Murata Manufacturing Co., Ltd.

Koji Onishi

Akio Igarashi

Takashi Murakami

Takuya Ishida

Yuuji Igarashi

Takao Miyamoto

Advantage is taken of the fact that tin has a higher efficiency of absorption of a laser beam than, for example, copper. A method of manufacturing a coil component includes preparing a wire that includes a linear, central conductor and an insulating coating that covers a circumferential surface of the central conductor, preparing a metal terminal that is to be electrically connected to the central conductor at an end portion of the wire and that has a surface on which a tin-containing film that contains tin is disposed and above which at least the end portion of the wire is to be disposed, and welding the central conductor of the wire to the metal terminal by irradiating at least the tin-containing film with a laser beam with the end portion of the wire disposed along the tin-containing film.

Method of manufacturing a coil component

A connection section of a terminal electrode includes a reference surface, and an end portion of a wire and the connection section of the terminal electrode are connected to each other via a weld lump rising from the reference surface. A cover section to regulate an upper limit of the rise of the wire from the reference surface is provided in the terminal electrode. The cover section is so positioned as to cover at least part of the wire when viewed in a direction perpendicular to a direction in which the reference surface extends.

Coil component

An adhesive layer is in contact with a rising portion of a metal terminal and an outer end surface of a flange portion of a drum-shaped core. A surface of the rising portion that faces the outer end surface is an inclined surface that inclines with respect to the outer end surface. The thickest portion of the adhesive layer is located near a position at which a distance between the inclined surface and the outer end surface is largest. The thickness of the thickest portion of the adhesive layer is 13 &#x3bc;m or more.

A weld nugget portion that is obtained by welding a central conductor of a wire and a receiving portion of a metal terminal is formed on the receiving portion that receives an end portion of the wire with the weld nugget portion expanding from a surface of the receiving portion along which the wire is disposed. An area ratio of a blowhole to a section of the weld nugget portion that is along an imaginary cut plane that is perpendicular to the surface of the receiving portion along which the wire is disposed is no less than 0% and no more than 8.4% (i.e., from 0% to 8.4%), preferably no less than 0% and no more than 1.3% (i.e., from 0% to 1.3%). A central axis of the central conductor of the wire in the weld nugget portion extends along the imaginary cut plane.

A method of manufacturing a coil component including a step of welding a wire to a metal terminal by laser welding capable of making positional displacement of the wire only minimally occur. As a metal terminal, a metal terminal having a connecting portion on which a positioning groove for receiving and positioning a portion of the wire is formed is prepared. The wire is temporarily fixed to the connecting portion in a state where the wire is positioned by being fitted in the positioning groove, and the wire and the metal terminal are welded to each other by irradiating a laser beam. The positioning groove is preferably formed into a V shape in cross section.

Method of manufacturing coil component

A coil component includes a wire including a linear central conductor and an insulating coating layer that covers a circumferential surface of the central conductor, and a terminal electrode that is electrically connected to the central conductor at an end portion of the wire. The terminal electrode includes a receiving portion to which the central conductor is welded. A weld nugget portion that is produced when the central conductor is welded and the receiving portion are welded to each other.

A terminal electrode is secured to a flange portion with an adhesive and includes a base disposed on an outer surface of the flange portion and a mounting portion disposed above a bottom surface of the flange portion and extending from a bent portion extending from the base and covering a ridge line along which the outer surface and the bottom surface meet. The mounting portion is not secured to the flange portion.

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.

A coil component including a wire has a central conductor and an insulating coating layer, and a terminal electrode has a connection part that is electrically connected to the central conductor. The connection part includes a receiving part that receives an end portion of the wire, and a welding part that extends from the receiving part via a fold-back part so as to face the receiving part. The wire becomes sandwiched between the receiving part and the welding part. The central conductor is welded to the welding part in the portion from which the insulating coating layer is removed. The distal end portion of the wire protrudes from the space between the receiving part and the welding part, with the insulating coating layer remaining on the distal end portion.

A coil component includes a conducting wire and a terminal electrode. The terminal electrode includes a first terminal piece and a second terminal piece that face and overlap each other with the conducting wire interposed therebetween. The first terminal piece and the second terminal piece are coupled to one another with a coupling portion and are integrated in a welded ball at a position different from a position of the coupling portion. An end portion of the conducting wire is in the welded ball.

A terminal electrode includes a base extending along the outer end face of a flange, a mounting part extending from the base along the bottom face of the flange via a first bending part that covers the edge portion where the outer end face and the bottom face meet, and a wire connection part extending from the base along a substantially horizontal face via a second bending part that covers the edge portion where the outer end face and the substantially horizontal face meet, the wire connection part being electrically connected to an end portion of a wire.

A coil component including a core, first metal terminals, second metal terminals and a wire. The first metal terminals and second metal terminals have mounting portions provided above the mounting surface and aligned above the mounting surface. One of the mounting portions of the first metal terminals has a first end surface facing one of the mounting portions of the second metal terminals and a second end surface other than the first end surface, and the first end surface has a chopped trace where surface roughness is higher than surface roughness of the second end surface.

Growing community of inventors

Nagaokakyo, Japan

Koji Onishi