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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Publication number
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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JP
Japan
Prior art keywords
coil
winding
component
coil component
shape
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
JP2002212940A
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Japanese (ja)
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JP3737461B2 (en
Inventor
Norihiro Ikeda
Yasunari Makiuchi
Isao Nagano
Hiroki Okada
岡田 宏樹
池田 紀宏
牧内 康徳
長野 勲
Original Assignee
Togo Seisakusho Corp
株式会社東郷製作所
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Togo Seisakusho Corp, 株式会社東郷製作所 filed Critical Togo Seisakusho Corp
Priority to JP2002212940A priority Critical patent/JP3737461B2/en
Publication of JP2004055920A publication Critical patent/JP2004055920A/en
Application granted granted Critical
Publication of JP3737461B2 publication Critical patent/JP3737461B2/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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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]
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)

  1. 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.
  2. 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)

Priority Applications (1)

Application Number Priority Date Filing Date Title
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Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2002212940A JP3737461B2 (en) 2002-07-22 2002-07-22 Coil component and method for forming coil component

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JP2008186980A (en) * 2007-01-30 2008-08-14 Tamura Fa System Co Ltd Coil, and forming method of the coil
JP2008277606A (en) * 2007-05-01 2008-11-13 Tamura Fa System Co Ltd Coupled coil winding device for rectangular wire
JP2009246220A (en) * 2008-03-31 2009-10-22 Sumitomo Electric Ind Ltd Reactor, and bobbin for reactor
JP2010010484A (en) * 2008-06-27 2010-01-14 Tamura Seisakusho Co Ltd Linked coil formation apparatus and method of controlling linked coil formation
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JP2010206029A (en) * 2009-03-04 2010-09-16 Sumitomo Electric Ind Ltd Coil member for reactor, method of manufacturing the same, and reactor
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JP2013247242A (en) * 2012-05-25 2013-12-09 Toyota Motor Corp Method for manufacturing coil component and apparatus for manufacturing the same
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CN103854831A (en) * 2012-12-05 2014-06-11 胜美达集团株式会社 Winding structure, coil winding, coil part, and coil winding manufacturing method
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US9287042B2 (en) 2012-06-13 2016-03-15 Nittoku Engineering Co., Ltd. Winding device and winding method for edgewise coil
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