JP2016103621A - Multilayer coil and method, inductor, transformer, wireless charger and relay - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a multilayer coil of a compact cubic volume, and a manufacturing method therefor, easy to adjust the magnitude of an indicative value and capable of saving a material without increasing an individual electrode pin.SOLUTION: The multilayer coil includes a first metal coil 110 and a second metal coil 120 which are respectively integrally molded. A first metal coil and a second metal coil are laminated with each other. An insulating film layer is provided on the air-core coil of the first metal coil and the second metal coil, to form a complete multilayer air-core coil. An electrode pin of the first metal coil is mutually disposed in deviation from an electrode pin of the second metal coil. The connection end of the first metal coil is electrically connected to the connection end of the second metal coil. An electrical connection point is covered with an insulating film layer.SELECTED DRAWING: Figure 17

Description

The present invention relates to a coil, and more particularly to a multilayer coil and a manufacturing method thereof. Furthermore, the present invention relates to inductors, transformers, wireless chargers and relays manufactured with multilayer coils.

A coil is generally used in an electronic device. For example, a primary winding coil and a secondary winding coil of a transformer, an induction coil of an inductor, a charging coil of a wireless charger, an AC / DC coil in an AC / DC electric machine, and the like. Among these, a transformer, an inductor, a wireless charger, an AC electric machine, and a DC electric machine are all electronic devices. These electronic devices are generally used by being soldered to a printed circuit board. Currently, a coil that is an existing technology is generally formed by winding an insulating metal wire, for example, a varnish wire or a cotton winding. The metal wire is generally formed by winding a metal wire having a circular cross-sectional area, and the metal wire may be an air core or may be solid. A coil formed by winding a metal wire having a circular cross-sectional area needs to be wound using a dedicated coil winder. The disadvantage is that the wound coil is regulated by a circular metal wire, so its inner diameter is relatively large, the volume is large, the required space soldered to the printed circuit board is large, This is not applicable to palm-type electronic devices such as tablet computers and palm-type identification number inspection devices, and is not applicable to printed circuit boards that require a small space occupancy rate. Furthermore, since the metal coil having a circular cross-sectional area is determined by the wire diameter, the cross-sectional area of the electrode pin of the metal coil becomes small. In order to increase the cross-sectional area of the electrode pin to meet the demands of soldering the printed circuit board, in general, a metal piece having a large cross-sectional area is soldered to the coil pin alone to form an electrode pin having a large cross-sectional area. In order to form an electrode pin having a large cross-sectional area, it is necessary to press the coil pin flatly. This complicates the coil manufacturing process. Moreover, when the metal coil of the said structure satisfy | fills the request | requirement of a different induction value parameter, generally it is necessary to replace | exchange the metal wire material from which a wire diameter differs. For this reason, it is difficult to adjust the magnitude of the coil induction value.

In order to solve the conventional technical problems, the present invention has a simple manufacturing process, a small volume, easy adjustment of the induction value, and can save material without increasing the number of electrode pins alone. An object is to provide a multilayer coil.

In order to solve the above technical problem, as a technical means, the present invention includes a first metal coil and a second metal coil manufactured by a flat metal piece, the first metal coil and the second metal coil. The metal coil is covered with an insulating film layer, and each of the first metal coil and the second metal coil includes an integrally formed electrode pin, an air core coil, and a connection end, and the electrode pin is the empty coil. Located outside the core coil, the connection end is located inside the air-core coil, or overlapped on the air-core coil, and the first metal coil and the second metal coil are mutually connected The laminated portion of the first metal coil and the air core coil of the second metal coil is formed as a complete multilayer air core coil, and the electrode pin of the first metal coil is the second metal coil. Metal coil electrode pins and phases The connection end of the first metal coil is electrically connected to the connection end of the second metal coil, and the electrical connection portion is covered with an insulating film layer. A multilayer metal coil that is a coil is provided.

Further, in the multilayer metal coil having the above structure, each of the first metal coil and the air core coil of the second metal coil has a single layer one turn or a single layer plural turns.

Furthermore, in the multilayer metal coil having the above structure, each of the air core coils of the first metal coil and the second metal coil is a single layer coil or a multilayer coil.

Further, in the multilayer metal coil having the above structure, each of the air-core coils of the first metal coil and the second metal coil has a multilayer one turn or a multilayer multiple turns.

Furthermore, in the multilayer metal coil having the above structure, the air core coils of the first metal coil and the second metal coil include a single coil connected to the electrode pin and a multi-coil connected to the single coil, The other end of the multi-coil is the connection end, and the single coil and the multi-coil are aligned to be folded as a multi-layer, multi-turn air-core coil.

Furthermore, in the multilayer metal coil having the above structure, a folding slit is provided at the folding position of the single coil and the multi-coil.

Further, in the multilayer metal coil having the above structure, the air core coils of the first metal coil and the second metal coil include a multi-coil formed by connecting a plurality of single coils, and one end of the multi-coil is the electrode. Connected to a pin, the other end of the multi-coil is the connection end, and the two adjacent single coils are aligned and folded as a multi-layer one-turn air-core coil.

Further, in the multilayer metal coil having the above structure, a folding slit is provided at a folding position between the two adjacent single coils and the single coil.

Furthermore, in the multilayer metal coil having the above-described structure, a multilayer closed air-core coil in which flat metal pieces distributed in a wave shape are aligned and folded is used for the multilayer one-turn air-core coil. . Furthermore, in the multilayer metal coil having the above structure, the shape of the air-core coil is any one of a circle, an ellipse, a rectangle, a triangle, a rhombus, and a polygon.

Furthermore, in the multilayer metal coil having the above-described structure, a bent hole is provided at a connection portion between the electrode pin and the air-core coil.

Furthermore, in the multilayer metal coil having the above structure, the insulating film layer is an insulating tape layer, a coating, a printed layer, or a powder electrostatic layer.

Further, in the multilayer metal coil having the above structure, the electrode pin of the first metal coil and the electrode pin of the second metal coil are provided on the same straight line, provided at a predetermined angle, or parallel to each other. Is provided.

Furthermore, in the multilayer metal coil having the above structure, electrical connection between the connection end of the first metal coil and the connection end of the second metal coil is performed by soldering or riveting.

Furthermore, in the multilayer metal coil having the above structure, the soldering is laser soldering.

Furthermore, in the multilayer metal coil having the above structure, the riveting is a riveting by a metal rivet.

Furthermore, in the multilayer metal coil having the above structure, the electrode pin is covered with an insulating film layer over the end face position of the electrode pin along the position connected to the air-core coil.

Compared with the prior art, the present invention is a multilayer metal coil in which a first metal coil and a second metal coil are laminated together and two connection ends are electrically connected. Since both the first metal coil and the second metal coil are insulated by the insulating film layer, the coil is insulated from the coil, and the two connection ends are electrically connected. In addition, since the insulating film layer is provided, the first metal coil and the second metal coil are insulated from each other. In the present invention, the first metal coil and the second metal coil manufactured using metal pieces are used to laminate and connect two metal coils, and the two metal coils have a sheet-like structure. Since the cross-sectional area is rectangular, there is an advantage that the volume is small. When compared with a metal wire having a circular cross-sectional area, when the volume is the same, the multi-layer metal coil according to the present invention can increase the induction value of the metal coil. If the induction values are the same, the volume can be further reduced, thus saving material. Furthermore, since the first metal coil and the second metal coil of the present invention are made of a flat metal piece, the thickness of the metal piece, the width of the formed coil, and the number of turns of the coil are determined by the wire diameter. It is possible to adjust arbitrarily without changing the different metal wires. Therefore, the magnitude of the induced value of the present invention can be adjusted more easily. Since the electrode pins of the multilayer metal coil according to the present invention are integrally formed in the air-core coil portion, it is possible to manufacture electrode pins having different widths, meet the requirements of the printed circuit board, and use the electrode pins alone. There is no need to increase it. Therefore, the manufacturing process of the multilayer metal coil according to the present invention is simple.

Furthermore, in order to solve the above technical problem, the present invention is a method of manufacturing a multilayer coil,
Step S1 of preparing a first metal coil and a second metal coil that are the same standard manufactured by a flat metal piece;
Step S2 for performing an insulation treatment with an insulating film layer on the first metal coil and the second metal coil;
The first metal coil and the second metal coil are laminated to each other, and a laminated portion of the first metal coil and the air core coil of the second metal coil is formed as a complete multilayer air core coil. Thus, the electrode pin of the first metal coil is shifted from the electrode pin of the second metal coil, the connection end of the first metal coil is in contact with the connection end of the second metal coil, That is, step S3 for butt or stack connection,
Step S4 for adjusting the distance, the sandwich angle, and the direction in which the two electrode pins are displaced from each other according to the requirements of the use environment;
The connection end of the first metal coil and the connection end of the second metal coil are electrically connected by solder soldering, laser soldering, or rivet formation using a metal rivet, and an insulating film is formed on the electrical connection portion. Step S5 in which the first metal coil and the second metal coil are connected as a multilayer coil by being subjected to the insulation treatment by the layers;
A method for manufacturing a multilayer coil is further provided.

Furthermore, in the manufacturing method of the multilayer metal coil having the above structure, a step of providing a first bent hole at a connection portion between the electrode pin of the first metal coil and the air-core coil, and the second metal The method further includes step S6 including a step of providing a second bending hole at a connection portion between the electrode pin of the coil and the air-core coil.

According to the method for manufacturing a multilayer metal coil according to the present invention, similarly, the manufacturing process is simple, the volume is small, the size of the induction value can be easily adjusted, and the material can be formed without increasing the number of electrode pins independently. Has a measurable advantage.

Furthermore, the present invention further provides an inductor including the multilayer metal coil having the above structure.

Furthermore, the present invention includes an iron core, at least one set of primary coils wound around the iron core, and at least one set of secondary coils, and both the primary coil and the secondary coil are multilayer coils having the above-described structure. There is further provided a transformer characterized in that.

Furthermore, the present invention further provides a wireless charger including a wireless charging coil which is a multilayer coil having the above structure.

Furthermore, the present invention further provides a relay including a relay coil which is a multilayer coil having the above structure.

Inductors, transformers, wireless chargers and relays according to the present invention all use multi-layered metal coils having the above-mentioned structure. Similarly, the manufacturing process is simple, the volume is small, and the magnitude of the induction value is adjusted. It has the advantage that the material can be saved without increasing the number of electrode pins alone.

It is a structure schematic diagram before the combination of Example 1 of this invention. It is a structure schematic diagram before the combination of Example 1 of this invention. It is a structure schematic diagram before the combination of Example 1 of this invention. It is the three-dimensional structure schematic diagram after the combination of Example 1 of this invention. It is a structure schematic diagram before the combination of Example 2 of this invention. It is a front structure schematic diagram after the combination of Example 2 of this invention. It is a side surface structure schematic diagram after the combination of Example 2 of this invention. It is a structure schematic diagram before the combination of Example 3 of this invention. It is a structure schematic diagram before the combination of Example 3 of this invention. It is a structure schematic diagram before the combination of Example 3 of this invention. It is the structure schematic after the combination of Example 3 of this invention. It is a structure schematic diagram before the combination of Example 4 of this invention. It is a structure schematic diagram before the combination of Example 4 of this invention. It is a structure schematic diagram before the combination of Example 4 of this invention. It is a front structure schematic diagram after the combination of Example 4 of this invention. It is a side surface structure schematic diagram after the combination of Example 4 of this invention. It is a three-dimensional structure schematic diagram after the combination of Example 4 of the present invention. It is the structure schematic before the combination of Example 5 of this invention. It is a structure schematic diagram of the metal coil after the combination of Example 5 of this invention. It is a front structure schematic diagram of the multilayer metal coil after the combination of Example 5 of this invention.

The present invention will be described in detail with reference to the drawings.
Example 1

As shown in FIGS. 1-4, the metal coil 100 which is the multilayer coil 100 which concerns on a present Example contains the 1st metal coil 110 and the 2nd metal coil 120 which were manufactured by the flat metal piece, The said 1st Each of the first metal coil 110 and the second metal coil 120 includes an integrally formed electrode pin, an air-core coil, and a connection end. As shown in FIG. 3, the first metal coil 110 includes the first electrode. It consists of a pin 111, a first air-core coil 112, and a first connection end 113. The second metal coil 120 includes a second electrode pin 121, a second air-core coil 122, and a second The first air core coil 112 of the first metal coil 110 is covered with an insulating film layer 114, and the second air core coil 122 of the second metal coil 120 is covered with the second air core coil 122. Is covered with an insulating film layer 124. That. Preferably, the electrode pin is covered with an insulating film layer over the end face position of the electrode pin along a position connected to the air-core coil. In other words, the electrode pin may be entirely covered with the insulating film layer, or may be partially covered with the insulating film layer. That is, a part or the whole of the first electrode pin 111 is covered with the insulating film layer 114, and a part or the whole of the second electrode pin 121 is covered with the insulating film layer 124. The electrode pin is located outside the air-core coil, the connection end is located inside the air-core coil, and the first metal coil 110 and the second metal coil 120 are laminated with each other, The laminated portion of the first air core coil 112 and the second air core coil 122 is formed as a complete multilayer air core coil. The first electrode pin 111 is shifted from the second electrode pin 121, the first connection end 113 is electrically connected to the second connection end 123, and the electrical connection portion is insulated. The membrane layer is covered. The insulating film layer may be an insulating tape layer, a coating, a printing layer, or a powder electrostatic layer. This is for realizing insulation between the coils of the formed multilayer metal coil and between the layers and preventing leakage current. Here, for the electrical connection, solder soldering, laser soldering, or riveting using a metal rivet is used. This is to electrically connect the first metal coil 110 and the second metal coil 120 as a complete multilayer metal coil. Laser soldering is non-contact soldering, thermal deformation of the first metal coil and the second metal coil to be soldered is small, solder spot is small, solder groove is narrow, condensing spot is small, and positioning is highly accurate. Has a possible effect.

The present invention is a multilayer metal coil in which a first metal coil 110 and a second metal coil 120 are laminated with each other and two connection ends are electrically connected. Since both the first air-core coil 112 of the first metal coil 110 and the second air-core coil 122 of the second metal coil 120 are subjected to insulation treatment by the insulating film layer, the coil and the coil Is a multi-layer metal in which the first metal coil 110 and the second metal coil 120 are laminated to each other because an insulating film layer is provided at the electrical connection location of the two connection ends. There is also insulation between the layers of the coil. In the present invention, the first metal coil 110 and the second metal coil 120 manufactured from metal pieces are used, two metal coils are stacked and connected, and the two metal coils have a sheet-like structure. Since the cross-sectional area is rectangular, there is an advantage that the volume is small. When compared with a metal wire having a circular cross-sectional area, when the volume is the same, the multi-layer metal coil according to the present invention can increase the induction value of the metal coil. If the induction values are the same, the volume can be further reduced, thus saving material. Furthermore, since the first metal coil 110 and the second metal coil 120 of the present invention are made of a flat metal piece, the thickness of the metal piece, the width of the formed coil, and the number of turns or turns of the coil. The number can be arbitrarily adjusted without replacing metal wires having different wire diameters. Therefore, the magnitude of the induced value of the present invention can be adjusted more easily, and the manufacturing process is further simplified. Since the electrode pins of the multilayer metal coil according to the present invention are integrally formed in the air-core coil portion, it is possible to manufacture electrode pins having different widths, meet the requirements of the printed circuit board, and use the electrode pins alone. There is no need to increase it. Therefore, the manufacturing process of the multilayer metal coil according to the present invention is simple.

As shown in FIGS. 1-3, the number of layers of the first metal coil 110 and the second metal coil 120 is a single layer, the number of turns is 1.5, and 0.5 in 1.5 turns. The turn means that it is equal to or larger than or smaller than 1/2 turn. As shown in FIG. 4, after the first metal coil 110 and the second metal coil 120 are electrically connected, a multilayer metal coil having two layers and two turns is formed. It should be noted that the number of turns of the first metal coil 110 and the second metal coil 120 may be formed as a single turn, that is, one turn, and is limited to the above specific implementation method. It is not a thing. In other words, each of the first metal coil 110 and the second metal coil 120 has a single-layer one turn, and after being electrically connected, a two-layer one-turn multilayer metal coil is formed. The first and second metal coils are manufactured by pressing, chemical etching, laser cutting, electric discharge machining, slow wire cutting, or other effective processing methods. Since the multilayer metal coil according to the present embodiment is electrically connected after the first metal coil 110 and the second metal coil 120 are directly laminated, there is no need to fold and therefore no leakage occurs. As a result, the electrical characteristics become more stable.

As a preferred implementation method, the first metal coil 110 and the second metal coil 120 in this embodiment are manufactured in the same standard because the size of the induction value of the formed multilayer metal coil can be easily adjusted. Is done. Here, the same standard means that the shape of the air-core coil is the same, the number of turns of the air-core coil is the same, the width of the air-core coil is the same, and the thickness of the air-core coil is the same. The width refers to the line width of the coil. Further, the same thickness means that the first metal coil 110 and the second metal coil 120 are manufactured from metal pieces having the same thickness. In order to meet the requirements of the use environment of the printed circuit board, the shape of the first air core coil 112 and the second air core coil 122 is a polygonal shape such as a circle, an ellipse, a rectangle, a triangle, a rhombus, and a pentagon. Either.

As a preferred implementation method, the first electrode pin 111 of the first metal coil 110 and the second electrode pin 121 of the second metal coil 120 in this implementation method are provided on the same straight line, or 0. It may be provided at an angle of ˜180 degrees, for example, 15 degrees, 30 degrees, 45 degrees, 90 degrees, 180 degrees, or in parallel. Therefore, the degree of freedom in manufacturing the two electrode pins according to this implementation method is extremely high, and the positional relationship and angle between the two electrode pins can be appropriately adjusted according to the requirements of the usage environment of the printed circuit board.

(Example 2)
As shown in FIGS. 5 to 7, the second embodiment is an improvement based on the first embodiment. The difference from the first embodiment is that in the second embodiment, the first bent hole 115 is connected to the first electrode pin 111 and the first air-core coil 112, and the second electrode pin 121 and the second electrode pin 121 are connected to each other. The second bending hole 125 is provided at each connection point with the two air-core coils 122. The bending hole in the second embodiment may be an elliptical hole, a circular hole or a rectangular hole, or a polygonal hole such as a triangular hole. Since the bending hole excludes the area of the connection portion between the electrode pin and the air-core coil in the first and second metal coils, the hardness of the connection portion between the electrode pin and the air-core coil is reduced. Therefore, when the electrode pin is bent, the bending angle of the electrode pin can be easily bent only by applying a small force, and the sandwiching angle and the positional relationship between the two electrode pins can be adjusted. .

As shown in FIGS. 5 to 7, after the first metal coil 110 and the second metal coil 120 in Example 2 are electrically connected, a multilayer metal coil having two layers and two turns is formed.

(Example 3)
As shown in FIGS. 8 to 11, the third embodiment is an improvement based on the second embodiment. The difference from the second embodiment is that, in the third embodiment, the first metal coil 110 and the second metal coil 120 are each a three-turn single layer formed integrally. However, it is not limited to 3 turns, and can be formed to 2 turns, 5 turns, 10 turns, etc. according to actual needs. For example, the first metal coil 110 and the second metal coil 120 are formed as a multilayer metal coil having two layers and three turns. The first metal coil 110 and the second metal coil 120 can be formed by pressing, chemical etching, laser cutting, electric discharge machining, slow wire cutting, or other effective processing methods. In Example 3, the area of the air-core coil portion was expanded or reduced by increasing the number of air-core coils that are multi-turns or decreasing the number of turns of the air-core coil portion, and the magnitude of the coil induction value was satisfied. In some cases, it is advantageous to produce a multilayer metal coil with a smaller volume.

Example 4
As shown in FIGS. 12 to 17, the fourth embodiment is an improvement based on the third embodiment. The difference from the third embodiment is that in the fourth embodiment, the air core coil of the first metal coil 110 and the air core coil of the second metal coil 120 are both multi-turn multilayers. As shown in FIGS. 12, 13, and 14, the multi-turn of the air-core coil includes a single coil connected to the electrode pin and a multi-coil connected to the single coil, and the number of turns of the multi-coil is 3 turns. And the connecting end is one end of a multi-coil. 12-16, after the single coil and the three-turn multi-coil are aligned, when the single coil is superimposed on the outer turns of the multi-coil, the folded first metal coil 110 and Each of the second metal coils 120 has two layers, one of which is a single coil and the other one is a multi-coil. After being electrically connected, a four-layer, three-turn multilayer metal coil is formed. Among them, the upper and lower two layers are single coils, and the middle two layers are multi-coils. The number of layers and the number of turns in Example 4 are not limited to the four layers and the three turns in this specific implementation method, and the number of layers and the number of turns can be formed according to the requirements of the actual use environment. In the fourth embodiment, when the area of the air-core coil portion is expanded or reduced by increasing or decreasing the number of turns of the multi-coil in the air-core coil, and the size of the coil induction value is satisfied, the multilayer metal having a smaller volume is used. In addition to the advantage of manufacturing the coil, the air-core coil has an advantage in that the manufacturing material can be saved because the single coil and the multi-coil are integrally formed.

As shown in FIGS. 13 and 14, as a preferred implementation method, a folding slit is provided at the folding position of the single coil and the multi-coil. That is, as shown in the elliptical broken line frame of FIG. The first metal coil 110 is provided with a first folding slit 116, and the second metal coil 120 is provided with a second folding slit 126. The folding slit may be arc-shaped, rectangular, semicircular, or elliptical as long as it is easy and convenient to align and fold the single coil and the multi-coil. Among these, arc-shaped, elliptical, or semicircular folding slits have electrical characteristics that allow current to flow easily.

(Example 5)
As shown in FIGS. 18 to 20, the fifth embodiment is an improvement based on the fourth embodiment. The difference from the fourth embodiment is that, in the fifth embodiment, the air-core coils of the first metal coil 110 and the second metal coil 120 include a multi-coil formed by connecting a plurality of single coils, and the multi-coil. One end of the multi-coil is connected to the electrode pin, the other end of the multi-coil is the connection end, and the two adjacent single coils are aligned and folded as a multi-layer one-turn air-core coil. After the core coil portion is folded, it is completely overlapped, and the first connection end 113 and the second connection end 123 are respectively overlapped on the air core coil.

As a preferable implementation method, a folding slit is provided at a folding position between the two adjacent single coils and the single coil. The folding slit may be arc-shaped, rectangular, semicircular, or elliptical as long as it is easy and convenient to align and fold the single coil and the multi-coil. Among these, arc-shaped, elliptical, or semicircular folding slits have electrical characteristics that allow current to flow easily.

As a preferred implementation method, the first metal coil 110 and the second metal coil 120 in the fifth embodiment are two single coils, and are formed in two layers and one turn after being folded. After the second metal coil 120 is electrically connected, a four-layer, one-turn multilayer metal coil is formed. After the layers of the multilayer air-core coil in Example 5 are laminated, they are completely overlapped and are not exposed to the inside or outside of the air-core coil. The multilayer metal coil having such a structure is applied to manufacture of an inductor, a transformer, and a relay, and is particularly applied to manufacture of an inductor having a core body such as a package housing or a carbon rod.

As a preferred implementation method, in the fifth embodiment, the number of coil turns of the air-core coil of the first metal coil 110 and the number of coil turns of the air-core coil of the second metal coil 120 are adjusted for the magnitude of the induction value. Can be the same or different.

(Example 6)
The sixth embodiment is an improvement based on the third embodiment. The difference from the third embodiment is that in this sixth embodiment, the multi-layer air core coils of the first metal coil 110 and the second metal coil 120 are aligned with the flat metal pieces distributed in a wave shape and folded. The formed multi-layer closed air-core coil is used. The wave shape is any one of a sine wave, a square wave, and a triangular wave. The multilayer closed air-core coil has a circular, elliptical, rectangular, triangular, rhombus, or polygonal shape. When the multi-layer metal coil having such a structure is compared with a metal wire having a circular cross-sectional area, when the volume is the same, the multi-layer metal coil according to the present invention increases the induction value of the multi-layer metal coil, If the induction values are the same, the volume is smaller and material savings are possible.

(Example 7)
Example 7 is a method for manufacturing a multilayer metal coil described in Examples 1 to 6,
Step S1 of preparing the first metal coil 110 and the second metal coil 120 which are the same standard manufactured by a flat metal piece,
Step S2 for performing an insulation process on the first metal coil 110 and the second metal coil 120 with an insulating film layer;
The first metal coil 110 and the second metal coil 120 are laminated with each other, and the laminated portion of the first metal coil 110 and the air core coil of the second metal coil 120 is a complete multilayer air core. By being formed as a coil, the electrode pin of the first metal coil 110 is shifted from the electrode pin of the second metal coil 120, and the connection end of the first metal coil 110 is the second metal coil. Step S3 in contact with the connection end of 120;
Step S4 for adjusting the distance, the sandwich angle, and the direction in which the two electrode pins are displaced from each other according to the requirements of the use environment;
The connection end of the first metal coil 110 and the connection end of the second metal coil 120 are electrically connected by soldering or metal rivet attachment, and an insulating process using an insulating film layer is performed on the electrical connection portion. Step S5 in which the first metal coil 110 and the second metal coil 120 are connected as a multilayer coil by being applied,
including.

As a preferred implementation method, the multilayer metal coil manufacturing method of this embodiment is configured such that the first bent hole is formed at the connection point between the first electrode pin 111 and the first air-core coil 112 of the first metal coil 110. 115, a step in which a second bent hole 125 is provided in a connection portion between the second electrode pin 121 of the second metal coil 120 and the second air core coil 122, and Step S6 having the following is further included.

According to the multilayer metal coil manufacturing method according to the seventh embodiment, since the multilayer metal coils according to the first to sixth embodiments are used, similarly, the manufacturing process is simple, the volume is small, and the induction value is large. The thickness can be easily adjusted, and the material can be saved without increasing the number of electrode pins alone.

(Example 8)
The eighth embodiment provides an inductor in which the multilayer metal coil according to any one of the first to sixth embodiments is used. The two electrode pins of the multilayer metal coil are provided with a tin layer, a gold plating layer or a silver plating layer. The housing further includes a multilayer air-core coil of the multilayer metal coil, and at least a part of the electrode pin is exposed to the outside of the housing.

Example 9
The ninth embodiment includes an iron core, at least one set of primary coils wound around the iron core, and at least one set of secondary coils. Both the primary coil and the secondary coil are the first to sixth embodiments. A transformer comprising the multilayer coil according to any one of the above.

(Example 10)
The tenth embodiment provides a wireless charger including the wireless charging coil that is the multilayer coil described in any of the first to sixth embodiments.

(Example 11)
The eleventh embodiment provides a relay including the relay coil that is the multilayer coil according to any one of the first to sixth embodiments.

Inductors, transformers, wireless chargers, and relays according to the present invention use the multilayer metal coil having the above-described structure. Similarly, the manufacturing process is simple, the volume is small, and the size of the induction value can be adjusted. It is easy and has the effect that the material can be saved without increasing the number of electrode pins alone.

The present invention is not limited to the above embodiment, and any changes made based on the specification and drawings of the present invention are intended to be included in the scope of the claims of the present invention.

100 multilayer metal coil 110 first metal coil 111 first electrode pin 112 first air core coil 113 first connection end 114 first insulating film layer 115 first folding hole 116 first folding slit 120 first 2nd metal coil 121 2nd electrode pin 122 2nd air-core coil 123 2nd connection end 124 2nd insulating film layer 125 2nd bending hole 126 2nd folding slit

Claims (22)

A first metal coil and a second metal coil manufactured by a flat metal piece, both of the first metal coil and the second metal coil are integrally formed, an electrode pin, an air core coil, and a connection end The air core coil is covered with an insulating film layer, the electrode pin is located outside the air core coil, and the connection end is located inside the air core coil, or Overlaid on the core coil, the first metal coil and the second metal coil are laminated to each other, and the laminated portion of the first metal coil and the air core coil of the second metal coil is: It is formed as a complete multilayer air-core coil, the electrode pins of the first metal coil are offset from the electrode pins of the second metal coil, and the connection end of the first metal coil is the end of the second metal coil Electrical connection with connection end It is, wherein the electrical connection points multilayer coil, wherein an insulating film layer is coated. The air core coils of the first metal coil and the second metal coil are both single-layer one turn or single-layer multiple turns.
The multilayer coil according to claim 1. The air core coils of the first metal coil and the second metal coil are both multi-layer one turn or multi-layer multiple turns.
The multilayer coil according to claim 1. The air core coils of the first metal coil and the second metal coil include a single coil connected to an electrode pin and a multi-coil connected to the single coil, and the other end of the multi-coil is the connection end. Yes, the single coil and the multi-coil are aligned and folded as a multi-layer multi-turn air-core coil,
The multilayer coil according to claim 3. A folding slit is provided at the folding position of the single coil and the multi-coil,
The multilayer coil according to claim 4. The air-core coils of the first metal coil and the second metal coil include a multi-coil formed by connecting a plurality of single coils, and one end of the multi-coil is connected to the electrode pin, The end is the connection end, and the two adjacent single coils are aligned and folded as a multi-layer one-turn air-core coil.
The multilayer coil according to claim 3. Folding slits are provided at the folding points of the two adjacent single coils and single coils.
The multilayer coil according to claim 6. The multilayer one-turn air-core coil uses a multilayer closed air-core coil formed by aligning and folding flat metal pieces distributed in a wave shape.
The multilayer coil according to claim 3. The shape of the air-core coil is any one of a circle, an ellipse, a rectangle, a triangle, and a rhombus.
The multilayer coil according to claim 1. A bending hole is provided at a connection portion between the electrode pin and the air-core coil,
The multilayer coil according to claim 1. The insulating film layer is an insulating tape layer, coating, printing layer or powder electrostatic layer,
The multilayer coil according to claim 1. The electrode pin of the first metal coil and the electrode pin of the second metal coil are provided on the same straight line, provided at a predetermined angle, or provided in parallel.
The multilayer coil according to claim 1. The electrical connection between the connection end of the first metal coil and the connection end of the second metal coil is performed by soldering or riveting.
The multilayer coil according to claim 1. The soldering is laser soldering,
The multilayer coil according to claim 13. The riveting is a riveting with a metal rivet.
The multilayer coil according to claim 13. The electrode pin is covered with an insulating film layer over an end surface position of the electrode pin along a position connected to the air-core coil.
The multilayer coil according to claim 1. A method for producing a multilayer coil according to claim 1,
Step S1 of preparing a first metal coil and a second metal coil that are the same standard manufactured by a flat metal piece;
Step S2 for performing an insulation treatment with an insulating film layer on the first metal coil and the second metal coil;
The first metal coil and the second metal coil are laminated to each other, and a laminated portion of the first metal coil and the air core coil of the second metal coil is formed as a complete multilayer air core coil. Thus, the electrode pin of the first metal coil is shifted from the electrode pin of the second metal coil, and the connection end of the first metal coil is contact-connected to the connection end of the second metal coil. Step S3,
Step S4 for adjusting the distance, the sandwich angle, and the direction in which the two electrode pins are displaced from each other according to the requirements of the use environment;
The connection end of the first metal coil and the connection end of the second metal coil are electrically connected by solder soldering, laser soldering, or rivet formation using a metal rivet, and an insulating film is formed on the electrical connection portion. Step S5 in which the first metal coil and the second metal coil are connected as a multilayer coil by being subjected to the insulation treatment by the layers;
The manufacturing method of the multilayer coil characterized by the above-mentioned. A step of providing a first bending hole at a connection portion between the electrode pin of the first metal coil and the air-core coil; and a connection portion between the electrode pin of the second metal coil and the air-core coil. Further includes step S6 having a process in which a second folding hole is provided,
The method of manufacturing a multilayer coil according to claim 17. The multilayer coil according to any one of claims 1 to 16, comprising:
An inductor characterized by that. The iron core, at least one set of primary coils wound around the iron core, and at least one set of secondary coils, wherein the primary coil and the secondary coil are both in any one of claims 1 to 16. A multilayer coil as described,
A transformer characterized by that. A wireless charging coil which is the multilayer coil according to any one of claims 1 to 16,
A wireless charger characterized by that. A relay coil that is the multilayer coil according to any one of claims 1 to 16,
A relay characterized by that.

Images