JP2008028301A - Laminated electric component and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve versatility and expansibility by improving winding efficiency, simplifying manufacturing processes (working processes), reducing manufacturing cost, improving manufacture accuracy, improving magnetic efficiency as a magnetic circuit, realizing miniaturization (thinning), contributing thinning and low cost from an insulating surface, and improving flexibility of the design. <P>SOLUTION: When a laminated electric component 1 is manufactured as provided by sequentially folding a continuous member 2 formed by a sheet body S to laminate, the continuous member 2 wherein a plurality of component constituting parts 3, ..., which are formed by the sheet body S and laid side by side in a direction and interconnecting parts 4, ..., which interconnect adjacent component constituting parts 3, ..., are continuously formed, is manufactured. Further, by folding two positions X1, X2, ..., of the interconnecting parts 4, ..., in the continuous member 2 in opposite directions, respectively, the component constituting parts 3, ..., are sequentially laminated. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a laminated electrical component in which continuous members formed of a sheet body are sequentially folded and laminated, and a method for manufacturing the same.

  Conventionally, a coil (laminated electrical component) in which a continuous member formed of a single conductor is sequentially bent and laminated is disclosed in JP-A-9-275023 (Patent Document 1) and JP-A-2001-338811 (Patent Document 2). Is known.

The continuous bending coil disclosed in Patent Document 1 is a continuous bending coil that is continuously folded and used for an electric element such as a high-frequency transformer or a high-frequency reactor, and has the same shape that is alternately inverted in a zigzag pattern. A continuous corrugated foil-shaped conductor is folded back in a direction deviated by a specific angle from a predetermined folded portion every time to form an annular continuous winding coil. Further, the flat coil body disclosed in Patent Document 2 includes a sheet-like conductor pattern having a spiral shape, and the sheet-like surface of the conductor pattern is substantially perpendicular to the spiral axis of the conductor pattern. It is arranged.
JP-A-9-275023 JP 2001-338811 A

  However, the above-described conventional laminated electrical components (continuous bending coil and flat coil body) have the following problems.

  First, since folding is performed sequentially at different angles, the number of windings obtained between any foldings is one turn or less, resulting in poor winding efficiency. In addition, since the shape when cutting from the hoop base material is complicated, the manufacturing process (processing process) is also complicated, which tends to cause an increase in manufacturing cost and a decrease in manufacturing accuracy.

  Second, since a folded portion exists in the conducting wire constituting the coil itself, the magnetic efficiency as a magnetic circuit is inferior, and it is disadvantageous for miniaturization (thinning).

  Thirdly, since the front and back surfaces of each layer are alternately reversed when laminated, it is necessary to perform the insulation treatment on the front and back surfaces, which is disadvantageous in reducing the thickness and cost from the insulation surface. become.

  Fourthly, since the sheet-like conductors are laminated, the heat is easily trapped inside the coil and is inferior in heat dissipation.

  Fifth, since the shape of the coil is limited to a shape having a certain symmetry, it is inferior in design freedom. In addition, the laminated electrical components that can be manufactured are limited to inductance components such as coils and transformers, are difficult to apply to other laminated electrical components, and are inferior in versatility and development.

  An object of the present invention is to provide a laminated electrical component that solves the problems existing in the background art.

  The laminated electrical component 1 according to the present invention is a laminated electrical component obtained by sequentially bending and laminating the continuous member 2 formed of the sheet body S in order to solve the above-described problem. The two positions X1, X2... Of the connecting portions 4 in the continuous member 2 in which a plurality of the component constituent portions 3... And the adjacent component constituent portions 3. It is characterized in that the component constituent parts 3 are sequentially laminated by bending in the opposite direction.

  In this case, according to a preferred aspect of the invention, the sheet body S may be a single conductor Sx, or a laminate Sy including two or more conductors Sa and Sb, or two electrode bodies Pa, You may comprise by the capacitance element body Mx or battery element body My containing Pb. On the other hand, each connecting portion 4 can be formed at a predetermined forming position F1 or F2 selected from a plurality of different forming positions F1, F2, and one or more predetermined connecting portions 4 can be The intermediate tap portions 11 can be continuously formed integrally.

  Further, in order to solve the above-described problem, the method for manufacturing the laminated electrical component 1 according to the present invention is performed when the laminated electrical component 1 is manufactured by sequentially bending and laminating the continuous members 2 formed by the sheet body S. And a continuous member 2 formed by continuously forming a plurality of component constituent parts 3... And a connecting part 4 connecting the adjacent part constituent parts 3... The component parts 3 are sequentially laminated to produce the laminated electrical component 1 by bending the two positions X1, X2,.

  According to the laminated electrical component 1 and the method for manufacturing the same according to the present invention, the following remarkable effects are obtained.

  (1) Since the coil can be folded at a constant angle sequentially, the number of turns in producing a coil obtained between arbitrary turns is 1 turn (360 [°]), and the winding efficiency can be improved. Moreover, since the shapes when cutting from the hoop base material are aligned in one direction, the manufacturing process (processing process) can be simplified, and the manufacturing cost can be reduced and the manufacturing accuracy can be improved.

  (2) Since there is no folded portion inside the coil itself when the coil is manufactured, the magnetic efficiency as the magnetic circuit can be increased, and it is advantageous for downsizing (thinning).

  (3) Since the front and back surfaces of each layer when stacked are in the same direction, when the surface is subjected to insulation treatment, it is sufficient to apply it to one surface, which can contribute to reduction in thickness and cost from the insulation surface. .

  (4) Since the entire shape of the laminated electrical component 1 can be selected to an arbitrary shape, the degree of freedom in design can be dramatically increased. Moreover, the multilayer electrical component 1 is not limited to an inductance component such as a coil or a transformer, but can be easily applied to other various multilayer electrical components, and is excellent in versatility and development. In this case, if the sheet body S uses a single conductor Sx, the coil 1c, the laminated body Sy including two or more conductors Sa and Sb, a transformer, and a capacitance including two electrode bodies Pa and Pb. If the element body Mx is used, an electric double layer capacitor can be formed, and if a battery element body My including two electrode bodies Pa and Pb is used, a fuel cell can be formed.

  (5) According to a preferred embodiment, if each connecting portion 4 is formed at a predetermined formation position F1 or F2 selected from a plurality of different formation positions F1 and F2, laminated electric power having a structure in which sheet-like conductors are laminated. Even in the case of the component 1, heat generation that tends to be trapped inside can be efficiently discharged to the outside, and the heat dissipation is excellent.

  (6) According to a preferred embodiment, if the intermediate tap portions 11 are continuously formed integrally with one or two or more predetermined connecting portions 4..., The intermediate tap portions 11 in the coil 1c and the transformer are replaced with other electrode lead portions. Can be easily provided in the same direction.

  Next, the best embodiment according to the present invention will be given and described in detail with reference to the drawings.

  First, the manufacturing method of the coil 1c (laminated electrical component 1) according to the present embodiment will be described with reference to FIGS.

  When the coil 1c is manufactured, as shown in FIG. 3, a connecting portion that is formed by the sheet body S and connects a plurality of component constituent portions 3 that are sequentially arranged in one direction and the adjacent component constituent portions 3. A continuous member 2 is prepared by continuously forming 4. In this case, one sheet-like conductor Sx formed of a conductive material such as a thin copper plate or copper foil becomes the sheet body S, and the sheet body S is punched out (cut out) by press molding, whereby the continuous member shown in FIG. 2 can be produced. Then, an insulation treatment such as applying an insulating material is performed on one surface (for example, only the upper surface) of the obtained continuous member 2. Insulating treatment such as sandwiching insulating paper may be performed at the time of stacking the component components 3.

  Further, as shown in the partial extraction diagram in FIG. 3, the component component portion 3 in the continuous member 2 becomes a rectangular frame portion indicated by hatching, and has a cutting portion 3 c in the upper right portion of the rectangular frame portion. One component component 3 is for one turn (one turn) when the coil 1c is manufactured. Further, as shown in the partial extraction diagram in FIG. 3, the connecting portion 4 becomes a strip portion indicated by different hatching with respect to the component component portion 3. Then, one end of the connecting portion 4 is continuously formed at the right end portion of the upper part 3u of the component component 3 in FIG. 3, and the other end of the connecting portion 4 is a vertical portion of the adjacent component component 3. The frame 3s is continuously formed at the upper end in the figure.

  When the continuous member 2 is obtained, the two positions X1, X2,... Of the connecting portions 4 in the continuous member 2 are bent in opposite directions. FIG. 2 shows a state during folding. Thereby, as shown in FIG.1 and FIG.2, several component structure part 3 ... is laminated | stacked, and it can bend | folded at a fixed angle sequentially, and makes the front and back of each layer at the time of lamination | stacking have the same direction. it can. FIG. 4 shows the coil 1c manufactured through the above steps, in which 21 is an electrode lead portion on one end side, and 22 is an electrode lead portion on the other end side.

  On the other hand, FIG. 5 shows a modification of the continuous member 2 when the coil 1c is manufactured. FIG. 5 shows the component part 3 formed in an arbitrary shape having no symmetry. In particular, there is an obstacle E at the place where the coil 1c is mounted, and inductance is generated while avoiding the obstacle E. It is effective when making it as large as possible. For example, it is optimal for use when picking up a limited space and effectively arranging components, such as a mobile phone or a notebook computer that requires a small, light, and thin shape. In FIG. 5, the same parts as those in FIG.

  FIG. 6 shows another modification of the continuous member 2 when the coil 1c is manufactured. In FIG. 6, the left part of the continuous member 2 is formed by forming each connecting portion 4... At a predetermined formation position F1 or F2 selected from a plurality of different (for example, two) formation positions F1 and F2. is there. As a result, the connecting portion 4 at the forming position F1 and the connecting portion 4 at the forming position F2 are offset in position, so even in the laminated electrical component 1 having a structure in which sheet-like conductors are laminated, heat generation is likely to occur inside. Can be efficiently discharged to the outside, heat dissipation can be improved, and the thickness of the stacked portions of the connecting portions 4 when the two positions X1, X2,. Can be dispersed.

  On the other hand, in FIG. 6, the right side portion of the continuous member 2 shows a case where intermediate tap portions 11... Are integrally formed continuously with one or more predetermined connecting portions 4. Thus, the intermediate tap portions 11... In the coil 1 c can be easily provided in the same direction as the other electrode lead portions 21 and 22. In addition, the basic form (basic shape) of the continuous member 2 in FIG. 6 is the same as the continuous member 2 shown in FIG. For this reason, in FIG. 6, the same parts as those in FIG.

  Next, the laminated electrical component 1 according to the modified embodiment of the present invention will be described with reference to FIGS. 7 and 8.

  FIG. 7 shows an example in which a sheet-like laminate Sy including two or more conductors Sa and Sb is used as the sheet body S. As shown in the enlarged enlarged view of FIG. 7, the multilayer body Sy is a laminate in which the insulating sheet 31, the conductor Sa, the insulating sheet 32, the conductor Sb, and the insulating sheet 33 are stacked in advance from the top so that there are five layers. The body Sy (sheet body S) is manufactured. The laminated electrical component 1 using this laminated body Sy can also be manufactured basically in the same manner as the basic embodiment shown in FIGS. By using such a laminated body Sy, it is possible to configure a transformer (laminated electrical component 1) in which one conductor Sa is a primary winding and the other conductor Sb is a secondary winding.

  FIG. 8 shows a configuration in which the sheet body S is formed as a capacitance element body Mx or a battery element body My including two electrode bodies Pa and Pb. Formed. The extracted enlarged view shown in FIG. 8A shows an example in the case of being manufactured as a capacitance element body Mx (sheet body S). As shown in FIG. 6A, when configured as a capacitance element body Mx, from above, an insulating sheet (separator) 41, an electrode body (current collector: anode electrode) Pa, a separator 42, an electrode body (current collector) Body: cathode electrode) Pb, and insulating sheet (separator) 43 are manufactured in this order as a capacitance element body Mx (sheet body S) laminated in advance so as to be all five layers. The laminated electrical component 1 using the capacitance element body Mx can also be manufactured basically in the same manner as the basic embodiment shown in FIGS. By using such a capacitance element body Mx, an electric double layer capacitor (multilayer electric component 1) can be configured.

  The extracted enlarged view shown in FIG. 8 (b) shows an example in which the battery element body My (sheet body S) is manufactured. As shown in FIG. 4B, when the battery element body My is configured, the insulating sheet (separator) 45, the electrode body (anode electrode) Pa, the electrolyte membrane 46, the electrode body (cathode electrode) Pb, In the order of the insulating sheet (separator) 47, the battery element body My (sheet body S) is manufactured in advance so as to have all five layers. The laminated electrical component 1 using this battery element body My can also be manufactured basically in the same manner as the basic embodiment shown in FIGS. By using such a battery element body My, a fuel cell (laminated electrical component 1) mounted on an automobile or the like can be configured.

  Thus, since the laminated electrical component 1 according to the present embodiment can be sequentially folded at a constant angle, the number of turns in manufacturing a coil obtained between arbitrary turns is 1 turn (360 [°]). Winding efficiency can be increased. Moreover, since the shapes when cutting from the hoop base material are aligned in one direction, the manufacturing process (processing process) can be simplified, and the manufacturing cost can be reduced and the manufacturing accuracy can be improved. Furthermore, since there is no folded portion inside the coil itself when the coil is manufactured, the magnetic efficiency as the magnetic circuit can be increased and it is advantageous for downsizing (thinning). In addition, since the front and back surfaces of each layer when laminated are all in the same direction, when the surface is subjected to insulation treatment, it is sufficient to apply it to one surface, which can contribute to reduction in thickness and cost from the insulation surface. In addition, since the entire shape of the laminated electrical component 1 can be selected as an arbitrary shape, the degree of freedom in design can be dramatically increased. Moreover, the multilayer electrical component 1 is not limited to an inductance component such as a coil or a transformer, but can be easily applied to other various multilayer electrical components, and is excellent in versatility and development.

  Although the best embodiment has been described in detail above, the present invention is not limited to such an embodiment, and the gist of the present invention is described in detail configuration, shape, material, quantity, manufacturing method, and the like. Any change, addition, or deletion can be made without departing from the scope.

  For example, the individual positions at which the two positions X1, X2,... Of the connecting parts 4 are bent in opposite directions are arbitrary, and are not limited to the illustrated positions. Further, the number of stacked layers Sy, the capacitance element body Mx, and the battery element body My, the number of different formation positions F1, F2, the number of intermediate tap portions 11... Are arbitrary. Furthermore, although the coil 1c, the transformer, the electric double layer capacitor, and the fuel cell are illustrated as the laminated electric component 1, it can be applied to other various laminated electric components such as a motor that can be similarly manufactured.

An exploded perspective view of the laminated electrical component according to the best embodiment of the present invention, Partial cross-sectional front view of the same laminated electrical component, A plan view including a partial extraction view of a continuous member used for the laminated electrical component, A perspective view of the laminated electrical component, The top view of the continuous member which concerns on the example of a change used for the laminated electrical component, The top view of the continuous member which concerns on the other modification used for the same laminated electrical component, The perspective view including the extraction enlarged view of the continuous member used for the lamination electrical component concerning the change embodiment of the present invention, The perspective view containing the extraction enlarged view of the continuous member used for the lamination electrical component concerning other change embodiments of the present invention,

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1: Laminated electrical component, 2: Continuous member, 3 ...: Component structure part, 4 ...: Connection part, 11 ...: Intermediate | middle tap part, S: Sheet body, Sx: Conductor, Sa: Conductor, Sb: Conductor, Sy: Laminated body, X1: position of connecting portion, X2: position of connecting portion, Pa: electrode body, Pb: electrode body, Mx: capacitance element body, My: battery element body, F1: forming position, F2: forming position

Claims (6)

  In a laminated electrical component in which continuous members formed by a sheet body are sequentially bent and stacked, a plurality of component component parts formed by a sheet body and sequentially arranged in one direction and the adjacent component component parts are connected to each other. A laminated electrical component, wherein the component component parts are sequentially laminated by bending two positions of the connecting part in opposite directions in a continuous member in which the parts are continuously formed.   2. The laminated electrical component according to claim 1, wherein the sheet body is a laminated body including one conductor or two or more conductors.   2. The laminated electrical component according to claim 1, wherein the sheet body is a capacitance element body or a battery element body including two electrode bodies.   2. The laminated electrical component according to claim 1, wherein each connecting portion is formed at a predetermined forming position selected from a plurality of different forming positions.   The laminated electrical component according to claim 1, wherein an intermediate tap portion is integrally formed continuously on one or two or more predetermined connecting portions.   In a method for manufacturing a laminated electrical component for producing a laminated electrical component obtained by sequentially bending and laminating continuous members formed by a sheet body, the plurality of component constituent parts formed by the sheet body and sequentially arranged in one direction and the adjacent ones The laminated electrical component is manufactured by sequentially laminating the component component parts by sequentially bending the two positions of the connection parts in the continuous member in opposite directions. A method for producing a laminated electrical component, characterized in that

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