Drum core and wire coil component

Abstract

A drum core includes a core portion that extends in an axial direction, first and second flange portions respectively disposed at first and second ends of the core portion in the axial direction, and first and second terminal electrodes respectively disposed at the first and second flange portions. The first flange portion includes a bottom surface that is substantially parallel to the axial direction and on which the first terminal electrode is disposed, an outer end surface that is substantially perpendicular to the axial direction and that faces outward away from the core portion, and a first ridge portion and a second ridge portion respectively disposed at a first end and a second end of the outer end surface in a width direction substantially parallel to the bottom surface and the outer end surface, and the first ridge portion and the second ridge portion have different shapes.

Claims

1. A drum core comprising: a core portion that extends in an axial direction; a first flange portion and a second flange portion respectively disposed at a first end and a second end of the core portion in the axial direction; and a first terminal electrode and a second terminal electrode respectively disposed at the first flange portion and the second flange portion, wherein the first flange portion includes a bottom surface that is substantially parallel to the axial direction and on which the first terminal electrode is disposed, an outer end surface that is substantially perpendicular to the axial direction and that faces outward away from the core portion, and a first ridge portion and a second ridge portion respectively disposed at a first end and a second end of the outer end surface in a width direction substantially parallel to the bottom surface and the outer end surface, and the first ridge portion and the second ridge portion have different shapes, and wherein the first ridge portion is at the first end of the outer end surface where the outer end surface meets the bottom surface, and the second ridge portion is at the second end of the outer end surface where the outer end surface meets the bottom surface.

2. The drum core according to claim 1, wherein the first ridge portion has a larger dimension in the axial direction than the second ridge portion.

3. The drum core according to claim 1, wherein the first ridge portion and the second ridge portion have curved shapes, and the first ridge portion has a radius of curvature larger than a radius of curvature of the second ridge portion.

4. The drum core according to claim 1, wherein the first flange portion further includes an inner end surface that is substantially perpendicular to the axial direction and faces the core portion, and a third ridge portion disposed at a first end of the inner end surface, on a same side as the first end of the outer end surface, and wherein the third ridge portion has a smaller dimension in the axial direction than the first ridge portion.

5. The drum core according to claim 4, wherein the first ridge portion and the third ridge portion have curved shapes, and the third ridge portion has a radius of curvature smaller than a radius of curvature of the first ridge portion.

6. The drum core according to claim 1, wherein the first flange portion further includes an inner end surface that is substantially perpendicular to the axial direction and faces the core portion, and a third ridge portion and a fourth ridge portion respectively disposed at a first end and a second end of the inner end surface, the first end and the second end of the inner end surface are respectively on a same side as the first end and the second end of the outer end surface, and wherein each of the third ridge portion and the fourth ridge portion has a smaller dimension in the axial direction than both of the first ridge portion and the second ridge portion.

7. The drum core according to claim 6, wherein the first ridge portion, the second ridge portion, the third ridge portion, and the fourth ridge portion have curved shapes, and each of the third ridge portion and the fourth ridge portion has a radius of curvature smaller than both of a radius of curvature of the first ridge portion and a radius of curvature of the second ridge portion.

8. The drum core according to claim 1, wherein the first ridge portion has a planar shape.

9. The drum core according to claim 1, wherein the first ridge portion includes, in combination, a curved shape continuous with a first end of the outer end surface and a planar shape continuous with the curved shape.

10. The drum core according to claim 1, wherein when viewed in a direction substantially orthogonal to the bottom surface, the first flange portion and the second flange portion are centrally symmetric with respect to a center of the core portion.

11. The drum core according to claim 1, wherein the first flange portion has a dimension in the axial direction of smaller than or equal to about 0.35 mm.

12. A wire coil component, comprising: the drumm core according to claim 1; and a plurality of wires wound around the core portion of the drum core.

13. The drum core according to claim 2, wherein the first ridge portion and the second ridge portion have curved shapes, and the first ridge portion has a radius of curvature larger than a radius of curvature of the second ridge portion.

14. The drum core according to claim 2, wherein the first flange portion further includes an inner end surface that is substantially perpendicular to the axial direction and faces the core portion, and a third ridge portion disposed at a first end of the inner end surface, on a same side as the first end of the outer end surface, and wherein the third ridge portion has a smaller dimension in the axial direction than the first ridge portion.

15. The drum core according to claim 2, wherein the first flange portion further includes an inner end surface that is substantially perpendicular to the axial direction and faces the core portion, and a third ridge portion and a fourth ridge portion respectively disposed at a first end and a second end of the inner end surface, the first end and the second end of the inner end surface are respectively on a same side as the first end and the second end of the outer end surface, and wherein each of the third ridge portion and the fourth ridge portion has a smaller dimension in the axial direction than both of the first ridge portion and the second ridge portion.

16. The drum core according to claim 2, wherein the first ridge portion has a planar shape.

17. The drum core according to claim 2, wherein the first ridge portion includes, in combination, a curved shape continuous with a first end of the outer end surface and a planar shape continuous with the curved shape.

18. The drum core according to claim 2, wherein when viewed in a direction substantially orthogonal to the bottom surface, the first flange portion and the second flange portion are centrally symmetric with respect to a center of the core portion.

19. The drum core according to claim 2, wherein the first flange portion has a dimension in the axial direction of smaller than or equal to about 0.35 mm.

20. A wire coil component, comprising: the drum core according to claim 2; and a plurality of wires wound around the core portion of the drum core.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a wire coil component;

(2) FIG. 2 is a cross-sectional view of a drum core according to a first embodiment;

(3) FIG. 3 is a cross-sectional view of a drum core according to a second embodiment;

(4) FIGS. 4A to 4C are cross-sectional views of a drum core according to a third embodiment;

(5) FIG. 5 is a cross-sectional view of a drum core according to a fourth embodiment; and

(6) FIG. 6 is a side view of a drum core held by jigs.

DETAILED DESCRIPTION

(7) Embodiments, which are aspects of the present disclosure, are described below with reference to the drawings.

First Embodiment

(8) A wire coil component 1 illustrated in FIG. 1 includes a drum core 2, and two wires 3a and 3b, wound around a core portion 4 of the drum core 2. The wire coil component 1 is, for example, a common-mode choke coil.

(9) The drum core 2 is formed from, for example, an electrical insulating material, specifically, a non-magnetic material such as alumina or resin, or a magnetic material such as ferrite or resin containing magnetic powder. Preferably, the drum core 2 is formed from a sintered body such as alumina or ferrite.

(10) The drum core 2 includes a core portion 4, having a quadrangular prism shape extending in the axial direction (direction of arrow A in FIG. 1), a first flange portion 5 and a second flange portion 6, respectively disposed at a first end and a second end of the core portion 4 in the axial direction, first terminal electrodes 10a and 10b and second terminal electrodes 10c and 10d, respectively disposed at the first flange portion 5 and the second flange portion 6. The core portion 4, the first flange portion 5, and the second flange portion 6 are integrated together.

(11) The first and second flange portions 5 and 6 have a width W and a height H larger than the width and the height of the core portion 4, and a thickness T smaller than the length of the core portion 4. The first and second flange portions 5 and 6 project from the core portion 4 into a flange shape. In the above description, the length of the core portion 4 and the thickness T of the first and second flange portions 5 and 6 correspond to the dimensions in the axial direction. The height corresponds to the dimension in the direction substantially perpendicular to a mount surface defined by the first terminal electrodes 10a and 10b and the second terminal electrodes 10c and 10d. The width corresponds to the dimension in the direction substantially perpendicular to both the length and the height. The thickness T is, for example, smaller than or equal to about 0.35 mm. The directions substantially parallel to the height and the width are respectively referred to as a height direction and a width direction (direction of arrow B in FIG. 1).

(12) The first flange portion 5 has bottom surfaces 5b and 5c, which are substantially parallel to the axial direction of the core portion 4 and on which the first terminal electrodes 10a and 10b are disposed, an outer end surface 7a, which is substantially perpendicular to the axial direction and faces outward away from the core portion 4, and a third side surface 8c and a fourth side surface 8d, which are disposed on both sides of the outer end surface 7a in the width direction B and are substantially perpendicular to the outer end surface 7a and substantially parallel to the axial direction. The first flange portion 5 also has inner end surface 9a, which is substantially perpendicular to the axial direction and faces inward toward the core portion 4.

(13) Similarly, the second flange portion 6 has bottom surfaces 6b and 6c, which are substantially parallel to the axial direction of the core portion 4 and on which the second terminal electrodes 10c and 10d are disposed, an outer end surface 7b, which is substantially perpendicular to the axial direction and faces outward away from the core portion 4, and a first side surface 8a and a second side surface 8b, which are disposed on both sides of the outer end surface 7b in the width direction B and which are substantially perpendicular to the outer end surface 7b and substantially parallel to the axial direction. The second flange portion 6 also has inner end surface 9b, which is substantially perpendicular to the axial direction and faces inward toward the core portion 4. As is clear from the above structure, the width direction B is substantially parallel to the bottom surfaces 5b, 5c, 6b, and 6c and the outer end surfaces 7a and 7b.

(14) The first terminal electrodes 10a and 10b and the second terminal electrodes 10c and 10d are disposed on the bottom surfaces 5c, 5c, 6b, and 6c of protruding steps extending in the height direction from the lower portions of the first and second flange portions 5 and 6. The first terminal electrodes 10a and 10b and the second terminal electrodes 10c and 10d are formed by baking electroconductive paste containing, for example, silver as an electroconductive component, and, as needed, plated with Ni, Cu, Sn, or other metal. Instead, the first terminal electrodes 10a and 10b and the second terminal electrodes 10c and 10d may be terminal metal fittings bonded to the first and second flange portions 5 and 6 and formed from electroconductive metal plates covering the bottom surfaces 5b, 5c, 6b, and 6c.

(15) The wires 3a and 3b are formed from, for example, an insulating coating formed from resin such as polyurethane or polyimide, and a copper wire coated with the insulating coating. The wires 3a and 3b are helically wound around the core portion 4 in two layers to form a coil C. The wire 3a has a first end 11a connected to the terminal electrode 10a, and a second end 11b connected to the terminal electrode 10c. The wire 3b has a first end 12a connected to the terminal electrode 10b, and a second end 12b connected to the terminal electrode 10d. The first terminal electrodes 10a and 10b and the second terminal electrodes 10c and 10d are connected to the wires 3a and 3b by, for example, thermocompression bonding or laser welding.

(16) A flat core 13 is a plate-shaped member bonded to top surfaces 5a and 6a (undersurfaces in FIG. 1), opposite to the bottom surfaces 5b, 5c, 6b, and 6c of the first and second flange portions 5 and 6 of the drum core 2 with a bonding agent. The flat core 13 is formed from a material the same as that of the drum core 2, and has a height t3, which is lower than or equal to ⅓ of the height of the wire coil component 1 including the flat core 13. Preferably, the flat core 13 may be formed from the same material as the drum core 2 to form a stable, closed magnetic circuit. Alternatively, the flat core 13 may be formed from resin to have a small thickness regardless of the material of the drum core 2.

(17) The shapes of the first and second flange portions 5 and 6 are described, below.

(18) As illustrated in FIG. 2, the first flange portion 5 includes a first ridge portion 15h and a second ridge portion 15f, respectively disposed at the first end and the second end of the outer end surface 7a in the width direction B, and a third ridge portion 15g and a fourth ridge portion 15e, respectively disposed at the first end and the second end of the inner end surface 9a in the width direction B. In the above description, the first ends are closer to the fourth side surface 8d, and the second ends are closer to the third side surface 8c. In the first flange portion 5, the inner end surface 9a, the third ridge portion 15g, the fourth side surface 8d, the first ridge portion 15h, the outer end surface 7a, the second ridge portion 15f, the third side surface 8c, the fourth ridge portion 15e, and the inner end surface 9a are continuous in this order.

(19) Similarly, the second flange portion 6 includes a first ridge portion 15a and a second ridge portion 15c, respectively disposed at the first end and the second end of the outer end surface 7b in the width direction B, and a third ridge portion 15b and a fourth ridge portion 15d, disposed at the first end and the second end of the inner end surface 9b in the width direction B. In the above description, the first ends are closer to the first side surface 8a, and the second ends are closer to the second side surface 8b. The first ends and the second ends are in the positions opposite to those in the first flange portion 5. In the second flange portion 6, the inner end surface 9b, the third ridge portion 15b, the first side surface 8a, the first ridge portion 15a, the outer end surface 7b, the second ridge portion 15c, the second side surface 8b, the fourth ridge portion 15d, and the inner end surface 9b are continuous in this order.

(20) The ridge portions 15a to 15h have curved shapes. In the second flange portion 6, the first ridge portion 15a and the second ridge portion 15c have different shapes. Specifically, the first ridge portion 15a and the second ridge portion 15c have curved shapes, and the first ridge portion 15a has a radius of curvature larger than the radius of curvature of the second ridge portion 15c. Thus, the first ridge portion 15a has a dimension in the axial direction longer than the second ridge portion 15c, and the first side surface 8a and the second side surface 8b are asymmetric with respect to each other.

(21) Now, the effect of the drum core 2 with the above structure is described.

(22) When a winding machine including jigs having different shapes, as in the jigs 31 and 32 in FIG. 6, is to hold the drum core 2, the drum core 2 has a smaller breaking/cracking risk while bearing a holding force to have a wire wound therearound. Specifically, to hold the second flange portion 6 of the drum core 2 with jigs, the first ridge portion 15a and the second ridge portion 15c, which have different shapes, may be in contact with one of the jigs over a larger contact area, and in contact with the other jig over a smaller contact area.

(23) Specifically, the radius of curvature of the first ridge portion 15a is larger than the radius of curvature of the second ridge portion 15c, and the first ridge portion 15a has a larger dimension in the axial direction than the second ridge portion 15c. Thus, the first ridge portion 15a is in contact with the corresponding jig over a small contact area, and the second ridge portion 15c is in contact with the corresponding jig over a large contact area.

(24) The inventor of the present application has found that jigs with different shapes have different correlations between the holding force exerted on the contact area and the breaking/cracking risk on the contact area. Specifically, for example, in the jigs 31 and 32 illustrated in FIG. 6, the inventor of the present application has found that the jig 31 has a smaller constant of proportionality of the breaking/cracking risk on the contact area relative to the constant of proportionality of the holding force exerted on the contact area, and the jig 32 has a larger constant of proportionality of the breaking/cracking risk on the contact area relative to the constant of proportionality of the holding force exerted on the contact area.

(25) Thus, in this case, the second ridge portion 15c that comes into contact with the jig 31 over a larger contact area is in contact with the jig 31, and the first ridge portion 15a that comes into contact with the jig 32 over a smaller contact area is in contact with the jig 32. Here, when the drum core 2 is held by a winding machine, the drum core 2 can bear a larger holding force while having the breaking/cracking risk reduced to a relatively low level. Specifically, the drum core 2 has a smaller breaking/cracking risk while bearing a larger holding force to have a wire wound therearound.

(26) The second flange portion 6 of the drum core 2 has a dimension substantially parallel to the axial direction (thickness T) of the first and second flange portions 5 and 6 of smaller than or equal to about 0.35 mm. Here, the first and second flange portions 5 and 6 are thin, and has low absolute strength. As described above, the drum core 2 more effectively reduces the breaking/cracking risk.

(27) The wire coil component 1 includes the drum core 2 and multiple, specifically, two wires 3a and 3b wound around the core portion 4 of the drum core 2. As the number of wires wound around the core portion 4 increases, the stress exerted on the drum core 2 increases, and the demand for the increase of the holding force or the reduction of the breaking/cracking risk increases. Thus, the wire coil component 1 including the two wires 3a and 3b more effectively exerts the above effect and has a stable quality.

(28) In the wiring step, the flange portion of the drum core 2 that is to be held is selectable. Thus, the first and second flange portions 5 and 6, which are designated for convenience sake, may be switched. Specifically, for example, the flange portion 5 may be a second flange portion and the flange portion 6 may be a first flange portion.

Second Embodiment

(29) FIG. 3 illustrates a second embodiment. A drum core 2a according to this embodiment includes a first flange portion 5, which includes a first ridge portion 15h and a third ridge portion 15g, disposed at the first ends of the outer end surface 7a and the inner end surface 9a in the width direction B. The first ridge portion 15h and the third ridge portion 15g respectively have the same shapes as the first ridge portion 15a and the third ridge portion 15b of the second flange portion. Thus, the third side surface 8c and the fourth side surface 8d are asymmetric with respect to each other. Other components are the same as those of the first embodiment.

(30) Thus, as shown in FIG. 3, when viewed in the direction substantially orthogonal to the bottom surfaces 5b, 5c, 6b, and 6c, the first flange portion 5 and the second flange portion 6 are centrally symmetric with respect to the center of the core portion 4.

(31) The drum core 2a having the above structure does not limit the flange portion that is to be held to either one of the first flange portion 5 and the second flange portion 6 to have wires 3a and 3b wound therearound, thereby improving manufacturing efficiency.

(32) The above drum core 2a has the following effects besides the effects obtained in the first embodiment.

(33) (1) The drum core 2a has substantially no difference between the bottom surface and the top surface. Thus, for example, this structure does not require an operator to select from the near side and the far side of FIG. 3 on which the terminal electrodes 10a to 10d are to be disposed and on which the flat core 13 is to be bonded. Thus, besides the step of winding the wires 3a and 3b around the drum core 2a, the step of forming the terminal electrodes 10a to 10d is also performed with improved efficiency.

Third Embodiment

(34) FIGS. 4A to 4C illustrate a third embodiment. In a drum core 2b according to this embodiment, the third ridge portions 15g and 15b and the fourth ridge portions 15e and 15d disposed on the inner end surfaces 9a and 9b of the first and second flange portions 5 and 6 have shapes changed from those of the other embodiment.

(35) Compared to the first ridge portions 15h and 15a and the second ridge portions 15f and 15c disposed closer to the outer end surfaces 7a and 7b, the third ridge portions 15g and 15b and the fourth ridge portions 15e and 15d disposed closer to the inner end surfaces 9a and 9b are affected to a lesser extent by the difference of jig shapes. The third ridge portions 15g and 15b and the fourth ridge portions 15e and 15d both have a small constant of proportionality of the breaking/cracking risk on the contact area relative to the constant of proportionality of the holding force exerted on the contact area, and can enhance the holding force with the increase of the contact area without largely affecting the breaking/cracking risk. Thus, the holding force can be further enhanced as the third ridge portions 15g and 15b and the fourth ridge portions 15e and 15d disposed closer to the inner end surfaces 9a and 9b have a smaller radius of curvature.

(36) Particularly, the radius of curvature of the third ridge portions 15g and 15b, respectively disposed on the same side as the first ridge portions 15h and 15a that have a large radius of curvature and come into contact with the jig over a smaller contact area, is preferably smaller than the radius of curvature of the first ridge portions 15h and 15a. Thus, the third ridge portions 15g and 15b have a dimension in the axial direction smaller than the first ridge portions 15h and 15a. In this structure, the third ridge portions 15g and 15b have large contact areas over which they come into contact with the jig, and the reduction of the holding force exerted on the first ridge portions 15h and 15a can be prevented. Thus, the holding force can be enhanced without a large effect on the breaking/cracking risk.

(37) In addition, the radii of curvature of the third ridge portions 15g and 15b and the fourth ridge portions 15e and 15d affect the areas of the flat portions of the bottom surfaces 5b, 5c, 6b, and 6c of the first and second flange portions 5 and 6. As the flat portions have larger areas, the wire coil component 1 is further stabilized on a mount substrate during being mounted thereon. Thus, the third ridge portions 15g and 15b and the fourth ridge portions 15e and 15d preferably have small radii of curvature.

(38) In FIG. 4A, illustrating an example of the drum core 2b, the third ridge portions 15g and 15b and the fourth ridge portions 15e and 15d have dimensions in the axial direction shorter than those of the first ridge portions 15h and 15a and the second ridge portions 15f and 15c. More specifically, the first ridge portions 15h and 15a, the second ridge portions 15f and 15c, the third ridge portions 15g and 15b, and the fourth ridge portions 15e and 15d have curved shapes, and the third ridge portions 15g and 15b and the fourth ridge portions 15e and 15d respectively have radii of curvature smaller than the radii of curvature of the first ridge portions 15h and 15a and the second ridge portions 15f and 15c. Other components are the same as those of the second embodiment illustrated in FIG. 3.

(39) In FIG. 4B, illustrating another example of the drum core 2b, the fourth ridge portions 15e and 15d have shorter dimensions in the axial direction than the first ridge portions 15h and 15a and the second ridge portions 15f and 15c. More specifically, the fourth ridge portions 15e and 15d have a radius of curvature smaller than the radii of curvature of the first ridge portions 15h and 15a and the second ridge portions 15f and 15c. Other components are the same as those of the second embodiment illustrated in FIG. 3.

(40) In FIG. 4C, illustrating another example of the drum core 2b, the third ridge portions 15g and 15b have dimensions in the axial direction smaller than the first ridge portions 15h and 15a and the second ridge portions 15f and 15c. More specifically, the third ridge portions 15g and 15b have a radius of curvature smaller than the radii of curvature of the first ridge portions 15h and 15a and the second ridge portions 15f and 15c. Other components are the same as those of the second embodiment illustrated in FIG. 3.

(41) As illustrated in FIGS. 4B and 4C, only either the third ridge portions 15g and 15b or the fourth ridge portions 15e and 15d may have smaller radii of curvature. As illustrated in FIG. 4C, the third ridge portions 15g and 15b and the fourth ridge portions 15e and 15d may be any radii of curvature smaller than those of the first ridge portions 15h and 15a and equivalent to those of the second ridge portions 15f and 15c. However, particularly preferably, both the third ridge portions 15g and 15b and the fourth ridge portions 15e and 15d have radii of curvature smaller than those of the first ridge portions 15h and 15a and the second ridge portions 15f and 15c.

(42) As is clear from the above description, the first ridge portions 15h and 15a, the second ridge portions 15f and 15c, the third ridge portions 15g and 15b, and the fourth ridge portions 15e and 15d do not necessarily have to have curved shapes, and may have a planar shape extending straight to connect the side surfaces 8a to 8d to the outer end surfaces 7a and 7b or the inner end surfaces 9a and 9b. Here, the contact area with the corresponding jig can be determined with the dimension in the axial direction, instead of the radii of curvature. Thus, the first ridge portions 15h and 15a, the second ridge portions 15f and 15c, the third ridge portions 15g and 15b and, and the fourth ridge portions 15e and 15d may have dimensions in the axial direction satisfying the above relationship.

(43) Particularly, the first ridge portions 15h and 15a having a planar shape can have a dimension in the axial direction larger than the second ridge portions 15f and 15c by being subjected to post processing such as cutting or grinding after forming a drum core. Thus, the first ridge portions 15h and 15a can be more easily formed.

Fourth Embodiment

(44) FIG. 5 illustrates a fourth embodiment. In a drum core 2c according to this embodiment, the first ridge portion 15a and the third ridge portion 15b according to the first embodiment are formed with combinations each including a curved shape 16 and a planar shapes 17, continuous with the curved shape 16.

(45) The above embodiments are mere examples, and all or some of the components of each embodiment may be flexibly combined with any component of another embodiment.

(46) While some embodiments of the disclosure have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the disclosure. The scope of the disclosure, therefore, is to be determined solely by the following claims.