JP2004055920A - Coil component and method for forming the same - Google Patents

Coil component and method for forming the same Download PDF

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JP2004055920A
JP2004055920A JP2002212940A JP2002212940A JP2004055920A JP 2004055920 A JP2004055920 A JP 2004055920A JP 2002212940 A JP2002212940 A JP 2002212940A JP 2002212940 A JP2002212940 A JP 2002212940A JP 2004055920 A JP2004055920 A JP 2004055920A
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coil
winding
coil elements
coil component
elements
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JP3737461B2 (en
Inventor
Hiroki Okada
岡田　宏樹
Yasunari Makiuchi
牧内　康徳
Isao Nagano
長野　勲
Norihiro Ikeda
池田　紀宏
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Togo Seisakusho Corp
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Togo Seisakusho Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil component and a method for forming the coil component capable of curtailing a space occupied by a coil component. <P>SOLUTION: In a coil component 10, a plurality of coil elements 11, 12 arranged in parallel are formed by one winding 1. Along with this, a connection part 1b of the winding 1 installed between the coil elements 11, 12 is accommodated in an external shape by end planes 11a, 12a of both the coil elements 11, 12. The plurality of coil elements 11, 12 are formed stepwise and eccentrically by the winding 1, in an axial direction thereof through the connection part 1b of the winding 1 between the coil elements 11, 12. Thereafter, the coil elements 11, 12 which are contiguous to each other by folding the connection part 1b of the winding 1 are arranged in parallel, and the connection part 1b is accommodated in the external shape by the end planes 11a, 12a of both the coil elements 11, 12. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、コイル部品及びコイル部品の成形方法に関する。
【０００２】
【従来の技術】
従来のコイル部品の一例を図１２により述べる。コイル部品１１０は、並列状に並べられた二つのコイル要素１１１，１１２を備えている。各コイル要素１１１，１１２は、それぞれ個別の巻線１０１，１０２によって形成されている。各巻線１０１，１０２の連結側の端部１０１ａ，１０２ａが連絡用ターミナル１１５を介して相互に連結されている。各連結側の端部１０１ａ，１０２ａと連絡用ターミナル１１５とは、ＴＩＧ溶接、レーザー溶接等の溶接手段によって接続されている。
【０００３】
【発明が解決しようとする課題】
しかしながら、上記従来のコイル部品１１０によると、連絡用ターミナル１１５を介して両コイル要素１１１，１１２の巻線１０１，１０２が相互に連結されている。このため、両コイル要素１１１，１１２と連絡用ターミナル１１５との接続にかかる溶接の関係上、連絡用ターミナル１１５及び各巻線１０１，１０２の連結側の端部（各コイル要素の連結側の端部もいう）１０１ａ，１０２ａが両コイル要素１１１，１１２の端面による外形から外側方（図１２において前方）へはみ出ることになり、コイル部品１１０の占有スペースの増大を余儀なくされるという問題があった。このことは、コイル部品１１０を組込むトランス等の電気部品の大型化を招く一因となることから、その改善が望まれている。
【０００４】
なお、特開２０００−１０５５３号公報に記載されたコイル部品もある。コイル部品では、連結用ターミナルを使用せずに、並列状に並ぶ複数のコイル要素が１本の巻線によって形成されている。しかし、コイル要素の相互間に架かる巻線の連絡部が両コイル要素の端面による外形から外側方へはみ出しているため、前記と同様、コイル部品の占有スペースの増大を余儀なくされるという問題があった。
【０００５】
そこで、本発明が解決しようとする課題は、コイル部品の占有スペースを削減することのできるコイル部品及びコイル部品の成形方法を提供することにある。
【０００６】
【課題を解決するための手段】
前記課題を解決する請求項１に記載された発明のコイル部品は、並列状に並ぶ複数のコイル要素を１本の巻線によって形成する。これとともに、コイル要素の相互間に架かる巻線の連絡部を両コイル要素の端面による外形内に収めている。このように構成すると、従来必要とされた連絡用ターミナル及び各コイル要素の連結側の端部が廃除されるとともに、両コイル要素の端面から外側方へはみ出す突出部分が廃除されることによって、コイル部品の占有スペースを削減することができる。
【０００７】
請求項２に記載された発明のコイル部品の成形方法は、１本の巻線によって複数のコイル要素を、その軸方向にかつコイル要素の相互間に連絡部を介して偏心させた状態で段違い状に形成する。その後、前記連絡部を折り返すようにして相互に連続するコイル要素を並列状に並べることにより、前記連絡部を両コイル要素の端面による外形内に収めたコイル部品を成形する。このように構成すると、並列状に並ぶ複数のコイル要素を１本の巻線によって形成するとともに、前記コイル要素の相互間に架かる前記巻線の連絡部を両コイル要素の端面による外形内に収めたコイル部品を成形することができる。したがって、従来必要とされた連絡用ターミナル及び各コイル要素の連結側の端部が廃除されるとともに、両コイル要素の端面から外側方へはみ出す突出部分が廃除されることによって、占有スペースを削減することのできるコイル部品を得ることができる。
【０００８】
【発明の実施の形態】
［実施の形態１］
本発明の実施の形態１を説明する。本実施の形態では、自動車用トランスに用いられるコイル部品を例示する。なお、コイル部品に係る方位を各図に矢印で示すとおりに定める。
図１に示すように、コイル部品１０を形成する巻線１には、例えば、表面に絶縁処理が施された所定の幅１ｗ及び厚さ１ｔの平角線（巻線と同一符号を付す）１が用いられている。なお、巻線１には、例えば、幅１ｗが６．０ｍｍで、厚さ１ｔが１．４ｍｍの平角線が用いられている。
【０００９】
図１及び図２に示すように、前記平角線１の巻き始め端部１ａを外方（前方）に引き出した状態で、幅１ｗを形成する面が相互に面接触するようにして、平角線１が上方へ積層状に所定回数巻回されることにより、第１のコイル要素１１が形成されている。さらに、その第１のコイル要素１１の巻き終りから巻線１の連絡部１ｂを折り返して、右側方へ引き延ばされている。続いて、第１のコイル要素１１の右側に並列状に、平角線１の幅１ｗを形成する面が相互に面接触するようにして、平角線１が下方へ積層状に所定回数巻回されることにより、第２のコイル要素１２が形成されている。また、第２のコイル要素１２において、巻線１は第１のコイル要素１１の巻線１と同一の巻き方向に巻回されている。また、巻線１の巻き終り端部１ｃは、巻き始め端部１ａと平行をなすようにして外方（前方）へ引き出されている。また、両コイル要素１１，１２は、左右方向を短辺とし、前後方向を長辺とする長四角形筒状に形成されている。前記両コイル要素１１，１２は、相互間に所定の間隔１０ｉ（図２参照）を隔てて形成されている。
【００１０】
すなわち、前記コイル部品１０は、並列状に並ぶ二つの同一巻き方向のコイル要素１１，１２を１本の巻線１によってエッジワイズ巻きすることによって形成されている。これとともに、両コイル要素１１，１２の相互間に架かる巻線１の連絡部１ｂは、両コイル要素１１，１２の端面１１ａ，１２ａ（図１においては両コイル要素１１，１２の上端面が相当する）による外形内に収められている。また、巻線１の連絡部１ｂは、両コイル要素１１，１２の端面１１ａ，１２ａの当該短辺部に沿うように折り曲げられている。
【００１１】
なお、前記巻線１の巻き始め端部１ａと巻き終り端部１ｃは、プレス加工、機械加工等によって巻線１の絶縁処理による絶縁皮膜を除去することによって接続端子とされる。また、各コイル要素１１，１２の中空部内には、図示しないトランス等の磁性コアが挿入される。また、前記コイル部品１０において、巻線１が通電された時の各コイル要素１１，１２に誘起される磁束の方向は互いに逆向きとなる、例えば第１のコイル要素１１での磁束の方向が上向きであれば、第２のコイル要素１２での磁束の方向は下向きとなる。また、上記したように、エッジワイズ巻きされた巻線１によって形成された両コイル要素１１，１２を有するコイル部品１０は、高周波用コイル部品に適している。
【００１２】
次に、上記したコイル部品１０の成形方法を説明する。まず、図３及び図４に示すように、１本の巻線１によって二つのコイル要素１１，１２を、その軸方向にかつコイル要素１１，１２の相互間に巻線１の連絡部１ｂを介して偏心させた状態で段違い状に形成する。すなわち、第１のコイル要素１１に対して第２のコイル要素１２を左上方に形成する。
【００１３】
また、前記巻線１の巻き始めにあたっては、巻き始め端部１ａを外方（前方）へ引き出しておく。また、巻き終わりにあたっては、巻き終り端部１ｃを巻き始め端部１ａと平行をなすように外方（前方）へ引き出しておく。また、巻線１の巻き方は、前にも述べたように、いわゆるエッジワイズ巻きと呼ばれる巻き方である。また、第１のコイル要素１１に対し第２のコイル要素１２は、所定の偏心量１０ｅ（図４参照）で左方へ偏心しているので、その偏心量１０ｅに応じて巻線１の連絡部１ｂが左方へ延びている。また、巻線１は、両コイル要素１１，１２において同一の巻き方向に巻かれるので、周知のコイル成形装置（巻線装置とも呼ばれる）を利用して自動的に巻回することができる。
【００１４】
その後、図５に示すように、前記巻線１の連絡部１ｂを折り返すようにして、第１のコイル要素１１の右側に第２のコイル要素１２を並列状に並べる。このとき、図４に示すように、第１のコイル要素１１の上端面上に第１のピン部材４１を配置するとともに、第２のコイル要素１２の下端面上（図４において下側）に第２のピン部材４２を配置する。第２のピン部材４２は、第１のピン部材４１の軸線を中心として回動可能に設けられたアーム部材４０に取付けられている。なお、各コイル要素１１，１２は、それぞれの巻線状態が崩れないように、各ホルダ（図示省略）によって保持されるものとする。
【００１５】
次に、前記アーム部材４０を、第１のピン部材４１の軸線を中心として図４において右回り方向（図４中、矢印Ｙ参照）に回動させることにより、第２のピン部材４２がアーム部材４０と一体的に回動される。これにより、図５に示すように、コイル要素１１，１２の相互間の巻線１の連絡部１ｂが折り返され、相互に連続するコイル要素１１，１２が並列状に、すなわち第１のコイル要素１１の右側に第２のコイル要素１２が並べられる。これと同時に、巻線１の連絡部１ｂが両コイル要素１１，１２の端面１１ａ，１２ａによる外形内に収められたコイル部品１０（図１参照）を成形することができる。なお、コイル部品１０から両ピン部材４１，４２が取り出されることで、コイル部品１０の成形が完了する。また、各ピン部材４１，４２にローラー部材（図示省略）を回転可能に設け、そのローラーを巻線１に対して接触回転させることによって、各ピン部材４１，４２と巻線１との間の摺動抵抗を削減することができる。
【００１６】
上記したコイル部品１０（図１及び図２参照）によると、従来必要とされた連絡用ターミナル（図１２中、符号１１５参照）及び各コイル要素１１，１２の連結側の端部（図１２中、符号１０１ａ，１０２ａ参照）が廃除される。これとともに、両コイル要素１１，１２の端面１１ａ，１２ａから外側方へはみ出す突出部分が廃除されている。これによって、コイル部品１０の占有スペースを削減することができる。
また、上記した成形方法によると、占有スペースを削減することのできるコイル部品１０を得ることができる。
【００１７】
また、従来必要とされた連絡用ターミナル（図１２中、符号１１５参照）が不要で、その連絡用ターミナルの接続にかかる巻線の絶縁皮膜の除去工程や、連絡用ターミナルと巻線との溶接工程を省略することができる。したがって、部品点数及び作業工程を削減することができ、ひいてはコストの低減を実現することができる。また、前記溶接工程での溶接強度のばらつきといった問題も解消されるので、品質のばらつきを低減することができる。また、前記溶接にかかる溶接設備も不要となるため、設備費用も低減することができる。
【００１８】
また、上記実施の形態のコイル部品１０においては、図５に示すように、両コイル要素１１，１２の相互間の巻線１の連絡部１ｂが、第１のコイル要素１１側の部位（符号、１ｂ１を付す）ではほぼ半円状に折り曲げられかつ第２のコイル要素１２側の部位（符号、１ｂ２を付す）では緩やかな「く」の字状に折り曲げられているが、その巻線１の連絡部１ｂの折り曲げ形状は、次に例示するように適宜変更することができる。
【００１９】
例えば、図６に示すものでは、巻線１の連絡部１ｂにおける第１のコイル要素１１側の部位１ｂ１１ではほぼチャンネル状に折り曲げられかつ第２のコイル要素１２側の部位１ｂ２１ではほぼクランク状に折り曲げられている。
また、図７に示すものでは、巻線１の連絡部１ｂにおける第１のコイル要素１１側の部位１ｂ１２ではほぼチャンネル状に折り曲げられかつ第２のコイル要素１２側の部位１ｂ２２では緩やかな「く」の字状に折り曲げられている。
また、図８に示すものでは、巻線１の連絡部１ｂにおける第１のコイル要素１１側の部位１ｂ１３ではほぼＣ字状に折り曲げられており、第２のコイル要素１２側の部位１ｂ２３では僅かに「く」の字状に折り曲げられている。
【００２０】
［実施の形態２］
本発明の実施の形態２を説明する。実施の形態２は、上記した実施の形態１の各コイル要素１１，１２をそれぞれボビンに巻き付けたものであるからその変更部分について詳述し、重複する説明は省略する。
図９に示すように、ボビン３０は、例えば樹脂製のもので、ほぼ角筒状をなす主体部３１と、その主体部３１の上下の両端部の外周部に環状に張出された上下のフランジ部３２，３３とを有している。しかして、上側のフランジ部３２における前縁部のうち左半部が切除されて開口溝３２ａが形成されている。上側のフランジ部３２の前縁部における開口溝３２ａ側の端部３２ｂが折り曲げ基準となっており、その端部３２ｂ上にはガイド凸部３２ｃが突出されている。
【００２１】
次に、実施の形態２にかかるコイル部品の成形方法を説明する。まず、実施の形態１と同様にして、図１０に示すように、１本の巻線１によって二つのコイル要素１１，１２を、その軸方向にかつ両コイル要素１１，１２の相互間に巻線１の連絡部１ｂを介して偏心させた状態で段違い状に形成する。このとき、巻線１は、各コイル要素１１，１２の各ボビン３０の主体部３１（図９参照）に対して巻付けられる。また、第２のコイル要素１２のボビン３０は、開口溝３２ａを有するフランジ部３２が下向きとなるように配置される。また、両コイル要素１１，１２の相互間の巻線１の連絡部１ｂは、第１のコイル要素１１ではボビン３０の開口溝３２ａ側から引き出され、第２のコイル要素１２ではボビン３０の開口溝３２ａ側から引き込まれている。
その後、前記実施の形態１と同様、前記巻線１の連絡部１ｂが折り返され、相互に連続するコイル要素１１，１２が並列状に並べられる（図１１参照）。
【００２２】
上記した実施の形態２によっても、前記実施の形態１と同様の作用効果が得られる。
また、各ボビン３０のフランジ部３２の前縁部における開口溝３２ａ側の端部３２ｂが折り曲げ基準となっているので、実施の形態１における各ピン部材４１，４２（図４及び図５参照）を省略することができる。
また、各ボビン３０におけるフランジ部３２に設けたガイド凸部３２ｃにより、巻線１の連絡部１ｂを緩やかに折り曲げることができる。なお、ガイド凸部３２ｃは省略することができる。
【００２３】
また、図１１に示すように、両コイル要素１１，１２の巻線１がそれぞれボビン３０に保持されており、両コイル要素１１，１２を並列状に並んだときに、両ボビン３０の対向する上側のフランジ部３２の端面が相互に当接するとともに、同じく下側のフランジ部３２の端面が相互に当接するようになっている。これにより、両コイル要素１１，１２の中心間距離１０ｄの寸法精度を向上することができる。
【００２４】
本発明は前記実施の形態に限定されるものではなく、本発明の要旨を逸脱しない範囲における変更が可能である。例えば、本発明のコイル部品１０は、トランスに限らず、モーター、その他の電気部品等にも適用することができる。また、コイル部品１０は、３つ以上のコイル要素を備えるものでもよい。また、巻線１には、平角線に代えて、丸線を使用することが考えられる。
【００２５】
【発明の効果】
以上述べたように、本発明のコイル部品及びコイル部品の成形方法によれば、従来必要とされた連絡用ターミナル及び各コイル要素の連結側の端部が廃除されるとともに、両コイル要素の端面から外側方へはみ出す突出部分が廃除されることによって、コイル部品の占有スペースを削減することができる。
【図面の簡単な説明】
【図１】本発明の実施の形態１にかかるコイル部品を示す斜視図である。
【図２】コイル部品を下面側から見た斜視図である。
【図３】コイル部品の半成形品を示す斜視図である。
【図４】コイル部品の半成形品を示す正面図である。
【図５】半成形品からコイル部品への成形方法を示す正面図である。
【図６】巻線の連絡部の折り返し形状の変更例１を示す正面図である。
【図７】巻線の連絡部の折り返し形状の変更例２を示す正面図である。
【図８】巻線の連絡部の折り返し形状の変更例３を示す正面図である。
【図９】本発明の実施の形態２にかかるボビンを示す斜視図である。
【図１０】コイル部品の半成形品を示す正面図である。
【図１１】コイル部品を示す正面図である。
【図１２】従来の技術にかかるコイル部品を示す斜視図である。
【符号の説明】
１　巻線（平角線）
１ａ　巻き始め端部
１ｂ　連絡部
１ｃ　巻き終り端部
１０　コイル部品
１１　第１のコイル要素
１１ａ　端面
１２　第２のコイル要素
１２ａ　端面[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a coil component and a method for forming a coil component.
[0002]
[Prior art]
An example of a conventional coil component will be described with reference to FIG. The coil component 110 includes two coil elements 111 and 112 arranged in parallel. Each coil element 111, 112 is formed by an individual winding 101, 102, respectively. The ends 101a and 102a on the connection side of the windings 101 and 102 are connected to each other via a communication terminal 115. The ends 101a and 102a on the connection side and the communication terminal 115 are connected by welding means such as TIG welding and laser welding.
[0003]
[Problems to be solved by the invention]
However, according to the above-described conventional coil component 110, the windings 101 and 102 of both coil elements 111 and 112 are connected to each other via the communication terminal 115. For this reason, due to the welding involved in the connection between the coil elements 111 and 112 and the communication terminal 115, the connection end of the communication terminal 115 and the windings 101 and 102 (the connection side end of each coil element). In other words, 101a and 102a protrude outward (forward in FIG. 12) from the outer shape formed by the end faces of both coil elements 111 and 112, and there is a problem that the space occupied by coil component 110 must be increased. This is one of the causes of an increase in the size of electric components such as a transformer into which the coil component 110 is incorporated. Therefore, an improvement is desired.
[0004]
There is also a coil component described in Japanese Patent Application Laid-Open No. 2000-10553. In the coil component, a plurality of coil elements arranged in parallel are formed by one winding without using a connection terminal. However, since the connecting portions of the windings extending between the coil elements protrude outward from the outer shape of the end faces of the two coil elements, there is a problem that the space occupied by the coil components must be increased as described above. Was.
[0005]
Therefore, an object of the present invention is to provide a coil component and a method of molding the coil component that can reduce the space occupied by the coil component.
[0006]
[Means for Solving the Problems]
According to a first aspect of the present invention, there is provided a coil component in which a plurality of coil elements arranged in parallel are formed by a single winding. At the same time, the connecting portions of the windings extending between the coil elements are accommodated in the outer shape of the end faces of both coil elements. With this configuration, the connection terminal and the connection-side end of each coil element, which are conventionally required, are eliminated, and the projecting portions protruding outward from the end faces of both coil elements are eliminated. The space occupied by components can be reduced.
[0007]
According to a second aspect of the present invention, there is provided a method of forming a coil component in which a plurality of coil elements are eccentric by a single winding in the axial direction and between the coil elements via a communication portion. It is formed in a shape. Then, by arranging the mutually continuous coil elements in parallel so that the connecting portion is folded back, a coil component in which the connecting portion is housed within the outer shape defined by the end faces of both coil elements is formed. According to this structure, the plurality of coil elements arranged in parallel are formed by one winding, and the connecting portions of the windings extending between the coil elements are accommodated in the outer shape defined by the end faces of the two coil elements. Coil parts can be formed. Therefore, the occupied space is reduced by eliminating the conventionally required connection terminal and the connection-side end of each coil element, and eliminating the protrusion protruding outward from the end faces of both coil elements. And a coil component that can be obtained.
[0008]
BEST MODE FOR CARRYING OUT THE INVENTION
[Embodiment 1]
Embodiment 1 of the present invention will be described. In the present embodiment, a coil component used for an automotive transformer will be exemplified. The direction of the coil component is determined as shown by an arrow in each drawing.
As shown in FIG. 1, a winding 1 forming a coil component 10 has, for example, a rectangular wire (the same reference numeral as the winding) 1 having a predetermined width 1 w and a thickness 1 t whose surface is insulated. Is used. The winding 1 is, for example, a rectangular wire having a width 1w of 6.0 mm and a thickness 1t of 1.4 mm.
[0009]
As shown in FIGS. 1 and 2, in a state where the winding start end 1 a of the rectangular wire 1 is pulled out (forward), the surfaces forming the width 1 w are in surface contact with each other, and the rectangular wire 1 The first coil element 11 is formed by winding a predetermined number of times upward in a stacked manner. Further, from the end of the winding of the first coil element 11, the connecting portion 1b of the winding 1 is folded back and extended rightward. Subsequently, the flat wire 1 is wound downward in a stacked manner a predetermined number of times in parallel with the right side of the first coil element 11 so that the surfaces forming the width 1w of the flat wire 1 are in surface contact with each other. Thereby, the second coil element 12 is formed. In the second coil element 12, the winding 1 is wound in the same winding direction as the winding 1 of the first coil element 11. The winding end 1c of the winding 1 is drawn out (forward) so as to be parallel to the winding start 1a. Each of the coil elements 11 and 12 is formed in a rectangular cylinder shape having a short side in the left-right direction and a long side in the front-rear direction. The two coil elements 11, 12 are formed with a predetermined space 10i (see FIG. 2) therebetween.
[0010]
That is, the coil component 10 is formed by edgewise winding two coil elements 11 and 12 having the same winding direction arranged in parallel with one winding 1. At the same time, the connecting portion 1b of the winding 1 extending between the coil elements 11 and 12 is connected to the end faces 11a and 12a of the coil elements 11 and 12 (the upper end faces of the coil elements 11 and 12 in FIG. ). Further, the connecting portion 1b of the winding 1 is bent along the short sides of the end faces 11a and 12a of the coil elements 11 and 12.
[0011]
The winding start end 1a and the winding end end 1c of the winding 1 are used as connection terminals by removing the insulating film by the insulation treatment of the winding 1 by press working, machining or the like. A magnetic core such as a transformer (not shown) is inserted into the hollow portion of each of the coil elements 11 and 12. In the coil component 10, the directions of the magnetic fluxes induced in the respective coil elements 11 and 12 when the winding 1 is energized are opposite to each other. For example, the direction of the magnetic flux in the first coil element 11 is changed. If it is upward, the direction of the magnetic flux in the second coil element 12 is downward. Further, as described above, the coil component 10 having the two coil elements 11 and 12 formed by the winding 1 wound edgewise is suitable for a high-frequency coil component.
[0012]
Next, a method of forming the above-described coil component 10 will be described. First, as shown in FIGS. 3 and 4, two coil elements 11 and 12 are connected by one winding 1, and a connecting portion 1 b of the winding 1 is formed in the axial direction and between the coil elements 11 and 12. It is formed in a step shape in a state where it is eccentric through the middle. That is, the second coil element 12 is formed on the upper left of the first coil element 11.
[0013]
When the winding of the winding 1 is started, the winding start end 1a is pulled out (forward). At the end of winding, the end-of-winding end 1c is pulled out (forward) so as to be parallel to the end-of-winding end 1a. As described above, the winding of the winding 1 is a so-called edgewise winding. In addition, since the second coil element 12 is eccentric to the left with a predetermined eccentricity 10e (see FIG. 4) with respect to the first coil element 11, the connecting portion of the winding 1 according to the eccentricity 10e. 1b extends to the left. Further, since the winding 1 is wound in the same winding direction in both the coil elements 11 and 12, the winding 1 can be automatically wound using a well-known coil forming device (also referred to as a winding device).
[0014]
Thereafter, as shown in FIG. 5, the second coil elements 12 are arranged in parallel on the right side of the first coil elements 11 such that the connecting portions 1b of the windings 1 are folded back. At this time, as shown in FIG. 4, the first pin member 41 is arranged on the upper end surface of the first coil element 11, and is placed on the lower end surface of the second coil element 12 (the lower side in FIG. 4). The second pin member 42 is arranged. The second pin member 42 is attached to an arm member 40 that is provided rotatably about the axis of the first pin member 41. The coil elements 11 and 12 are held by respective holders (not shown) so that their respective winding states are not broken.
[0015]
Next, by rotating the arm member 40 in the clockwise direction in FIG. 4 (see the arrow Y in FIG. 4) about the axis of the first pin member 41, the second pin member 42 It is rotated integrally with the member 40. Thereby, as shown in FIG. 5, the connecting portion 1b of the winding 1 between the coil elements 11 and 12 is folded back, and the mutually continuous coil elements 11 and 12 are arranged in parallel, that is, the first coil element. The second coil element 12 is arranged on the right side of 11. At the same time, it is possible to form the coil component 10 (see FIG. 1) in which the connecting portion 1b of the winding 1 is contained within the outer shape defined by the end faces 11a and 12a of the coil elements 11 and 12. Note that the molding of the coil component 10 is completed by removing the two pin members 41 and 42 from the coil component 10. In addition, a roller member (not shown) is rotatably provided on each of the pin members 41 and 42, and the roller is contacted and rotated with respect to the winding 1, so that a gap between the pin members 41 and 42 and the winding 1 Sliding resistance can be reduced.
[0016]
According to the above-described coil component 10 (see FIGS. 1 and 2), a communication terminal (see reference numeral 115 in FIG. 12) and a connection-side end portion of each coil element 11, 12 (see FIG. , 101a and 102a). At the same time, the protruding portions protruding outward from the end faces 11a, 12a of both coil elements 11, 12 are eliminated. Thereby, the space occupied by the coil component 10 can be reduced.
Further, according to the above-described molding method, it is possible to obtain the coil component 10 capable of reducing the occupied space.
[0017]
In addition, a conventionally required contact terminal (see reference numeral 115 in FIG. 12) is not required, and a step of removing an insulating film of a winding involved in connection of the contact terminal and welding of the contact terminal and the coil are performed. The step can be omitted. Therefore, the number of components and the number of working steps can be reduced, and the cost can be reduced. In addition, problems such as variations in welding strength in the welding process are eliminated, and variations in quality can be reduced. In addition, since welding equipment for the welding is not required, equipment costs can be reduced.
[0018]
Further, in the coil component 10 according to the above-described embodiment, as shown in FIG. 5, the connecting portion 1 b of the winding 1 between the two coil elements 11 and 12 is connected to a portion (reference numeral) on the first coil element 11 side. , 1b1), it is bent in a substantially semicircular shape, and at the portion (reference numeral, 1b2) on the side of the second coil element 12, it is bent in a gentle "ku" shape. The bent shape of the connecting portion 1b can be appropriately changed as exemplified below.
[0019]
For example, in the configuration shown in FIG. 6, the portion 1b11 of the connecting portion 1b of the winding 1 on the side of the first coil element 11 is bent substantially in a channel shape, and the portion 1b21 of the connecting portion 1b on the side of the second coil element 12 is substantially crank-shaped. It is bent.
7, the portion 1b12 of the connecting portion 1b of the winding 1 on the side of the first coil element 11 is bent substantially in a channel shape, and the portion 1b22 of the connecting portion 1b of the winding 1 on the side of the second coil element 12 is gradually bent. ”.
8, the connecting portion 1b of the winding 1 is bent substantially in a C-shape at a portion 1b13 on the first coil element 11 side and slightly at a portion 1b23 on the second coil element 12 side. It is bent in the shape of a "ku".
[0020]
[Embodiment 2]
Embodiment 2 of the present invention will be described. In the second embodiment, each of the coil elements 11 and 12 of the first embodiment is wound around a bobbin. Therefore, the changed portions will be described in detail, and redundant description will be omitted.
As shown in FIG. 9, the bobbin 30 is made of, for example, a resin, and includes a main body 31 having a substantially rectangular cylindrical shape, and upper and lower upper parts which are annularly protruded from outer peripheral portions of upper and lower ends of the main body part 31. It has flange portions 32 and 33. Thus, an opening groove 32a is formed by cutting off the left half of the front edge of the upper flange portion 32. An end 32b on the side of the opening groove 32a at the front edge of the upper flange portion 32 is a bending reference, and a guide convex portion 32c is projected on the end 32b.
[0021]
Next, a method for forming a coil component according to the second embodiment will be described. First, in the same manner as in the first embodiment, as shown in FIG. 10, two coil elements 11 and 12 are wound by one winding 1 in the axial direction and between the coil elements 11 and 12. The wire 1 is formed eccentrically via the connecting portion 1b to form a step. At this time, the winding 1 is wound around the main body 31 (see FIG. 9) of each bobbin 30 of each of the coil elements 11 and 12. The bobbin 30 of the second coil element 12 is arranged such that the flange 32 having the opening groove 32a faces downward. The connecting portion 1b of the winding 1 between the coil elements 11 and 12 is drawn out from the opening groove 32a side of the bobbin 30 in the first coil element 11, and the opening of the bobbin 30 in the second coil element 12. It is drawn in from the groove 32a side.
Thereafter, as in the first embodiment, the connecting portion 1b of the winding 1 is folded back, and the mutually continuous coil elements 11, 12 are arranged in parallel (see FIG. 11).
[0022]
According to the second embodiment, the same operation and effect as in the first embodiment can be obtained.
Further, since the end 32b on the side of the opening groove 32a at the front edge of the flange portion 32 of each bobbin 30 is a bending reference, each pin member 41, 42 in the first embodiment (see FIGS. 4 and 5). Can be omitted.
In addition, the connecting portion 1b of the winding 1 can be gently bent by the guide convex portion 32c provided on the flange portion 32 of each bobbin 30. Note that the guide projection 32c can be omitted.
[0023]
As shown in FIG. 11, the windings 1 of the coil elements 11 and 12 are held by bobbins 30, respectively. When the coil elements 11 and 12 are arranged in parallel, the bobbins 30 face each other. The end surfaces of the upper flange portion 32 are in contact with each other, and the end surfaces of the lower flange portion 32 are also in contact with each other. As a result, the dimensional accuracy of the center distance 10d between the coil elements 11 and 12 can be improved.
[0024]
The present invention is not limited to the above embodiment, and can be modified without departing from the spirit of the present invention. For example, the coil component 10 of the present invention can be applied not only to a transformer but also to a motor, other electric components, and the like. Further, the coil component 10 may include three or more coil elements. In addition, a round wire may be used for the winding 1 instead of the flat wire.
[0025]
【The invention's effect】
As described above, according to the coil component and the method for molding the coil component of the present invention, the connection terminal and the connection-side end of each coil element that have been conventionally required are eliminated and the end faces of both coil elements are eliminated. The occupied space of the coil component can be reduced by eliminating the protruding portion that protrudes outward from the coil component.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a coil component according to a first embodiment of the present invention.
FIG. 2 is a perspective view of the coil component as viewed from a lower surface side.
FIG. 3 is a perspective view showing a semi-molded product of a coil component.
FIG. 4 is a front view showing a semi-molded product of a coil component.
FIG. 5 is a front view showing a method of forming a semi-molded product into a coil component.
FIG. 6 is a front view showing a first modification of the folded shape of the connecting portion of the winding.
FIG. 7 is a front view showing a second modification of the folded shape of the connecting portion of the winding.
FIG. 8 is a front view showing a third modification of the folded shape of the connecting portion of the winding.
FIG. 9 is a perspective view showing a bobbin according to a second embodiment of the present invention.
FIG. 10 is a front view showing a semi-molded product of a coil component.
FIG. 11 is a front view showing a coil component.
FIG. 12 is a perspective view showing a coil component according to a conventional technique.
[Explanation of symbols]
1 winding (flat wire)
1a Winding start end 1b Communication part 1c Winding end end 10 Coil component 11 First coil element 11a End face 12 Second coil element 12a End face

Claims (2)

並列状に並ぶ複数のコイル要素を１本の巻線によって形成するとともに、前記コイル要素の相互間に架かる前記巻線の連絡部を両コイル要素の端面による外形内に収めたことを特徴とするコイル部品。A plurality of coil elements arranged in parallel are formed by a single winding, and a connecting portion of the winding extending between the coil elements is accommodated in an outer shape defined by end faces of both coil elements. Coil parts. １本の巻線によって複数のコイル要素を、その軸方向にかつコイル要素の相互間に連絡部を介して偏心させた状態で段違い状に形成し、その後、前記連絡部を折り返すようにして相互に連続するコイル要素を並列状に並べることにより、前記連絡部を両コイル要素の端面による外形内に収めたコイル部品を成形することを特徴とするコイル部品の成形方法。A single winding forms a plurality of coil elements in a stepped manner in the axial direction and in a state where the coil elements are eccentric via the communication section between the coil elements, and thereafter, the connection sections are folded back to form a stepped shape. Forming a coil component in which the connecting portions are accommodated within the outer shape defined by the end faces of both coil elements by arranging coil elements that are continuous with each other in parallel.
JP2002212940A 2002-07-22 2002-07-22 Coil component and method for forming coil component Expired - Fee Related JP3737461B2 (en)

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