JP2016039322A - Coil and coil component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil which is excellent in connection workability with external equipment and also to provide a coil component equipped with the coil.SOLUTION: A coil includes: a pair of coil elements 11, 12 in which winding wires 11w, 12w each having a rectangular cross section of a conductor are subjected to flatwise winding in a multilayer form, one end of each of which is arranged in the innermost periphery, and the other end of each of which is led out to the outermost periphery; and an inside connection part 13 which connects one end of the winding wire 11w and one end of the winding wire 12w to each other. The pair of coil elements is arranged so as to have an axis common to each other.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a coil combined with a magnetic core and the like, and a coil component including the coil. In particular, the present invention relates to a coil excellent in connection workability with an external device.

  Coil parts are used as parts of various products such as automobiles, electrical equipment, and industrial machines. The coil component includes a coil formed by winding a winding and a magnetic core on which the coil is disposed. Specific examples of the coil component include a motor, a transformer, a choke coil, a reactor, an antenna, and an ignition coil.

  For example, in Patent Document 1, a coil in which a first coil (coil element) and a second coil (coil element) wound with a conductive foil are connected in parallel, and a rectangular shape, two opposing sides A reactor including a first coil and a soft magnetic core (magnetic core) around which the second coil is wound is disclosed. The first coil and the second coil are respectively drawn conductor portions that are conductively connected to the external connection terminal at the winding start end portion of the innermost conductor foil and the winding end end portion of the outermost conductor foil. Is provided.

JP 2013-229527 A

  In the coil described above, connection workability between the end of the winding of each coil element and an external device such as an external connection terminal becomes complicated. Since the lead conductor portion connected to the external connection terminal is provided at the winding start end portion of the innermost conductor foil of each coil element, when connecting the lead conductor portion to the external connection terminal, the lead conductor is This is because it is difficult to manage.

  The present invention has been made in view of the above circumstances, and one of its purposes is to provide a coil excellent in connection workability with an external device.

  Another object of the present invention is to provide a coil component including the coil.

  In the coil according to one aspect of the present invention, a winding having a rectangular conductor cross section is flat-wise wound in multiple layers, one end of the winding is disposed on the innermost periphery, and the other end of the winding is pulled out on the outermost periphery. A pair of coil elements and an inner connecting portion that connects one ends of the windings. The pair of coil elements are arranged so as to have a common axis.

  The coil component which concerns on 1 aspect of this invention is provided with the coil which concerns on 1 aspect of the said invention, and the magnetic core by which this coil is arrange | positioned.

  The coil is excellent in connection workability with an external device.

  The coil component is excellent in connection workability between the coil and the external device.

It is a schematic perspective view which shows the coil which concerns on embodiment. It is a top view which shows before winding of the coil | winding which comprises the coil which concerns on embodiment. It is process explanatory drawing explaining an example of the manufacturing method of the coil which manufactures the coil which concerns on embodiment. It is process explanatory drawing explaining the other example of the manufacturing method of the coil which manufactures the coil which concerns on embodiment. It is a schematic perspective view which shows the coil components which concern on embodiment. It is a disassembled perspective view which shows the outline of the coil components which concern on embodiment.

<< Description of Embodiments of the Present Invention >>
First, the contents of the embodiment of the present invention will be listed and described.

  (1) In the coil according to the embodiment, a winding having a rectangular conductor cross section is flat-wise wound in multiple layers, one end of the winding is disposed on the innermost periphery, and the other end of the winding is pulled out on the outermost periphery. A pair of coil elements and an inner connecting portion that connects one ends of the windings. The pair of coil elements are arranged so as to have a common axis.

  According to said structure, it is excellent in the connection workability | operativity with an external apparatus. By forming the coil elements by flatwise winding the windings in multiple layers, the other end of the winding can be drawn out to the outermost periphery of the coil elements. Therefore, the other end of the winding and the connection work with the external device can be performed on the outer peripheral side of the coil having a relatively wide space. In addition, by connecting the ends of the windings arranged on the innermost periphery of the coil element with the inner connecting portion, one end of the winding is connected from the innermost periphery of the coil element for connection with an external device or the like. There is no need to pull out or separately connect the connection conductor to one end of the winding disposed on the innermost periphery of the coil element.

  In addition, according to the above configuration, after winding the winding, the extra length is reduced when winding the winding so that one end, the connection conductor, and the like are pulled out from the innermost circumference of the coil element. There is no need to consider it, and the winding work can be simplified.

  Furthermore, according to said structure, compared with the case where a pair of coil element is arrange | positioned so that an axis | shaft may have a common axis | shaft, it arrange | positions in the innermost periphery of a coil element. It is easy to connect one end of each winding.

  (2) One form of the coil is that the conductor of the winding is made of a normal conductive material.

  According to said structure, it is excellent in the productivity of a coil. This is because, compared with superconducting materials, normal conducting materials are excellent in toughness and ductility, and therefore are easy to wind. Moreover, according to said structure, it is not necessary to cool to cryogenic temperature compared with a superconducting material.

  (3) As one form of the said coil, it is mentioned that an inner side connection part is along the axial direction of a coil element.

  According to said structure, it is not necessary to perform bending process, such as a spiral shape, with respect to an inner side connection part.

  (4) As one form of the coil, it may be provided with an insulating layer interposed between the layers of the coil element.

  According to said structure, the insulation between each layer of a coil element can be improved.

  (5) The coil component which concerns on embodiment is provided with the coil as described in any one of said (1)-(4), and the magnetic core by which a coil is arrange | positioned.

  According to said structure, a connection with a coil and an external apparatus is easy.

<< Details of Embodiment of the Present Invention >>
Details of embodiments of the present invention will be described below with reference to the drawings. In addition, this invention is not limited to these illustrations, is shown by the claim, and intends that all the changes within the meaning and range equivalent to a claim are included.

Embodiment 1
The coil which concerns on embodiment has a connection part which connects a pair of coil element formed by winding a coil | winding, and coil elements. The main feature of this coil is that each coil element is formed by winding a winding of a specific shape in a specific direction, and the connecting portion connects the coil elements at the innermost circumference, It exists in the point arrange | positioned so that an axis | shaft may mutually be common. Hereinafter, the coil will be mainly described with reference to FIGS. 1 and 2, the coil manufacturing method will be described with reference to FIGS. 3 and 4, and the coil components including the coil will be sequentially described with reference to FIGS.

〔coil〕
The coil 1 includes a pair of coil elements 11 and 12 and an inner connecting portion 13 that connects the coil elements 11 and 12 to each other.

[Coil element]
The pair of coil elements 11 and 12 are formed by winding a plurality of flat-wise windings of windings 11w and 12w having a rectangular conductor cross section. Flatwise winding refers to winding the windings 11w and 12w in the conductor thickness direction. In other words, flatwise winding in multiple layers means that the winding is not wound spirally at a predetermined pitch, but is wound spirally on the same plane. The thickness direction of the conductor refers to the direction along the short side of the conductor cross section.

  Compared with the case where the windings 11w and 12w are wound, for example, edgewise, the flatwise winding is (1) easy to increase the space factor, (2) easy to bend and improve productivity, and (3) heat dissipation to the same extent. (4) Although it depends on the size of the conductor cross section, it is easy to suppress eddy currents. Edgewise winding refers to winding the windings 11w and 12w in the width direction of the conductor. The width direction of the conductor means a direction along the long side of the conductor cross section. The reason why the space factor is easily increased is that, when edgewise winding is performed, a gap is easily generated between turns, whereas flatwise winding is easy to wind without generating a gap between turns. The reason why it is easy to bend is that the flatwise winding is bent to the side where the conductor cross section is shorter than the edgewise winding. The reason why it is easy to improve heat dissipation is that no gap is generated between the turns as described above, and adjacent turns of the windings 11w and 12w are easily brought into surface contact with each other.

  Further, the flatwise winding is, for example, (1) easy to increase the space factor, and (2) easy to improve heat dissipation, as compared with the case where the winding of the conductor has a circular shape (round wire). (3) It is easy to bend to the same extent. (4) Although it depends on the size of the conductor cross section, it is easy to suppress eddy current. The reason why the space factor is easy to increase is that when winding round wires in a line, the windings are in line contact with each other and a gap is formed at the triple point of the winding. It is because it is easy to wind without generating a gap. The reason why it is easy to improve heat dissipation is that, as described above, the round wire is in line contact, whereas the flatwise winding allows the turns adjacent to the inner and outer peripheries to be in surface contact. The reason why it is easy to bend is that it is bent to the side where the conductor cross section is short as described above.

  In each of the coil elements 11 and 12, one end (inner end portions 11i and 12i) of the windings 11w and 12w is arranged on the innermost periphery, and the other end (outer end portions 11o and 12o) of the winding is drawn to the outermost periphery. ing. One ends (inner ends 11i, 12i) of the windings 11w, 12w in the coil elements 11, 12 are connected to an inner connecting portion 13 described later. On the other hand, the other ends (outer end portions 11o and 12o) of the windings 11w and 12w in the coil elements 11 and 12 are connected to, for example, a terminal member (not shown), and power is supplied to the coil 1 via the terminal member. An external device (not shown) such as a power source that supplies power is connected. Since the inner end portions 11i and 12i are coupled to each other by the inner coupling portion 13 and the outer end portions 11o and 12o are pulled out to the outermost periphery, connection workability with an external device or the like can be improved. For connection with an external device, it is not necessary to draw out the inner end portions 11i and 12i from the innermost circumference of the coil elements 11 and 12 and to connect a connection conductor to the innermost circumference of the coil elements 11 and 12. In addition, the outer end portions 11o and 12o are arranged on the outermost periphery of the coil elements 11 and 12, so that the outer end portions 11o and 12o can be routed and the outer end portions 11o and 12o can be connected to an external device with a coil. This is because it can be performed on the outer peripheral side of 1. The direction in which the outer end portions 11o and 12o are drawn can be appropriately selected in the radial direction of the coil elements 11 and 12, and can be the same direction (FIG. 1) or different directions (for example, opposite directions).

  The arrangement of the pair of coil elements 11 and 12 is coaxial and arranged in parallel in the axial direction. If it does so, it will be easy to connect the inner side edge parts 11i and 12i arrange | positioned by the inner side connection part 13 at the innermost periphery of the coil elements 11 and 12. FIG. It is preferable that the distance between the coil elements 11 and 12 along the axial direction is as close as possible to the extent that mutual insulation can be secured. If it does so, the space factor of the coil 1 can be raised and the coil 1 can be reduced in size.

  The number of turns of each coil element 11, 12 can be appropriately selected according to the application of the coil 1. The number of turns in FIG. 1 is an example, and is a number for convenience of explanation. The number of turns of both coil elements 11 and 12 is the same. The winding directions of the coil elements 11 and 12 are opposite to each other, but the direction of the magnetic flux formed by the coil elements 11 and 12 is the same by the inner connecting portion 13.

  Each of the coil elements 11 and 12 is a hollow cylindrical body (here, a square cylindrical shape). The end face shape of each of the coil elements 11 and 12 can be appropriately selected according to the shape of a magnetic core 2 (FIG. 5) described later. For example, when the shape of the magnetic core 2 (inwardly projecting portion 21i in FIG. 5) inserted into the coil elements 11 and 12 is a prismatic shape, a rectangular corner is rounded (rectangular tube shape), or the magnetic core 2 is In the case of a columnar shape, it can be a circular shape (cylindrical shape).

[Inner connection part]
The inner connecting portion 13 connects the inner end portions 11i and 12i of the pair of coil elements 11 and 12. By providing the inner connecting portion 13, it is not necessary to pull out the inner end portions 11 i and 12 i from the inner peripheral surfaces of the coil elements 11 and 12. Therefore, it is not necessary to bend the inner end portions 11i and 12i in the edgewise direction and pull them out in the axial direction of each coil element, and an excessive force is not applied to the windings 11 and 12 themselves. Further, after winding the windings 11w and 12w, it is necessary to consider the extra length when winding the windings 11w and 12w so that the inner end portions 11i and 12i are drawn out of the coil element. There is no. The inner connecting portion 13 is preferably along the axial direction of the coil elements 11 and 12. Along the axial direction means that the longitudinal direction of the inner connecting portion 13 is parallel to the axial direction of the coil elements 11 and 12. By doing so, it is not necessary to perform a bending process such as a spiral on the inner connecting portion 13.

  The inner connecting portion 13 may be formed in series with the windings 11w and 12w, or may be formed as a separate member independent of the coil elements 11 and 12. The member in which the inner connecting portion 13 is formed in series with the windings 11w and 12w is formed by connecting the windings 11w and 12w and the inner connecting portion 13 in series from a single long plate as shown in the left figure of FIG. It can be produced by cutting out a long Z-shaped piece. When formed by a separate member, the inner connecting portion 13 can use a cut piece of the same winding as the windings 11w and 12w forming the coil elements 11 and 12. Since the cut piece has the same material, cross-sectional shape, and cross-sectional area as the windings 11w, 12w constituting the coil elements 11, 12, it is easy to join the ends of the windings 11w, 12w. Specific methods for this joining include welding, soldering, and crimping. Here, as shown in the right diagram of FIG. 2, the inner connecting portion 13 is formed of a member different from both the coil elements 11 and 12.

  When the inner connecting portion 13 is formed of a member independent of the coil elements 11 and 12, the shape, size, and cross-sectional area of the inner connecting portion 13 are appropriately determined according to the inner dimensions such as the shape and inner diameter of the coil elements 11 and 12. You can choose. The shape of the inner connecting portion 13 can be, for example, the same rectangular shape as the conductors of the windings 11w and 12w. The size (width and thickness) and cross-sectional area of the inner connecting portion 13 can be made equal to the size (width and thickness) and cross-sectional area of the conductor.

(Winding)
As the windings 11w and 12w, a bare wire made of a bare conductor may be used, or a covered wire having an insulation coating made of an insulating material such as enamel (typically polyamideimide) on the outer periphery of the conductor. It may be used. In particular, when an insulating layer 14 to be described later is provided, bare wires can be preferably used for the windings 11w and 12w. This is because the insulating layer 14 can improve the insulation between the bare wires. If a bare wire is used, it is not necessary to coat the outer periphery of the conductor with enamel, so that the productivity of the coil 1 can be easily improved. This is because the insulating layer 14 can be formed along with the winding work of the windings 11w and 12w.

<Conductor material>
Examples of the material of the conductors of the windings 11w and 12w include a normal conductive material and a superconductive material. Examples of the normal conductive material include copper, copper alloy, aluminum, and aluminum alloy. Examples of the superconducting material include metal superconducting materials such as Nb—Sn alloys and Nb—Ti alloys, and ceramic superconducting materials such as Bi (for example, Bi2223) and RE123. If composed of a normal conducting material, compared to a superconducting material, it is excellent in toughness and ductility, so that it is easy to wind and the productivity of the coil can be increased. In addition, if it is made of a normal conductive material, it is not necessary to cool to a very low temperature. If composed of a superconducting material, a large current is likely to flow compared to a normal conducting material.

<Conductor shape and size>
The shape of the conductor is rectangular as described above. The sizes (width and thickness) of the conductor cross sections of the windings 11w and 12w satisfy the size (required characteristics) according to the application of the coil component 100 combined with the magnetic core 2, and are easy to perform flat-wise winding. It is preferable that That is, the size of the conductor cross section depends on the use of the coil component 100. For example, the aspect ratio (width / thickness) of the conductor cross section is 1.5 or more and 1 × 10 ⁵ or less, and more preferably 3 or more and 1 X10 ⁴ or less is mentioned. The conductor cross-sectional width (long side length) of the windings 11w and 12w is, for example, 0.5 mm or more and 100 mm or less, and more preferably 2 mm or more and 30 mm or less. Examples of the conductor cross-sectional thickness (short side length) of the windings 11w and 12w include 1 × 10 ⁻³ mm to 5 mm, and further include 1 × 10 ⁻² mm to ² mm.

[Insulation layer]
The coil 1 preferably includes an insulating layer 14 interposed between the respective layers of the coil elements 11 and 12. The insulating layer 14 insulates between the windings 11w and 12w (conductor). In FIG. 1, the surface of the insulating layer 14 is hatched for convenience of explanation. This also applies to FIGS. 5 and 6 described later.

The width of the insulating layer 14 may be the same as the width of the windings 11w and 12w (conductor), and the thickness of the insulating layer 14 may be 1 × 10 ⁻⁴ mm or more. If the thickness of the insulating layer 14 is 1 × 10 ⁻⁴ mm or more, it is easy to improve the insulation between the windings 11w and 12w (conductor). Although the thickness of the insulating layer 14 depends on the number of turns of the windings 11w and 12w and the thickness of the conductor, the thickness of the entire coil 1 is set so as not to be too thick. As for the thickness of the insulating layer 14, 0.5 mm or less is mentioned, for example. The thickness of the insulating layer 14 is preferably 1 × 10 ⁻⁴ mm or more and 1 × 10 ⁻¹ mm or less.

  The constituent material of the insulating layer 14 is tetrafluoroethylene-hexafluoropropylene copolymer (FEP) resin, polytetrafluoroethylene (PTFE) resin, silicon rubber, polyamideimide resin, polyimide resin, polyesterimide resin, polyester resin, etc. Insulating material

  The insulating layer 14 is formed, for example, when the insulating material 14 is sprayed and coated on one side of the windings 11w and 12w (conductor) before winding or when the windings 11w and 12w (conductor) are wound. The insulating tape made of the above insulating material can be wound together with the windings 11w and 12w. At this time, the back surface of the conductor (the surface located on the inner peripheral side when it is wound, but excluding the surface facing the inner connecting portion 13) is coated, or an insulating tape is arranged to be together with the windings 11w and 12w. Or the like, the insulating layer 14 is formed on the innermost periphery of the coil elements 11 and 12. In this case, when the coil 1 is combined with the magnetic core 2, the insulation between the coil 1 and the magnetic core 2 can be enhanced in addition to the increase in the insulation between the conductors. On the other hand, if the surface of the conductor (the surface positioned on the outer periphery side when wound) is coated, or if an insulating tape is disposed and wound together with the winding, the coil element 11, as shown in FIG. In the innermost periphery of 12, the insulating layer 14 is not formed and a conductor is arranged. Therefore, when the coil 1 is combined with the magnetic core 2, an insulating member to be described later may be disposed between the coil 1 and the magnetic core 2. If it does so, the insulation between the coil 1 and the magnetic core 2 can be improved.

[Others]
The coil 1 may include a pair of coil elements 11 and 12. In that case, it is mentioned that a plurality of pairs of coil portions are provided with the pair of coil elements 11 and 12 as a pair of coil portions. The plurality of pairs of coil portions are coaxially arranged in parallel in the axial direction. And the adjacent coil parts are the outer end part 11o (12o) of the coil element 11 (12) in one coil part, and the outer end part 12o (11o) of the coil element 12 (11) in the other coil part. Are connected by an outer connecting portion (not shown). The outer connecting portion may be formed of a member independent of both coil portions, for example, a member similar to the inner connecting portion 13 described above. The shape, cross-sectional area, and material of the outer connecting portion are preferably the same as the shape, cross-sectional area, and material of the windings 11w, 12w that constitute the coil elements 11, 12. The connection (joining) between the outer connecting portion and the outer end portions 11o and 12o of both coil portions can be performed by soldering as described above.

[Coil manufacturing method]
The coil 1 can be manufactured, for example, by using the core 200 (FIGS. 3 and 4). For the winding core 200, an appropriate bar having excellent strength can be suitably used. Since the coil elements 11 and 12 of the coil 1 are formed by winding the windings 11w and 12w flatwise, the windings 11w and 12w can be easily wound around the core 200. Specifically, the coil 1 is manufactured by fixing the winding core 200 and winding the windings 11w and 12w, or rotating the winding core 200 and winding the windings 11w and 12w around the winding core 200. . First, the windings 11w and 12w, the inner connection part 13, and the winding core 200 are prepared.

(When fixing the core)
The back surface of one end portion (inner end portion 11 i) of the windings 11 w and 12 w is joined to the front surface of the inner connecting portion 13. For example, as shown in the right diagram of FIG. 2, one end of a winding 11 w to be one coil element 11 is joined to one end of a rectangular plate-shaped inner coupling portion 13 so as to be orthogonal to each other, and the rectangular plate-shaped inner coupling portion 13 is joined. One end of the winding 12w to be the other coil element 12 is joined to the other end of the coil so as to be orthogonal. However, the drawing directions of the winding 11 w that is the one coil element 11 and the winding 12 w that is the other coil element 12 are opposite to the inner connecting portion 13. Next, the back surface of the inner connecting portion 13 is fixed to the core 200 (the left diagram in FIG. 3). In this state, one coil 11w and the other coil 12w are wound in the direction of the arrow to produce both coil elements 11 and 12 (right figure in FIG. 3). At this time, after one coil element 11 is produced by rotating one winding 11w along the circumferential direction of the core 200 and winding it around the core 200, the other coil 12w is replaced with one coil 11w. The other coil element 12 may be manufactured by rotating in the opposite direction to and wound around the core 200. Alternatively, the coil elements 11 and 12 may be simultaneously manufactured by rotating the windings 11w and 12w in opposite directions and winding them simultaneously.

(When rotating the core)
The back surface of the inner coupling part 13 is fixed to the winding core 200 (the left figure in FIG. 4). Subsequently, when the windings 11w and 12w and the inner coupling portion 13 are separate members (the right diagram in FIG. 2), the surface of the inner coupling portion 13 and one winding 11w are joined (the second from the left in FIG. 4). Figure). For example, one end of the winding 11 w to be one coil element 11 is joined to one end of the rectangular plate-like inner coupling portion 13 so as to be orthogonal. Then, the coil element 11 is manufactured by rotating the winding core 200 in the direction of the arrow and winding the winding 11w (third view from the left in FIG. 4). Next, the other winding 12w is joined to the surface of the inner connecting portion 13 by soldering or the like (fourth view from the left in FIG. 4). For example, one end of the winding 12w that becomes the other coil element 12 is joined to the other end of the rectangular plate-shaped inner coupling portion 13 so as to be orthogonal. At this time, the drawing direction of the winding 12 w to be the other coil element 12 is opposite to the drawing side of the winding 11 w to be the one coil element 11 with respect to the inner connecting portion 13. And the coil element 12 is produced by rotating the winding core 200 in the opposite direction to the case of winding up one winding 11w and winding up the winding 12w (FIG. 4 right figure).

[Function and effect]
The coil 1 described above is excellent in connection workability with an external device or the like. The reason is as follows. (1) The outer end portions 11o and 12o themselves can be routed and the outer end portions 11o and 12o can be connected to an external device on the outer peripheral side of the coil 1 having a relatively large space. (2) It is not necessary to pull out the inner end portions 11i and 12i from the innermost circumference of the coil elements 11 and 12 for connection with an external device or the like. (3) It is not necessary to connect the connection conductor to the innermost ends 11i and 12i of the innermost circumference of the coil elements 11 and 12. In the above (1), the outer end portions 11o and 12o can be drawn to the outermost periphery of the coil elements 11 and 12 by forming the coil elements 11 and 12 by winding the windings 11w and 12w in multiple layers. Because. The above (2) and (3) are because the inner end portions 11i and 12i on the innermost circumference of the coil elements 11 and 12 are connected to each other by the inner connecting portion 13. Moreover, since this coil 1 is excellent in the connection workability | operativity with an external apparatus etc., it can utilize suitably for the coil of coil components.

[Coil parts]
An example of the coil component will be described with reference to FIGS. The coil component 100 includes the above-described coil 1 and a magnetic core 2 on which the coil 1 is disposed.

[coil]
The coil 1 includes the above-described pair of coil elements 11 and 12 and the above-described inner coupling portion 13 (FIGS. 5 and 6). The conductors of the windings 11w and 12w and the inner connecting portion 13 are made of the above-described normal conductive material. An insulating layer 14 is provided between the layers of the coil elements 11 and 12.

[core]
The magnetic core 2 is an E-core that combines an E-core 21 having a portion where the coil 1 is disposed and an I-core 22 that is not disposed in the coil 1 and is connected to the E-core 21 to form a closed magnetic path together with the E-core 21. I core is provided. The form of the magnetic core 2 is not limited to the form including the EI core, but includes, for example, a form including an EE core in which a pair of E-shaped cores are combined, or a TU in which a T-shaped core and a U-shaped core are combined. Various forms such as a form provided with a core, a form provided with an annular core (O-shaped core), and a form provided with a quadrangular frame-shaped core in which four I-shaped cores are combined in a ring shape can be employed. A gap material or an air gap can be provided between the cores.

  The E core 21 includes a base portion 21b, an inner overhang portion 21i, and a pair of outer overhang portions 21o. When the magnetic core 2 is combined with the coil 1, the base portion 21 b of the E core 21 is disposed so as to protrude from the end face of the coil 1 (FIG. 5). The shape of the base 21b is a thin prismatic body. The inner overhanging portion 21 i of the E core 21 protrudes from the base portion 21 b in a direction perpendicular to the base portion 21 b and is disposed inside the coil elements 11 and 12 when combined with the coil 1. The shape of the inner overhanging portion 21i is a rectangular parallelepiped shape, and the corners thereof are rounded so as to follow the inner peripheral surfaces of the coil elements 11 and 12 (FIG. 6). The length of the inner overhanging portion 21 i is slightly longer than the length of the coil 1 in the axial direction. The outer overhanging portion 21o of the E core 21 protrudes in a direction parallel to the inner overhanging portion 21i from the base 21b across the inner overhanging portion 21i on the outer periphery of the coil 1. The shape of the outer overhanging portion 21o is a thin prismatic body. The upper surfaces of the base portion 21b and the outer overhang portion 21o (upper side of the paper in FIGS. 5 and 6) and the lower surfaces of the base portion 21b and the lower surface (lower side of the paper surface in the figure) are flush with each other. These upper surfaces are higher than the upper surface of the inner overhang portion 21i, and these lower surfaces are lower than the lower surface of the inner overhang portion 21i.

  The I core 22 includes a base portion 22 b similar to the base portion 21 b of the E core 21. When the magnetic core 2 is combined with the coil 1, the base 22 b is disposed so as to protrude from the end face of the coil 1 (FIG. 5). The shape of the base 22b (I core 22) is a thin prismatic body. The upper surface and the lower surface of the base portion 22b are flush with the upper surface and the lower surface of the base portion 21b of the E core 21 and the outer overhang portion 21o. The end surface of the base 22b (I core 22) is connected to the end surface of the inner overhanging portion 21i of the E core 21 and the end surface of both outer overhanging portions 21o. By connecting these end faces, when the coil 1 is excited, the magnetic core 2 forms a closed magnetic circuit. The two cores 21 and 22 can be connected with an adhesive, for example.

(Constituent materials)
A known soft magnetic material can be used for the E core 21 and the I core 22. Soft magnetic materials include, for example, compacted compacts obtained by pressure-molding soft magnetic powder, magnetic powder-dispersed resin compacts in which soft magnetic powder is dispersed in a resin, laminated bodies in which a plurality of electromagnetic steel sheets are laminated, sintered bodies, etc. Can be used. The soft magnetic powder is typically an iron alloy such as pure iron (purity 99 mass% or more), Fe—Si—Al alloy, Fe—Si alloy, Fe—Al alloy, Fe—Ni alloy, etc. Etc. The soft magnetic particles may have an insulating coating formed on the surface thereof. Examples of the material for the insulating coating include insulating resins such as phosphate and silicone resin, and oxides such as silica. By having an insulating coating on the surface of the soft magnetic particles, particularly when each core is formed of a compacted body, eddy current loss can be reduced and the magnetic properties of the magnetic core can be improved. As the resin, a thermosetting resin such as an epoxy resin or a thermoplastic resin such as a PPS resin can be used. Here, both the cores 21 and 22 are comprised with a compacting body.

[Others]
An insulating member (not shown) that insulates between the coil 1 and the magnetic core 2 (inner overhanging portion 21i) may be provided. In particular, when the insulating layer 14 is not provided on the innermost periphery of the coil 1 and a bare conductor is disposed, the insulation between the coil 1 and the magnetic core 2 can be improved by providing an insulating member. Therefore, it is preferable. The insulating member is constituted by, for example, covering with insulating tape, insulating paper, insulating sheet, insulating resin coating (injection molding, etc.), coating of an insulating material, a bobbin that is separately manufactured and assembled to the coil 1 or the magnetic core 2. Can be mentioned. Examples of the constituent material of the insulating member include the same materials as those of the insulating layer 14 described above. As described above, when the insulating layer 14 is provided on the innermost periphery of the coil 1, the insulating member may not be provided.

[Manufacturing method of coil parts]
The coil component 100 can be manufactured by preparing the coil 1 in advance and combining it with the magnetic core 2, or depending on the shape of the magnetic core 2, by winding the windings 11 w and 12 w around the magnetic core 2. When the coil 1 is prepared in advance, the coil 1 is manufactured using a winding core other than the magnetic core, as in the above-described “coil manufacturing method”. On the other hand, when winding a winding around a magnetic core, it can be manufactured by using the magnetic core as the above-described core.

[Function and effect]
According to the coil component 100 described above, the connection workability between the outer end portions 11o and 12o and the external device is excellent. This is because the outer end portions 11o, 12o are disposed on the outermost periphery of the coil elements 11, 12. Moreover, the coil component 100 is excellent in productivity. The reason is as follows. (1) It is easy to perform a combination work of the coil 1 and the magnetic core 2. (2) When the coil component 100 is manufactured by winding the windings 11w, 12w and the like around the magnetic core 2, the winding work of the windings 11w, 12w can be simplified. (3) It is not necessary to draw out the inner end portions 11i, 12i from the innermost periphery of the coil elements 11, 12 to the outside after the coil component 100 is manufactured. (4) There is no need to separately connect a connection conductor or the like to the inner end portions 11i, 12i. The above (1), (3), and (4) are because the inner end portions 11i and 12i on the innermost circumference of the coil elements 11 and 12 are connected to each other by the inner connecting portion 13. More specifically, in the above (1), the inner end portions 11i, 12i and the connection conductors connected to the inner end portions 11i, 12i are not drawn out from the innermost periphery of the coil elements 11, 12. For this reason, the combination of the coil 1 and the magnetic core 2 is hardly hindered by the inner end portions 11i, 12i, the connection conductor, and the like. In (2) above, the windings 11w and 12w are arranged so that the inner ends 11i and 12i are drawn out from the innermost circumference of the coil elements 11 and 12 after the windings 11w and 12w are wound. This is because it is not necessary to consider the extra length when winding.

  The coil of the present invention can be used for coils of various coil components (for example, reactors, transformers, motors, choke coils, antennas, fuel injectors, ignition coils, etc.). The coil component of the present invention can be used for a reactor, a transformer, a motor, a choke coil, an antenna, a fuel injector, an ignition coil, and the like.

DESCRIPTION OF SYMBOLS 100 Coil parts 1 Coil 11, 12 Coil element 11w, 12w Winding 11i, 12i Inner edge part 11o, 12o Outer edge part 13 Inner connection part 14 Insulation layer 2 Magnetic core 21 E core 22 I core 21b, 22b Base 21i Inner overhang Part 21o Outer overhang 200 Winding core

Claims (5)

A pair of coil elements in which a winding having a rectangular cross section of the conductor is flat-wise wound in multiple layers, one end of the winding is disposed on the innermost periphery, and the other end of the winding is drawn to the outermost periphery,
An inner connecting portion that connects the one ends of the windings;
The pair of coil elements are coils arranged so as to have a common axis.   The coil according to claim 1, wherein a conductor of the winding is made of a normal conductive material.   The coil according to claim 1, wherein the inner connecting portion is along an axial direction of the coil element.   The coil according to any one of claims 1 to 3, further comprising an insulating layer interposed between the layers of the coil element.   A coil component comprising the coil according to any one of claims 1 to 4 and a magnetic core on which the coil is disposed.

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