JP2013016715A - Method of manufacturing coil component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a coil component which achieves improved characteristics and downsizing.SOLUTION: A conductor wire 20 folded back in a U-shape is wound from both end parts thereof at the same time with respect to a first winding core part 11 and a second winding core part 12 of a core 10 made of a seamless integral matter, thereby continuously integrally forming a first coil 21 and a second coil 22. The conductor wire 20 is not completely wound up to a folding point, but is wound leaving a part closer to the folding part. Then, the remaining unwound part of the conductor wire 20 is wound while linearly stretching the both parts of the conductor wire 20. Thereby, a first lead-out terminal 23 is continuously integrally formed on the first coil 21, and a second lead-out terminal 24 is continuously integrally formed on the second coil 22.

Description

  The present invention relates to a method of manufacturing a coil component in which a conductive wire is wound around a seamless core having a first core portion and a second core portion in parallel.

  2. Description of the Related Art Conventionally, a coil component in which a winding is mounted on a core that forms a substantially rectangular closed magnetic path is known. For example, after splitting the core and attaching a separately created winding, the coil component can be joined together by abutting the core, or the winding can be directly applied to the core that is integrally formed in a substantially square shape. It is formed by winding (see, for example, Patent Document 1).

JP-A-4-330704

  However, when dividing and joining the core, the effective permeability is lower than when the core is integrally formed, so the number of windings is large, and the wire diameter is large. There was a problem that it was difficult to downsize. Moreover, although the coil component described in Patent Document 1 uses an integrally formed core, two independent windings are wound around the core, and the two windings are continuous. It is not an integrated structure. Furthermore, when the core is formed integrally, it is not possible to wind the end of the winding in a state of being pulled out long, so a lead terminal must be connected to the end of the winding, and the contact resistance There is a problem in that the characteristics increase and the characteristics deteriorate.

  The present invention has been made based on such a problem, and an object of the present invention is to provide a method of manufacturing a coil component that can improve characteristics and can be miniaturized.

  In the coil component manufacturing method of the present invention, the first winding is mounted on the first core portion of the core made of a seamless integral body having the first core portion and the second core portion that are arranged in parallel. A method of manufacturing a coil component in which a second winding is mounted on a two-core part, wherein a lead wire folded into a U-shape or a U-shape with respect to the first and second core parts is provided. The windings are wound simultaneously from both ends, and the first winding and the second winding are continuously formed integrally.

  According to the coil component manufacturing method of the present invention, the first and second core parts are wound simultaneously from both ends with the U-shaped or U-shaped conductors. In addition, the first winding and the second winding can be continuously formed integrally with the core made of a single piece with no joint. Therefore, saturation can be improved, the number of windings can be reduced, and the wire diameter can be reduced. Therefore, the size can be reduced. In addition, the contact resistance can be reduced, the characteristics can be improved, and the connection process between the first winding and the second winding is not required, and the manufacturing process can be simplified.

  Further, after winding the conductor wire while leaving a part of the folded side from the both ends, the first winding is obtained by extending the both ends of the conductor wire in a straight line and winding the remaining part of the conductor wire not wound. The first lead terminal can be integrally formed to a free length continuously, and the second lead terminal can be integrally formed to a free length continuously to the second winding. . Therefore, the contact resistance can be further reduced, the characteristics can be further improved, and the connection process between the first extraction terminal and the second extraction terminal is not required, and the manufacturing process can be further simplified.

It is a figure showing the structure of the coil component manufactured by the manufacturing method of the coil component which concerns on one embodiment of this invention. It is a figure showing 1 process of the manufacturing method of the coil components which concern on one embodiment of this invention. FIG. 3 is a diagram illustrating a process following FIG. 2. FIG. 4 is a diagram illustrating a process following FIG. 3.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  FIG. 1 shows the configuration of a coil component 1 manufactured by the manufacturing method according to the present embodiment, and FIGS. 2 to 4 show the steps in the manufacturing method according to the present embodiment. . The manufacturing method of the coil component 1 according to the present embodiment is, for example, as shown in FIG. 1, a core made of a seamless integral body having a first core portion 11 and a second core portion 12 that are arranged in parallel. The coil component 1 in which the first winding 21 is mounted on the first winding core portion 10 and the second winding 22 is mounted on the second winding core portion 12 is manufactured.

  First, for example, as shown in FIG. 2, the first core portion 11 and the second core portion 12 that are arranged in parallel, and one end of the first core portion 11 and one end of the second core portion 12 are coupled. The first coupling portion 13, the second coupling portion 14 that couples the other end of the first winding core portion 11 and the other end of the second winding core portion 12, and the core 10 made of a seamless integral body. prepare. The core 10 forms, for example, a so-called substantially square-shaped closed magnetic circuit, and is formed of a magnetic material such as ferrite. The first core portion 11 and the second core portion 12 are preferably formed in a columnar shape with a substantially circular cross-section, but as a columnar shape with an elliptical cross-sectional shape or a prismatic shape with a polygonal cross-sectional shape. Also good. Further, bobbins 15 and 16 made of synthetic resin, for example, may be disposed on the outer periphery of the first core portion 11 and the second core portion 12.

  Next, for example, a conductive wire 20 made of copper, aluminum, or the like is prepared. For example, as shown in FIG. 3, a U-shape (see FIG. 3 (A)) or a U-shape (FIG. 3 (B) )). The conducting wire 20 may be, for example, one whose surface is coated with an insulating coating (so-called coated conducting wire) or one whose surface is not coated with an insulating coating, for example, a flat wire. Subsequently, for example, as shown in FIG. 4 (A), the conductor 20 is wound around the first core part 11 via the bobbin 15 from one end, and the bobbin 16 is wound around the second core part 12 at the same time. Then, the conductive wire 20 is wound from the other end portion to form the first winding 21 around the first core portion 11 and the second winding 22 around the second core portion 12. In that case, the conducting wire 20 is wound edgewise so that the plane of the flat wire intersects the direction of the center line of the first core portion 11 or the second core portion 12. In addition, in FIG. 4, although the state which winds the conducting wire 20 around the 1st core part 11 is represented notionally, since the winding with respect to the 2nd core part 12 is the same, the corresponding code | symbol is shown. Shown together in parentheses.

  Further, the conductive wire 20 is not completely wound until the U-shaped or U-shaped folding is performed, and is wound while leaving a part on the folded side. For example, as shown in FIG. It is preferable to wind the remaining part of the wire 20 that is not wound, while extending both ends of the wire linearly. As a result, the first lead terminal 23 is formed integrally with the first winding 21, and the second lead terminal 24 is formed integrally with the second winding 22. The first winding 21 and the second winding 22 are continuously and integrally formed by winding one conductive wire 20 from both ends. Note that a plurality of conductive wires 20 may be wound around the core 10, and a plurality of first windings 21 and second windings 22 may be disposed on the core 10. Thereby, for example, the coil component shown in FIG. 1 is obtained.

  As described above, according to the present embodiment, the conductive wire 20 folded in a U-shape or a U-shape is wound around the first core portion 11 and the second core portion 12 from both ends at the same time. Therefore, the first winding 21 and the second winding 22 can be continuously formed integrally with the core 10 made of a seamless integral body. Therefore, saturation can be improved, the number of windings can be reduced, and the wire diameter can be reduced. Therefore, the size can be reduced. Further, the contact resistance can be reduced, the characteristics can be improved, and the connection process between the first winding 21 and the second winding 22 is not required, and the manufacturing process can be simplified.

  Further, after winding the both ends of the conducting wire 20 while leaving a part on the folded side, extending both ends of the conducting wire 20 in a straight line while winding the remaining unwrapped portion of the conducting wire 20, The first lead terminal 23 can be formed integrally with the first winding 21 to a free length, and the second lead terminal 24 can be continuously formed with the second winding 22 so as to have a free length. Can be formed. Therefore, the contact resistance can be further reduced, the characteristics can be further improved, and the connection process between the first extraction terminal 23 and the second extraction terminal 24 is not required, and the manufacturing process can be further simplified. .

  The present invention has been described with reference to the embodiment. However, the present invention is not limited to the above embodiment, and various modifications can be made. For example, the core 10 may be formed of a seamless integral body, and the first coupling portion 13 and the second coupling portion 14 are respectively coupled to the first winding core portion 11 and the second winding core portion 12 and closed. You may comprise by a cyclic | annular thing, and form the 1st core part 11, the 2nd core part 12, the 1st coupling | bond part 13, and the 2nd coupling | bond part 14 by winding a ribbon core cyclically | annularly, You may make it comprise a closed magnetic circuit.

  Moreover, although each process was demonstrated in the said embodiment, not all the processes may be included and the other process may be included.

  It can be used for coil parts.

  DESCRIPTION OF SYMBOLS 1 ... Coil component, 10 ... Core, 11 ... 1st core part, 12 ... 2nd core part, 13 ... 1st coupling | bond part, 14 ... 2nd coupling | bond part, 15, 16 ... Bobbin, 20 ... Conductor, 21 ... 1st winding, 22 ... 2nd winding, 23 ... 1st extraction terminal, 24 ... 2nd extraction terminal

Claims (3)

The first winding is mounted on the first core portion of the core made of a seamless unit having the first core portion and the second core portion in parallel, and the second winding is mounted on the second core portion. A method for manufacturing a mounted coil component, comprising:
The first and second core portions are wound simultaneously with U-shaped or U-shaped conductive wires from both ends, and the first winding and the second winding are continuously integrated. A method of manufacturing a coil component, characterized in that the coil component is formed.   2. The method of manufacturing a coil component according to claim 1, wherein a flat wire is used as the conducting wire and the first and second core portions are wound edgewise.   After winding the first core part and the second core part while leaving a part on the folded side from both ends of the conducting wire, the both ends of the conducting wire are linearly extended, and the remaining unwrapped conductor By winding a part, the first lead terminal is formed integrally with the first winding, and the second lead terminal is formed integrally with the second winding. The manufacturing method of the coil components of Claim 1 or Claim 2.

Images