COIL COMPONENT AND METHOD FOR PRODUCING SAME

• US 20160351323A1
• Filed: 03/09/2015
• Published: 12/01/2016
• Est. Priority Date: 03/14/2014
• Status: Active Grant

• Current Assignee: Panasonic Intellectual Property Management Co., Ltd. (Panasonic Holdings Corporation)
• Original Assignee: Panasonic Intellectual Property Management Co., Ltd. (Panasonic Holdings Corporation)
• Inventors: WAKAMORI, Ikuya, SATOU, Manabu, OHTSUBO, Mutsuyasu
• Granted Patent: US 9,984,809 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 17/041 Means for preventing rotation or displacement of the core
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• 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 41/0246 Manufacturing of magnetic circuits by moulding or by pressing powder magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36
• CPC Class Codes: H01F 41/064 Winding non-flat conductive wires, e.g. rods, cables or cords
• CPC Class Codes: H01F 41/10 Connecting leads to windings making electric connections in general H01R43/00

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.

Claims

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 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,

wherein the holding member has a first slit and a second slit which faces the first slit, and

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.

2. The coil component according to claim 1, wherein

the holding member has a step-formed portion recessed toward a center of the magnetic core, and

the end portion of the coil element overlaps with the holding member at tile step-formed portion.

3. 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.

4. 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.

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

6. 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 a holding member made of a processed metal plate to an end portion of the coil element;

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;

a terminal forming step of bending the holding member to form a terminal,

wherein the holding member has a first slit and a second slit which faces the first slit, and

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.

7. The method for producing a coil component according to claim 6, wherein

the holding member has a step-formed portion, and

the first slit and the second slit are formed in the step-formed portion.

8. The method for producing a coil component according to claim 6, 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.

9. The method for producing a coil component according to claim 7, 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.

10. The method for producing a coil component according to claim 6, wherein the step-formed portion of the holding member has a fourth slit connecting the first slit with the second slit.