JP2010056273A - Method of manufacturing coil component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil component manufacturing method reducing the time for winding wires in two layers of a lower layer wire and an upper layer wire. <P>SOLUTION: In the coil component manufacturing method, at the step of starting winding of a second wire of the coil component, before completion of winding of a first wire 31-1 on a wound core part 12 and when the lower layer reference wound core part 12 on which three first wires 31-1 are present in a sectional view taken along a plane passing through a position 10a where winding of the second wire 31-2 on the wound core part 12 is started and a shaft has been formed at a position closer to the other end of the shaft than the position 10a above the wound core part 12, winding of the second wire 31-2 on the wound core part 12 is started at the position 10a. At the simultaneous winding step, the first wire 31-1 and the second wire 31-2 are simultaneously wound on the wound core part 12 circumferentially from one end side toward the other end side of the shaft of the wound core 12. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a coil component, and more particularly to a method of manufacturing a coil component that performs so-called layer winding (multilayer winding) in which a conductive wire is wound in two layers of a lower conductive wire and an upper conductive wire on a coil core.

2. Description of the Related Art Conventionally, a coil component manufacturing method is known in which a so-called layer winding (multi-layer winding) is performed in which a conductive wire is wound in two layers of a lower conductive wire and an upper conductive wire around a coil core. Japanese Patent Laying-Open No. 2006-121013 (Patent Document 1) describes a method for manufacturing such a coil component. In the manufacturing method described in the publication, after the winding of the lower layer of the conducting wire is completed on the core portion, the upper layer of the conducting wire is wound around the winding core portion, thereby forming the lower layer conducting wire and the upper layer conducting wire. It has a two-layer structure.
JP 2006-121013 A

  However, in the conventional method of manufacturing a coil component, the time taken to wind both the lower conductor and the upper conductor is at least the time from the start of winding the lower conductor to the completion of winding. It took more than the sum of the time from the start of winding of the upper conductor to the completion of winding.

  Then, an object of this invention is to provide the manufacturing method of the coil components which can shorten the time concerning winding at the time of winding a conducting wire by two layers, the lower conducting wire and the upper conducting wire.

  In order to achieve the above object, according to the present invention, the first conductive wire forms a lower layer from one end side to the other end side of the axial center around the axial center of the winding part of the coil component. A method of manufacturing a coil component having a conductive wire winding process in which a first conductive wire and a second conductive wire are spirally wound in two layers around the winding portion so as to form an upper layer, respectively, and the conductive wire winding process A first conductor winding start step of starting winding the first conductor before starting winding of the second conductor to the winding section, and winding of the first conductor to the winding section. Before the completion of the winding, the second conductor winding is placed on the other end side of the shaft center from the second conductor winding start position on the winding portion where the second conductor starts to be wound around the winding portion. When the lower reference winding portion in which at least two of the first conductors are present is formed in a cross-sectional view cut along a plane passing through the starting position and the axis, the second conductor is formed. A second wire winding start step of starting winding the second conductive wire around the winding portion from the starting position, and a circumference of the winding portion from one end side to the other end side of the axial center of the winding portion. There is provided a method of manufacturing a coil component having a simultaneous winding step of winding the first conductive wire and the second conductive wire simultaneously in the direction. Each of the first conductor and the second conductor is not limited to one conductor. For example, when two conductors are paired to form one conductor, the one conductor is the first conductor, A second conductor is formed.

  The conducting wire winding process includes a first conducting wire winding start process for starting winding the first conducting wire before starting winding to the winding portion of the second conducting wire, and winding the first conducting wire to the winding portion. Before completion, the second conductor winding start position and the shaft center are located on the other end side of the shaft center from the second conductor winding start position on the winding portion where the second conductor starts to be wound around the winding portion. When the lower reference winding portion in which at least two first conductors are present in a cross-sectional view taken along the plane passing through is formed, the second conductor is turned from the second conductor winding start position to the winding portion. In order to perform the second conductor winding start process to start winding, the second conductor in the upper layer between the adjacent first conductors in the lower layer in a cross-sectional view cut along a plane passing through the second conductor winding start position and the axis. Even if the wire enters, the lower part reference winding part in which the movement of the winding part in the axial center direction is restricted is formed, so that the axial direction of the winding part, etc. It is possible to prevent movement of the first conductor to the side. For this reason, even when the second conductor of the upper layer enters between the first conductors of the adjacent lower layer in a cross-sectional view cut by a plane passing through the winding start position and the axis of the second conductor, they are adjacent to each other. It is possible to prevent the second conductive wire in the upper layer from completely entering between the first conductive wires in the lower layer, and the first conductive wire and the second conductive wire can be stacked in two layers in a bowl shape in the same sectional view. .

  In addition, since there is a simultaneous winding step of winding the first conducting wire and the second conducting wire simultaneously in the circumferential direction of the winding portion from one end side to the other end side of the axis of the winding portion, The second conductor can be wound while the first conductor is being wound, and the first conductor and the second conductor can be efficiently wound around the winding portion, so that the coil part can be manufactured. The time concerning can be shortened.

  Here, in the second conductor winding start step, the lower reference winding portion is formed by supplying the first conductor wire from the flyer nozzle of the flyer winding device and winding it around the core portion. It is preferable.

  In the second conductor winding start step, the lower reference winding part is formed by supplying the first conductor from the flyer nozzle of the flyer winding device and winding it around the core part. The nozzle for supplying the second conductive wire forming the upper layer can be moved to the vicinity of the winding start position of the second conductive wire while preparing the second conductive wire to be wound around the winding portion. can do.

  Further, in the second conducting wire winding start step and the simultaneous winding step, the second conducting wire is supplied from the spindle nozzle of the spindle winding device and wound around the winding core, and at the end of the simultaneous winding step, When the winding of the first conductor to the winding part is completed and the winding of the second conductor to the winding part is not completed, the second conductor is further transferred to the winding part. At the same time that the second conductor is wound, the flyer nozzle is swung around the axis of the winding core at the same angular velocity as the second conductor. It is preferable to wind around the winding part around which is wound.

  In the second conducting wire winding start process and the simultaneous winding process, the second conducting wire is supplied from the spindle nozzle of the spindle winding device and wound around the winding core, and when the simultaneous winding process ends, the second winding to the winding part is performed. When the winding of the first conducting wire is completed and the winding of the second conducting wire to the winding part is not completed, the second conducting wire is further wound around the winding part and simultaneously the second conducting wire is wound. In order to wind only the second conducting wire around the winding portion around which the first conducting wire is wound by turning the flyer nozzle around the axis of the winding core portion at the same angular velocity as the angular velocity of the upper layer, The second conductive wire to be formed can be wound around the winding portion with a desired number of turns.

  Further, in the first conductor winding start step, the second conductor winding start step, and the simultaneous winding step, the first conductors adjacent to each other in a sectional view taken along a plane passing through the axis of the winding part. It is preferable to wind the first conducting wire so that the conducting wires are in a state of being separated from each other.

  In the first conducting wire winding start step, the second conducting wire winding start step, and the simultaneous winding step, the first conducting wires adjacent to each other in a sectional view cut by a plane passing through the axis of the winding part are separated from each other. In order to wind the first conductor so as to be, the second conductor is wound in a state in which a part of the lower part of the second conductor that forms the upper layer enters between adjacent first conductors in the same sectional view. It is possible to prevent the second conductor from being wound in a cramped state. For this reason, the 2nd conducting wire which makes an upper layer can be wound without being disturbed, and can be wound in the state where it arranged neatly.

  As mentioned above, this invention can provide the manufacturing method of the coil components which can shorten the time concerning winding at the time of winding a conducting wire by two layers, a lower conducting wire and an upper conducting wire.

  A method for manufacturing a coil component according to an embodiment of the present invention will be described. First, the coil component manufactured by the manufacturing method of a coil component is demonstrated based on FIG. The coil component is a common mode filter 1 manufactured by a coil component manufacturing method described later, and includes a core 10, a winding 30, and a metal terminal 40 as shown in FIG.

  The core 10 includes a core portion 12 and a pair of flange portions 13 formed at both ends of the core portion 12 in the axial direction. The core 10 is a so-called drum core. The core 10 is made of a magnetic material (for example, ferrite) or a non-magnetic material (for example, ceramic). The core portion 12 has a quadrangular prism shape, and each flange portion 13 has a rectangular parallelepiped shape. The core part 12 and the collar part 13 are integrally formed. The core 10 has an H shape in a cross section parallel to the direction of the axis A of the core 12 (FIG. 2 and the like). Hereinafter, since each of the flange portions 13 has substantially the same shape, it will be described only on one side unless otherwise specified. As shown in FIG. 1, the longitudinal direction of the core portion 12 is the X-axis direction, the core portion. The 12 width directions are defined as the Y-axis direction, and the direction orthogonal to the X-axis direction and the Y-axis direction is defined as the Z-axis direction. The external dimensions of the common mode filter 1 are about 4.5 mm in the X-axis direction, about 3.2 mm in the Y-axis direction, and about 2.1 mm in the Z-axis direction. The winding core part 12 corresponds to a winding part.

  Each flange 13 includes a first portion 14 connected to the core portion 12, a second portion 15 extending from the first portion 14 in the Y-axis direction, and the opposite of the second portion 15. And a second portion 16 extending in the direction. The first portion 14 and the second portion 15 are configured to be plane symmetric with respect to the ZX plane passing through the axis A (FIG. 2 and the like) of the core portion 12.

  The first portion 14 has a substantially rectangular parallelepiped shape in which the Z-axis direction is the longitudinal direction and the Y-axis direction is the width direction, and has substantially the same width as the core portion 12. The first portion 14 has a pair of first side surfaces 14a and 14b, a pair of second side surfaces 14c and 14d, and a pair of third side surfaces 14e and 14f. The first side surfaces 14a and 14b are positioned so as to face each other when viewed in the X-axis direction. The second side surfaces 14c and 14d face each other when viewed in the Z-axis direction, and are positioned so as to extend in a direction intersecting each first side surface 14a and 14b (in the present embodiment, a direction orthogonal). is doing. The third side surfaces 14e and 14f are opposed to each other when viewed in the Y-axis direction, and intersect with the first side surfaces 14a and 14b and the second side surfaces 14c and 14d (in this embodiment, It is positioned so as to extend in the direction perpendicular to the direction. The first side surfaces 14 a and 14 b are orthogonal to the direction of the axis A of the core portion 12. The core portion 12 is connected to the first side surface 14b.

  The second portion 15 has a substantially rectangular parallelepiped shape extending in the Y-axis direction from the third side surface 14e of the first portion 14 and having the longitudinal direction in the Z-axis direction. The second portion 15 has a pair of first side surfaces 15a and 15b, a pair of second side surfaces 15c and 15d, and a third side surface 15e. The first side surfaces 15a and 15b are positioned so as to face each other when viewed in the X-axis direction. The second side surfaces 15c and 15d are positioned so as to face each other in the Z-axis direction and extend in a direction intersecting with the first side surfaces 15a and 15b. The third side surface 15e is positioned so as to extend in a direction intersecting with the first side surfaces 15a and 15b and the second side surfaces 15c and 15d. The first side surfaces 15 a and 15 b are orthogonal to the direction of the axis A of the core portion 12. A step is formed between the second side surface 14c and the third side surface 14e of the first portion 14 and the second side surface 15c of the second portion 15, and the second side surface 15c of the second portion 15 is formed. Is lower than the second side surface 14c of the first portion 14.

  The second portion 16 extends in the Y-axis direction from the third side surface 14f of the first portion 14, and has a substantially rectangular parallelepiped shape in which the Z-axis direction is the longitudinal direction. The second portion 16 has a pair of first side surfaces 16a and 16b, a pair of second side surfaces 16c and 16d, and a third side surface 16e. The first side surfaces 16a and 16b are positioned so as to face each other when viewed in the X-axis direction. The second side surfaces 16c and 16d are positioned so as to face each other when viewed in the Z-axis direction and to extend in a direction intersecting with the first side surfaces 16a and 16b. The third side surface 16e is positioned so as to extend in a direction intersecting with the first side surfaces 16a and 16b and the second side surfaces 16c and 16d. The first side surfaces 16a and 16b are orthogonal to the direction of the axis A (FIG. 2 and the like) of the core 12. A step is formed between the second side surface 14c and the third side surface 14f of the first portion 14 and the second side surface 16c of the second portion 16, and the second side surface 16c of the second portion 16 is formed. Is lower than the second side surface 14c of the first portion 14.

  The winding 30 is composed of two conductor wires 31 (a first conducting wire 31-1 and a second conducting wire 31-2). The two conductor wires 31 are covered with insulation, and from one flange portion 13-1 side to the other flange portion 13-2 side around the axis A (FIG. 2 and the like) of the core portion 12 of the core 10. On the other hand, the first conductor 31-1 is formed in a lower layer and the second conductor 31-2 is formed in an upper layer in a spiral manner around the core portion 12 in two layers. The two conductor wires 31 are electrically insulated from each other and magnetically coupled to each other. As each conductor wire 31, an insulation coating copper wire (for example, a polyamide imide (AIW) copper wire etc.) whose outer diameter is about 80 micrometers-about 90 micrometers and whose core wire joint is about 70 micrometers can be used.

  The metal terminal 40 includes first metal terminals 41 and 42 and second metal terminals 51 and 52. The first metal terminals 41 and 42 are respectively attached to the second portion 15 of the flange 13. The second metal terminals 51 and 52 are respectively attached to the second portion 16 of the flange portion 13. A first conductor 31-1 is electrically connected to the first metal terminal 42 and the second metal terminal 51. A second conducting wire 31-2 is electrically connected to the first metal terminal 41 and the second metal terminal 52.

  The first metal terminals 41, 42 include a first terminal portion 43, a pair of second terminal portions 44, 45 extending from each end portion of the first terminal portion 43, and a second terminal portion 44. The first and second piece portions 46 and 47 extend. The first terminal portion 43, the pair of second terminal portions 44 and 45, and the first and second piece portions 46 and 47 are formed by bending a metal plate. The first terminal portion 43 faces the first side surface 15 a of the second portion 15 of the flange portion 13. The second terminal portion 44 faces the second side surface 15 c of the second portion 15 of the flange portion 13. The second terminal portion 45 faces the second side surface 15 d of the second portion 15 of the flange portion 13. The distal ends of the pair of second terminal portions 44 and 45 are bent in the direction of the core portion 12.

  The first and second piece portions 46 and 47 are for connecting the conductor wire 31, and sandwich the conductor wire 31 with the second terminal portion 44. The first and second piece portions 46 and 47 extend from one end portion of the second terminal portion 44 in the Y-axis direction. The first piece portion 46 is a locking piece for fixing the conductor wire 31 and is bent to sandwich the conductor wire 31 with the second terminal portion 44 as shown in FIG. . The second piece portion 47 is a locking piece that is mainly brought into a molten state by laser welding, and sandwiches the conductor wire 31 with the second terminal portion 44 by being bent. As shown in FIG. 1, the first metal terminal 41 and the first metal terminal 41 are formed by performing laser welding in a state where the conductor wire 31 is sandwiched between the first and second piece portions 46 and 47 and the second terminal portion 44. The conductor wire 31 is mechanically and electrically connected. In the state before bending, the angle formed between the first piece portion 46 and the second terminal portion 44 is approximately 45 °, and the angle formed between the second piece portion 47 and the second terminal portion 44 is It is approximately 90 °.

  In a state where the first metal terminals 41 and 42 are not attached to the flange portion 13, the angles formed by the first terminal portion 43 and the pair of second terminal portions 44 and 45 are both acute angles (for example, , About 86 °). In addition, the length of the first terminal portion 43 in the Z-axis direction is slightly smaller than the length of the first side surface 15a in the Z-axis direction when the first metal terminals 41 and 42 are not attached to the flange portion 13. In particular, the distance between the ends of the pair of second terminal portions 44 and 45 in the Z-axis direction is slightly smaller than the length of the first side surface 15a in the Z-axis direction.

  The first metal terminals 41 and 42 are provided in the second portion 15 of the flange 13 by sandwiching the pair of second side surfaces 15 c and 15 d by the pair of second terminal portions 44 and 45. When the first metal terminals 41 and 42 are respectively attached to the second portion 15 of the flange portion 13, the first metal terminals 41 and 42 are expanded while the interval between the pair of second terminal portions 44 and 45 is widened. The second portion 15 is extrapolated to the second portion 15 from the first side surface 15a side.

  The second metal terminals 51 and 52 include a first terminal portion 53, a pair of second terminal portions 54 and 55 extending from each end portion of the first terminal portion 53, and a second terminal portion 54. The first and second piece portions 56 and 57 extend. The first terminal portion 53, the pair of second terminal portions 54 and 55, and the first and second piece portions 56 and 57 are formed by bending a metal plate. The first terminal portion 53 faces the first side surface 16 a of the second portion 16 of the flange portion 13. The second terminal portion 54 faces the second side surface 16 c of the second portion 16 of the flange portion 13. The second terminal portion 55 faces the second side surface 16 d of the second portion 16 of the flange portion 13. The distal ends of the pair of second terminal portions 54 and 55 are bent in the direction of the core portion 12.

  The first and second piece portions 56 and 57 are for connecting the conductor wire 31, and sandwich the conductor wire 31 with the second terminal portion 54. The first and second piece portions 56 and 57 extend from the other end of the second terminal portion 54 in the Y-axis direction. The first piece portion 56 is a locking piece for fixing the conductor wire 31, and the conductor wire 31 is sandwiched between the second terminal portion 54 by being bent. The second piece portion 57 is a locking piece that is mainly brought into a molten state by laser welding, and sandwiches the conductor wire 31 with the second terminal portion 54 by being bent. As shown in FIG. 1, by performing laser welding in a state where the conductor wire 31 is sandwiched between the first and second piece portions 56 and 57 and the second terminal portion 54, the second metal terminal 51 and The conductor wire 31 is mechanically and electrically connected. In the state before bending, the angle formed between the first piece portion 56 and the second terminal portion 54 is approximately 45 °, and the angle formed between the second piece portion 57 and the second terminal portion 54 is It is approximately 90 °.

  In a state where the second metal terminals 51 and 52 are not attached to the flange portion 13, the angles formed by the first terminal portion 53 and the pair of second terminal portions 54 and 55 are both acute angles (for example, , About 86 °). Further, the length of the first terminal portion 53 in the Z-axis direction is slightly smaller than the length of the first side surface 16a in the Z-axis direction when the second metal terminals 51 and 52 are not attached to the flange portion 13. The distance between the ends of the pair of second terminal portions 54, 55 in the Z-axis direction is slightly smaller than the length of the first side surface 16a in the Z-axis direction.

  The second metal terminals 51 and 52 are provided on the second portion 16 of the flange portion 13 by sandwiching the pair of second side surfaces 16 c and 16 d by the pair of second terminal portions 54 and 55. When the second metal terminals 51 and 52 are respectively attached to the second portion 16 of the flange portion 13, the second metal terminals 51 and 52 are expanded while the interval between the pair of second terminal portions 54 and 55 is widened. The second portion 16 is extrapolated to the second portion 16 from the first side surface 16a side.

  Next, the coil component manufacturing apparatus 1001 will be described with reference to FIGS. The coil component manufacturing apparatus 1001 rotates the core 10 about the axis A of the core portion 12 of the core 10 as a rotation axis, thereby causing the second conductor 31-2 (FIG. 2B, etc.) to be wound on the core portion 12. A so-called spindle winding device that winds around the core 10 and a flyer winding device that turns the nozzle 1021 around the core 10 and winds the first conductor 31-1 around the core portion 12. Yes. More specifically, as shown in FIG. 2B and the like, the coil component manufacturing apparatus 1001 includes a core support portion 1010 for supporting the core 10 of the coil component 1, the first conductor 31-1, Nozzle of a flyer winding device for supplying the second conducting wire 31-2 and winding the first conducting wire 31-1 and the second conducting wire 31-2 around the core 10 supported by the core support portion 1010, respectively. 1021 and a nozzle 1022 (FIG. 4 and the like) of a spindle winding device.

  The core support part 1010 is comprised so that the one collar part 13-1 of the core 10 can be hold | maintained as FIG.2 (b) etc. show. The core support portion 1010 is supported by a rotating device (not shown), and is configured to be rotatable about the axis A of the core portion 12 of the core 10 supported by the core support portion 1010 as a rotation axis. When the first conductive wire 31-1 and the second conductive wire 31-2 are wound around the core portion 12 of the core 10, the core 10 is also rotated by rotating the core 10 while being supported by the core support portion 1010. The first conducting wire 31-1 and the second conducting wire 3-2 that are rotated from the axis A of the winding core portion 12 as the rotation axis and are fed from the nozzles 1021 and 1022 can be wound around the winding core portion 12.

  The core support portion 1010 is provided with a pair of clamps 1013 and 1014. The clamps 1013 and 1014 are fed from the nozzles 1021 and 1022, respectively, the first conducting wire 31-1 and the second conducting wire 31-2. One end of each can be pinched. One ends of the first conducting wire 31-1 and the second conducting wire 31-2 sandwiched between the clamps 1013 and 1014 are fixed to the core support portion 1010 so as not to move. Therefore, when the nozzles 1021 and 1022 are moved as will be described later, one end of the first conducting wire 31-1 and the second conducting wire 31-2 is fixed. The first conducting wire 31-1 and the second conducting wire 31-2 are respectively fed out from the nozzles 1021, 1022.

  As described above, two nozzles are provided, one of the flyer winding device (nozzle 1021) and the one of the spindle winding device (nozzle 1022). Each of the lead wires 31-2 can be fed out. The nozzle 1022 of the spindle winding device is supported by nozzle drive means (not shown), and its longitudinal direction is oriented in a direction perpendicular to the axis A of the core portion 12 of the core 10 supported by the core support portion 1010. It is possible to move in a three-dimensional space in any direction while maintaining the state.

  Further, the nozzle 1021 for the flyer winding device has a direction in which the longitudinal direction of the nozzle is perpendicular to the axis A of the core portion 12 of the core 10 supported by the core support portion 1010 and is directed from the base end to the tip end of the nozzle. Centered on the axis A of the core portion 12 of the core 10 supported by the core support portion 1010 in a state where the core is always oriented in the direction of the axis A of the core portion 12 of the core 10 supported by the core support portion 1010. It is possible to turn. Further, it is possible to move in the direction of the axis A of the core part 12 of the core 10 supported by the core support part 1010 while turning or without turning.

  Further, the coil component manufacturing apparatus 1001 includes a laser unit (not shown), and the laser unit (not shown) is configured by a YAG laser irradiation apparatus that can irradiate a pulse laser. The laser unit (not shown) is supported by a laser drive device (not shown) connected to a control device (not shown). The laser part can be moved in an arbitrary direction in a three-dimensional space by a laser driving device (not shown), and irradiates the second piece parts 47 and 57 with laser as will be described later. 47, 57, the first conducting wire 31-1, and the second conducting wire 31-2 can be electrically connected and connected.

  The coil component manufacturing apparatus 1001 includes a cutter (not shown), and the cutter (not shown) can cut the first conductor 31-1 and the second conductor 31-2. The cutter (not shown) can move in any direction in the three-dimensional direction, and is retracted and retracted except when the first conducting wire 31-1 and the second conducting wire 31-2 are cut. The first conductive wire 31-1 and the second conductive wire 31-2 fed from the nozzles 1021, 1022 and the nozzles 1021, 1022, respectively, are configured not to interfere with each other.

  Next, the manufacturing method of a coil component is demonstrated. In the method of manufacturing a coil component, first, as shown in FIG. 2, the core 10 is supported by the core support portion 1010 by holding one flange portion 13-1 of the core 10 by the core support portion 1010.

  Next, a conducting wire winding process is performed. In the conductive wire winding step, the first conductive wire 31-1 and the second conductive wire 31-2 are fed out from the nozzles 1021, 1022, respectively, and the first conductive wire 31-1 and the second conductive wire 31-2 are clamped 1013, 1014. And the first conductor 31-1 and the second conductor 31-2 near one end are fixed to the core support 1010. Then, the nozzle 1022 is made to stand by at a position in front of the core 10 in the axial direction of the core 12, that is, a position below the core 10 in FIG. One conducting wire 31-1 is hung on the first piece portion 46 in one flange 13-1. And the nozzle 1021 is further moved and the front-end | tip of the nozzle 1021 is made to oppose the part vicinity of the core part 12 connected to the collar part 13-1. 2A corresponds to one end side of the axis A and the upper side corresponds to the other end side of the axis A.

  Next, a first conductor winding start process is performed. In the first conducting wire winding start step, first, the nozzle 1021 is turned around the axis A of the core 12 and moved from one end side to the other end of the axis A of the core 12 to thereby wind the winding. The winding of the first conducting wire 31-1 around the core 12 is started. As shown in FIGS. 2 (c), 3 (c), 4 (b), 5 and 6 (b), the first conducting wire 31-1 is a second conducting wire winding start position 10a described later. And the adjacent first conductors 31-1 are wound so as to be in contact with each other in a cross-sectional view taken along a plane passing through the axis A of the core 12.

  Next, a second conductor winding start process is performed. In the second conducting wire winding start step, first, the first conducting wire 31-1 is further wound by turning the total two-turn strong nozzle 1021 after starting to wind the first conducting wire, as shown in FIG. As shown, in a cross-sectional view taken along a plane passing through a second conductor winding start position 10a, which will be described later, and the axis A of the winding core portion 12, the shaft is more axial than the second conductor winding start position 10a on the winding portion 12. On the other end side of the core A (FIG. 2 (a), etc.), a lower reference winding portion 13A having three first conductive wires 31-1 is formed. Next, the turning of the nozzle 1021 is stopped.

  While the lower layer reference winding portion 13A is being formed, the following steps are performed simultaneously. First, the nozzle 1022 is moved, the first conducting wire 31-1 is hung on the first piece portion 56, and the nozzle 1022 is opposed to the portion of the core portion 12 connected to the one flange portion 13-1. Let Then, the cutter (not shown) is moved, and the first conductor 31-1 and the second conductor 31-2 clamped by the clamp are moved by a cutter (not shown) at a predetermined location on the side opposite to the nozzle. The one conducting wire 31-1 and the second conducting wire 31-2 are cut. The above is the process performed simultaneously while forming the lower layer reference winding portion 13A.

  Then, by rotating the core support portion 1010 about the axis A of the core portion 12, as shown in FIG. 3C, the first conductor 31-1 constituting the lower layer reference winding portion 13A is formed. The second conducting wire 31-2 is started to be wound so as to abut the portion facing the one flange portion 13-1 and the one flange portion 13-1. The position where the second conductor 31-2 starts to be wound forms the second conductor winding start position 10a. The above is the second conducting wire winding start step, and the second winding 31-2 starts to be wound in the second conducting wire winding start step, and the simultaneous winding step described later starts to be performed at the same time.

  Next, a simultaneous winding process is performed. As described above, when the core support portion 1010 is rotated around the axis A of the core portion 12 in order to wind the second conducting wire 31-2, the nozzle 1021 does not turn, but the core portion 12 does not rotate. Since it is moving from one end side to the other end side in the direction of the axis A, the first conducting wire 31-1 supplied from the nozzle 1021 is also shown in FIG. 4 (b) like the second conducting wire 31-2. As shown in the drawing, the wire is wound around the core 12 at the same angular velocity. As shown in FIG. 4B and the like, the second conducting wire 31-2 is a cross-sectional view cut by a plane passing through a second conducting wire winding start position 10a described later and the axis A of the core portion 12, The adjacent second conducting wires 31-2 are wound so as to be in contact with each other. The above is the simultaneous winding process.

  At this time, in a cross-sectional view taken along a plane passing through the second conducting wire winding start position 10a and the axis A of the core part 12, the second layer forming the upper layer between the adjacent first conducting wires 31-1 forming the lower layer. Even when the conducting wire 31-2 enters, the lower layer reference in which the movement of the core 12 in the direction of the axis A is restricted by the friction caused by the contact between the first conducting wire 31-1 and the core 12 By forming the winding part 13A, the movement of the first conducting wire 31-1 to the other axial end side of the winding core part 12 can be prevented. For this reason, in the cross-sectional view cut along the plane passing through the second conductor winding start position 10a and the axis A of the core portion 12, the upper second conductor 31 is disposed between the adjacent lower first conductors 31-1. -2 enters, the upper second conductive wire 31-2 is prevented from completely entering between the adjacent lower first conductive wires 31-1, and the first cross-sectional view is the first. The conductive wire 31-1 and the second conductive wire 31-2 can be stacked in two layers in a bowl shape.

  Moreover, the 1st conducting wire 31-1 and the 2nd conducting wire 31-2 are wound simultaneously to the circumferential direction of the core part 12 toward the other end side from the one end side of the axial center A of the core part 12. As shown in FIG. Since it has a simultaneous winding process, the second conducting wire 31-2 can be wound while the first conducting wire 31-1 is being wound, and the first conducting wire 31-1 and the second conducting wire 31-1 can be efficiently wound. The conductive wire 31-2 can be wound around the core portion 12, and the time required for manufacturing the coil component can be shortened.

  About the 1st conducting wire 31-1, before starting the winding of the 2nd conducting wire 31-2, lower layer reference | standard winding part 13A is formed, and in the above-mentioned simultaneous winding process, the 1st conducting wire 31- Since the first and second conducting wires 31-2 are wound at the same angular velocity, the winding core portion 12 is still at the time when the winding of the first conducting wire 31-1 around the winding core portion 12 is completed. The winding of the second conductor 31-2 is not completed. For this reason, next, the process of winding the 2nd conducting wire 31-2 further is performed. More specifically, the movement of the nozzle 1021 in the direction of the axis A of the core 12 is stopped, and the nozzle has the same angular velocity as that of the core support 1010 that rotates about the axis A of the core 12. 1021 is swiveled by the number of rotations for rotating the core support 1010 about the axis A of the core 12.

  By doing in this way, since the nozzle 1021 does not turn relative to the core 10, the first conducting wire 31-1 from the nozzle 1021 is not wound around the core portion 12, but the nozzle The second conductor 31-2 from 1022 is wound around the core portion 12 in the same manner as in the simultaneous winding step. When a desired number of turns are wound around the core 12 and the winding of the second conductor 31-2 is completed, the rotation of the core support 1010 and the turning of the nozzle 1021 are stopped. The above is the conductor winding process.

  Next, the nozzle 1021 is moved, and the first conductor 31-1 is hung on the first piece portion 56 in the other flange 13-2, and the nozzle 1022 is moved to move the second conductor 31-2. Is hung on the first piece portion 46. Then, the first conducting wire 31-1 and the second conducting wire 31-2 are sandwiched between the second piece portions 57 and 47 and the second terminal portions 54 and 44, respectively, and from the second terminal portions 54 and 44, respectively. Also, the first conductor 31-1 and the second conductor 31-2 are cut at a predetermined portion near the nozzle 1021 and the nozzle 1022.

  Next, by irradiating the second piece portions 57 and 47 with laser, insulation of the portions of the first conducting wire 31-1 and the second conducting wire 31-2 facing the second piece portions 57 and 47 is performed. The coating is peeled off, and the first conductor 31-1 and the second conductor 31-2 are electrically connected to the second piece portions 57 and 47 and the second terminal portions 54 and 44 for connection. A coil component is manufactured through the above steps.

  In the second conductor winding start process, the first conductor 31-1 is supplied from the nozzle 1021 of the flyer winding device and wound around the core 12 to form the lower layer reference winding portion 13A. While forming the lower layer reference winding portion 13A, which is a time when the core support portion 1010 does not hinder the movement of the nozzle 1022 because the support portion 1010 is not rotating, the second conductive wire 31-2 constituting the upper layer is provided. The nozzle 1022 for supply can be moved to the vicinity of the second conducting wire winding start position 10a, and preparations for winding the second conducting wire 31-2 around the core portion 12 can be made.

  In the second conducting wire winding start step and the simultaneous winding step, the second conducting wire 31-2 is supplied from the nozzle 1022 of the spindle winding device and wound around the winding core portion 12, and wound at the end of the simultaneous winding step. When the winding of the first conducting wire 31-1 around the core portion 12 is completed and the winding of the second conducting wire 31-2 around the winding core portion 12 is not completed, the second conducting wire 31-2 is further added. Is wound around the core portion 12 and at the same time the nozzle 1021 is swung around the axis A of the core portion 12 at the same angular velocity as the second lead wire 31-2. -2 is wound around the core portion 12 around which the first conducting wire 31-1 is wound, so that the second conducting wire 31-2 constituting the upper layer is also wound around the core portion 12 with a desired number of turns. can do.

  The method of manufacturing a coil component according to the present invention is not limited to the above-described embodiment, and various modifications and improvements can be made within the scope described in the claims. For example, in the first conducting wire winding start process, the second conducting wire winding start process, and the simultaneous winding process, the first conducting wire 31-1 has a second conducting wire winding start position 10 a and an axis of the core portion 12 described later. The first conductive wires 31-1 adjacent to each other are wound so as to be in contact with each other in a cross-sectional view taken along a plane passing through the center A, but the present invention is not limited to this.

  For example, in the first conducting wire winding start step, the second conducting wire winding start step, and the simultaneous winding step, the first conducting wires 31-adjacent to each other in a cross-sectional view cut by a plane passing through the axis A of the core portion 12. You may wind the 1st conducting wire 31-1 so that one may be in the state mutually spaced apart. In this case, for example, the first conductor 31-1 uses an insulating coated copper wire having an outer diameter of 80 μm and a core wire diameter of about 70 μm, and the second conductor 31-2 has an outer diameter of 90 μm and a core wire diameter. Uses an insulation coated copper wire of about 70 μm. Then, the first conductors 31-1 adjacent to each other in the same sectional view are separated by 15 μm. As a result, the second conductive wires 31-2 adjacent in the same cross-sectional view are separated from each other by 5 μm.

  By winding in this way, a part of the lower part of the second conducting wire 31-2 constituting the upper layer enters the space between the first conducting wires 31-1 adjacent to each other in the same sectional view, and the second conducting wire 31- 2 can be wound, and the second conductor 31-2 can be prevented from being wound in a cramped state. For this reason, the 2nd conducting wire 31-2 which makes an upper layer can be wound without winding disorder, and can be wound in the state where it arranged neatly.

  Further, in the second conductor winding start process, the axis A of the core 12 is wound in a cross-sectional view cut along a plane passing through the second conductor winding start position 10a and the axis A of the core 12. Although the lower reference winding part 13 </ b> A in which three first conductive wires 31-1 exist on 12 is formed, the number is not limited to three. What is necessary is just two or more.

  Further, in the second conductive wire winding start step, the portion facing the first flange portion 13-1 and the first flange portion 13-1 among the portions of the first conductive wire 31-1 forming the lower layer reference winding portion 13A. The second conducting wire 31-2 has started to be wound so as to be in contact with each other, but the second conducting wire winding start position is not limited to this position. For example, the second conductor 31-2 may start to be wound so as to abut on the first conductor from the left and the second conductor from the left in the drawing of the first conductor 13-1 shown in FIG.

  Further, in order to form the lower layer reference winding portion 13A, the nozzle 1021 of the flyer winding device is swung around the axis A of the winding core portion 12, but the lead wire fed out from the nozzle 1022 is formed in the lower layer. As one conducting wire 31-1, the lower layer reference winding portion 13A may be formed by a spindle winding device. In this case, the conducting wire fed out from the nozzle 1021 may be the first conducting wire 31-2 that forms the upper layer.

  Further, the first conducting wire is not necessarily constituted by one conducting wire. For example, when two conductors are paired to form a set of conducting wires, the one set of conducting wires may constitute the first conducting wire. In this way, for example, a three-line common mode filter in which the lower layer is so-called bifilar wound and the upper layer is so-called aligned wound as in the present embodiment is configured.

  Moreover, the connection method to the metal terminals 5 and 6 of the 1st conducting wire 31-1 and the 2nd conducting wire 31-2 is not limited to the laser welding which is the method by this Embodiment. Moreover, although the drum core was used as the core 10, it is not limited to a drum core.

  The method for manufacturing a coil component of the present invention is extremely useful in the field of so-called layer winding (multilayer winding) in which a conductive wire is wound in two layers of a lower conductive wire and an upper conductive wire on a coil core.

The perspective view which shows the coil components manufactured by the manufacturing method of the coil components by this Embodiment. The side view which shows a mode that the lower layer reference | standard winding part is formed in the 2nd conducting-wire winding start process of the manufacturing method of the coil components by this Embodiment. The front view which shows a mode that the lower layer reference | standard winding part is formed in the 2nd conducting-wire winding start process of the manufacturing method of the coil components by this Embodiment. The principal part sectional drawing which shows a mode that the lower layer reference | standard winding part is formed in the 2nd conducting-wire winding start process of the manufacturing method of the coil components by this Embodiment. The side view which shows a mode that the winding of a 2nd conducting wire is started in the 2nd conducting wire winding start process of the manufacturing method of the coil components by this Embodiment. The front view which shows a mode that the winding of a 2nd conducting wire is started in the 2nd conducting wire winding start process of the manufacturing method of the coil components by this Embodiment. The principal part sectional drawing which shows a mode that the winding of a 2nd conducting wire is started in the 2nd conducting wire winding start process of the manufacturing method of the coil components by this Embodiment. The front view which shows the simultaneous winding process of the manufacturing method of the coil components by this Embodiment. The principal part sectional drawing which shows the simultaneous winding process of the manufacturing method of the coil components by this Embodiment. The principal part sectional drawing which shows the simultaneous winding process of the manufacturing method of the coil components by this Embodiment. The front view which shows a mode that only the 2nd conducting wire is wound after the simultaneous winding process of the manufacturing method of the coil components by this Embodiment. The principal part sectional drawing which shows a mode that only the 2nd conducting wire is wound after the simultaneous winding process of the manufacturing method of the coil components by this Embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Common mode filter 10 Core 10a 2nd conducting-wire winding start position 12 Core part 13-1 One collar part 13-2 The other collar part 13A Lower layer reference | standard winding part 31-1 1st conducting wire 31-2 2nd Conductor wire 1021, 1022 nozzle

Claims (4)

The first conductor is spirally formed so that the first conductor is a lower layer and the second conductor is an upper layer from one end side to the other end side of the axis centered on the axis of the winding part of the coil component. A method of manufacturing a coil component including a conductive wire winding step of winding a conductive wire and a second conductive wire in two layers around the winding portion,
The conducting wire winding step includes a first conducting wire winding start step of starting winding the first conducting wire before starting winding of the second conducting wire around the winding portion;
Before completion of winding of the first conducting wire around the winding portion, the second conducting wire starts to be wound around the winding portion, and the second conducting wire winding start position on the winding portion is more than the winding start position. On the other end side of the shaft center, a lower reference winding portion is formed in which at least two of the first conductor wires exist in a cross-sectional view taken along a plane passing through the second conductor winding start position and the shaft center. A second conductor winding start step of starting winding the second conductor from the second conductor winding start position to the winding portion,
A simultaneous winding step of simultaneously winding the first conductor and the second conductor in the circumferential direction of the winding portion from one end side to the other end side of the axial center of the winding portion; A method for manufacturing a coil component, comprising:   In the second conductive wire winding start step, the lower reference winding portion is formed by supplying the first conductive wire from the flyer nozzle of the flyer winding device and winding it around the core portion. A method for manufacturing a coil component according to claim 1. In the second conducting wire winding start step and the simultaneous winding step, the second conducting wire is supplied from the spindle nozzle of the spindle winding device and wound around the winding core,
When the winding of the first conducting wire around the winding portion is completed at the end of the simultaneous winding step and the winding of the second conducting wire around the winding portion is not completed, the second winding is further performed. The second wire is wound around the axis of the winding core at the same angular velocity as the second winding of the second conductor. 3. The method of manufacturing a coil component according to claim 2, wherein only the conducting wire is wound around the winding portion around which the first conducting wire is wound.   In the first conducting wire winding start step, the second conducting wire winding start step, and the simultaneous winding step, the first conducting wires that are adjacent to each other in a sectional view taken along a plane passing through the axis of the winding portion. The method for manufacturing a coil component according to any one of claims 1 to 3, wherein the first conductive wire is wound so that they are separated from each other.

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