. A method of producing a coil component, comprising the steps of:

forming a coil having coil terminal portions drawn therefrom, and a terminal plate having a frame provided with a coil arrangement hole and terminal formation parts protruding toward a center of the coil arrangement hole, respectively, and opposing each other;

assembling the coil and the terminal plate such that the coil is arranged between the terminal formation parts of the frame of the terminal plate, protruding toward the center of the coil arrangement hole, respectively, and opposing each other, and the coil terminal portions of the coil are arranged on the back side of the terminal formation parts, respectively;

forming a green compact by arranging a mold such that the coil arranged between the terminal formation parts of the frame of the terminal plate, base parts of the coil terminal portions of the coil arranged on the back side of the terminal formation parts, and tip parts of the terminal formation parts protruding toward the center of the coil arrangement hole, respectively, and opposing each other, are embedded in the mold, respectively, filling the mold with granulation powder, and pressing the granulation powder filled in the mold;

forming a core embedding the coil, the base parts of the coil terminal portions of the coil arranged on the back side of the terminal formation parts, and the tip parts of the terminal formation parts protruding toward the center of the coil arrangement hole, respectively, and opposing each other, by heat-hardening the green compact, and cutting off the frame of the terminal plate from protruded parts of the terminal formation parts, protruded from opposing side surfaces of the core, respectively, thereby forming terminals protruded from the opposing side surfaces of the core, respectively, on the back side of which, protruded parts of the coil terminal portions of the coil, protruded from the opposing side surfaces of the core, respectively, being arranged, respectively;

connecting the terminals protruded from the opposing side surfaces of the core, respectively, and the protruded parts of the coil terminal portions of the coil, protruded from the side surfaces of the core and arranged on the back side of the terminals protruded from the opposing side surfaces of the core, respectively, with each other; and

bending the terminals protruded from the opposing side surfaces of the core, respectively, and the protruded parts of the coil terminal portions of the coil, protruded from the opposing side surfaces of the core and arranged on the back side of the terminals protruded from the opposing side surfaces of the core, respectively, connected to each other, along the opposing side surfaces of the core, using a jig, and further bending the terminals bent along the opposing side surfaces of the core along a bottom surface of the core, respectively.

2. The method according to claim 1, wherein the step of forming a coil and a terminal plate includes forming the coil terminal portions of the coil in flat shapes, respectively.

3. The method according to claim 2, wherein the step of forming a green compact includes forming first grooves and second grooves in opposing side surfaces of the green compact, the first grooves formed in the second grooves, and the first grooves and the second grooves formed such that when the terminals protruded from the opposing side surfaces of the core, respectively, formed by cutting off the frame of the terminal plate from the protruded parts of the terminal formation parts, protruded from the opposing side surfaces of the core, respectively, and the protruded parts of the coil terminal portions of the coil formed in flat shapes, protruded from the opposing side surfaces of the core and arranged on the back side of the terminals protruded from the opposing side surfaces of the core, respectively, are bent along the opposing side surfaces of the core, the protruded parts of the coil terminal portions of the coil formed in flat shapes, protruded from the opposing side surfaces of the core and arranged on the back side of the terminals protruded from the opposing side surfaces of the core, respectively, are accommodated in the first grooves, and the terminals protruded from the opposing side surface of the core, respectively, are accommodated in the second grooves.

4. The method according to claim 1, wherein the step of assembling the coil and the terminal plate includes forming the coil terminal portions of the coil in flat shapes, respectively.

5. The method according to claim 4, wherein the step of forming a green compact includes forming first grooves and second grooves in opposing side surfaces of the green compact, the first grooves formed in the second grooves, and the first grooves and the second grooves formed such that when the terminals protruded from the opposing side surfaces of the core, respectively, formed by cutting off the frame of the terminal plate from the protruded parts of the terminal formation parts, protruded from the opposing side surfaces of the core, respectively, and the protruded parts of the coil terminal portions of the coil formed in flat shapes, protruded from the opposing side surfaces of the core and arranged on the back side of the terminals protruded from the opposing side surfaces of the core, respectively, are bent along the opposing side surfaces of the core, the protruded parts of the coil terminal portions of the coil formed in flat shapes, protruded from the opposing side surfaces of the core and arranged on the back side of the terminals protruded from the opposing side surfaces of the core, respectively, are accommodated in the first grooves, and the terminals protruded from the opposing side surface of the core, respectively, are accommodated in the second grooves.

6. The method according to claim 1, wherein the step of forming a core and cutting off the frame of the terminal plate includes cutting the coil terminal portions of the coil into a predetermined length.