JP2018190934A - Coil component and coil device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress a clearance between coil elements into a short distance, to block considerable deterioration of magnetic characteristics and to secure a valley where a long screw for leg fitting passes, before and after two coil elements.SOLUTION: A coil component comprises a first coil element 711 and a second coil element 712 that are formed in parallel in a square cylinder shape by using one flat wire 701, winding and laminating a coil in one direction in an edge-wise winding manner between one end 701A and another end 701B that become connection terminals, and bending the flat wire at a predetermined position of the wound and laminated coil. The coil component also comprises a coupling part 713 for coupling both the coil elements 711 and 712. In the coupling part 713, a curvature radius of an inter-element flat-wise bent portion 723D is adjusted thereby securing a space where a long screw 762A for fastening both legs 761A and 761B pass in an upper valley between the coil elements 711 and 712.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a coil component used for various motors for inverter circuits, automobiles, and the like, and more specifically to this coil device, and more specifically, two rectangular tube shapes that are formed by a single rectangular wire and are arranged close to each other. The present invention relates to a coil component composed of laminated coils and a coil device using the same.

A coil component such as a reactor can generate inductance by adopting a configuration in which a winding coil is wound around a magnetic core.
Various types of reactors are known depending on the purpose of use, from large capacity for power transmission systems to communication device parts. Such a reactor is generally housed in a case made of metal or the like with the legs attached.

  By the way, in a reactor or the like used for an in-vehicle booster circuit, a configuration in which two laminated coil elements are formed in parallel so as to have a high inductance value when a high current is passed is known. ing.

As a conventional example of such a reactor, one in which two coil elements arranged in parallel are formed by edgewise winding of a single rectangular wire is known (for example, see Patent Documents 1 to 3 below). ).
In Patent Document 1, a first coil element and a second coil element, which are wound while forming a rectangular wire into a circular shape by edgewise winding, are formed in parallel. The rectangular wire passed between these two coil elements is twisted 180 degrees between these two coil elements and passed from one to the other.

  In Patent Documents 2 and 3, a rectangular wire is wound as a whole at a position where the magnetic cores constituting the closed loop face each other, with a rectangular wire bent into a bent portion by edgewise winding. The coil element and the second coil element are formed in parallel. Further, in the connecting portion of these two coil elements, a flat wire enters from one coil element between the opposing side surfaces of the two coil elements, and the other It is formed to be passed to the coil element.

Japanese Patent No. 3398855 Japanese Patent No. 5482432 Japanese Patent No. 5408030

  In the technique described in Patent Document 1 described above, a twisted rectangular wire enters the gap between the two coil elements, and the distance between the two coil elements increases, making it difficult to make the coil device compact.

  For example, if the gap between the two coil elements is increased even by several millimeters, the magnetic characteristics are greatly deteriorated. Therefore, it is desirable to have a configuration in which such a twist of the rectangular wire does not occur.

On the other hand, in the techniques described in Patent Documents 2 and 3, the following problems are pointed out.
That is, with respect to the first coil element and the second coil element formed in parallel, the legs of the pair of U-shaped cores are inserted into the hollow portions of the respective coil elements from the front and rear in the axial direction of the coil elements, and the tips are brought into contact with each other. A coil device main body is formed. Generally, the main body legs are attached to the coil device main body before and after the axial direction of the coil element, and the coil device main body is fixed away from the mounting surface of the substrate or the housing. It is supposed to be configured. In this case, although several methods can be taken to fix the pair of legs to the coil device main body, in order to have a simple configuration, the main body legs provided before and after the coil element axial direction are It is often desirable to use a long screw extending from the front side to the rear side on at least one side of the upper part and the lower part of the coil element and to connect the coil device main body so as to sandwich the coil device body.

  However, in the techniques described in Patent Documents 2 and 3, since a connecting portion of a rectangular wire is inserted between both coil elements, and the long screw is arranged avoiding this connecting portion, the coil device There was a problem that the whole was enlarged.

  The present invention has been made in view of such circumstances. The gap between the coil elements can be set to a small distance to prevent a significant deterioration in magnetic characteristics, and the two coil elements are wound around the core. Provided are a coil component and a coil device capable of ensuring a gap through which a long screw passes between two coil elements when assembled so that legs are attached to the front and rear of a coil device body that is rotated. It is intended to do.

In order to solve the above problems, a coil component and a coil device according to the present invention have the following features.
The coil component according to the present invention is
A coil winding body formed by laminating a single rectangular wire into a rectangular shape having corners R by edgewise winding is divided into two at a predetermined position and folded, and the opposing side surfaces are A first coil element and a second coil element arranged so as to be parallel to each other, and a connecting portion that connects both the coil elements;
The connecting portion includes an inter-element connecting portion disposed between the opposing side surfaces, the inter-element connecting portion, a winding end portion of the first coil element, and a winding start portion of the second coil element. A loop coupling portion that is formed along a side surface that is interposed between at least one of the coil element side and that is adjacent to the opposing side surface of the corresponding coil element side,
The inter-element connecting portion does not have a twisted shape of a flat wire, and the flat wire is formed at the winding end side end of the first coil element and the winding start side end of the second coil element. A flatwise bent portion between the first and second elements bent by flatwise bending, and an intermediate portion extending between the flatwise bent portions between these two elements,
The loop connecting portion is extended by extending from an inter-element flatwise bent portion of the inter-element connecting portion, a loop portion bent by edgewise winding, an edgewise winding portion, and bent by flatwise bending. A loop portion flatwise bent portion connected to at least one of the flat wire on the winding end side of the first coil element and the flat wire on the winding start side of the second coil element, from the inter-element connecting portion side They are provided in this order.

  Moreover, it is preferable that the said intermediate part has the edgewise winding part between the elements bent by edgewise winding.

Moreover, it is preferable that the said intermediate part is arrange | positioned in parallel between these opposing side surfaces between the opposing side surfaces between the said two coil elements.
Further, the intermediate portion has a flat width between the second elements located on the winding start side of the second coil element from a flat width bending portion between the first elements located on the winding end side of the first coil element. It is also possible to incline so that it may approach the said 2nd coil element as it goes to a bending part.
In addition, a radius of curvature of at least one of the flatwise bent portions between the first and second elements, in which the flat wire is bent by flatwise bending, is a side corner portion of the coil element along the flatwise bent portion. It is preferable that it be formed to have a radius of curvature equal to or greater than.

The coil device of the present invention includes any one of the above-described coil components, and a magnetic core portion that forms a closed magnetic path by inserting legs into the hollow portions of the coil components. Is.
In this case, it is also possible to provide device legs that hold a coil device body in which the coil component and the magnetic core portion are combined in a predetermined position.

Here, the above-mentioned “edgewise winding” or “edgewise winding” means that a short side, which is one side edge of a rectangular wire, is wound vertically and laminated in a plate shape. To do.
Further, the above-mentioned “flatwise bending” refers to bending a flat wire in the long side direction, with one surface on the long side in the rectangular cross section of the flat wire as the inner surface and the other surface as the outer surface. Shall.

In the coil component according to the present invention, the connecting portion that connects the first coil element and the second coil element, the inter-element connecting portion that fits into the gap between the two coil elements, the inter-element connecting portion, and Along the side surface that is interposed between at least one of the winding end portion of the first coil element and the winding start portion of the second coil element and is adjacent to one of the opposing side surfaces of the two coil elements It is set as the structure provided with the loop connection part formed sequentially.
That is, according to the coil component of the present invention, since the inter-element connecting portion that fits into the gap between the two coil elements does not have a twisted shape, as described in Patent Document 1, two coils are used. It can be avoided that the torsion-shaped portion of the connecting portion is fitted between the elements, and the interval between the two coil elements is increased, so that the core can be miniaturized and the deterioration of the magnetic characteristics can be avoided. be able to.
In addition, unlike Patent Document 1, there is no portion where the flat wire is twisted or bent over 180 degrees, so that problems such as peeling of the electric wire film do not occur.
Also, if the end faces of the two coil elements folded back by the connecting portion are faced, the edgewise winding manufacturing process can be performed by bending and winding the rectangular wire in the same direction. Man-hours can be reduced and the winding machine mechanism can be simplified.

Furthermore, according to the coil component and the coil device of the embodiment of the present invention, the transition between the inter-element connection portion and the loop connection portion is performed by flat-wise bending, and the curvature radius of the flat-wise bending portion is adjusted. Is easy. Therefore, by adjusting this radius of curvature and forming the rectangular wire along the R shape of the corners of the coil elements, a space for passing the long screws through the valleys where the corners between the coil elements face each other is secured. Therefore, even when both legs attached to the coil device main body are simply fastened using such long screws, it is possible to easily prevent the coil parts and the coil device from becoming large.

It is a perspective view of the coil component which concerns on the 1st Embodiment of this invention. It is a perspective view which shows the state which combined the coil component and core which concern on embodiment of FIG. 1 of this invention. It is a perspective view which shows the structure which attached the leg part to the coil apparatus main body formed by combining the coil component and core which concern on the 1st Embodiment of this invention. FIG. 4 is a plan view when the structure shown in FIG. 3 is viewed from above. It is a perspective view which shows the state which attached the leg part to the coil apparatus main body by the simple structure different from the structure shown in FIG. It is a perspective view of the coil component which concerns on the 2nd Embodiment of this invention. It is a perspective view of the coil component which concerns on the 3rd Embodiment of this invention. It is a perspective view of the coil components which concern on the 4th Embodiment of this invention. It is a perspective view of the coil components which concern on the 5th Embodiment of this invention. It is a perspective view of the coil components which concern on the 6th Embodiment of this invention.

  Hereinafter, coil parts according to embodiments of the present invention will be described with reference to the drawings. The coil component of this embodiment is applied to a reactor, for example.

A reactor is used, for example, as an electric circuit element of various devices mounted on an automobile, and includes a magnetic core and a reactor coil wound around the core. Usually, a reactor core is inserted into the reactor coil. Leg portions are attached to the reactor main body, and the reactor main body can be accommodated in the case while ensuring insulation between the reactor main body and the case.
<First Embodiment>

As shown in FIG. 1, the coil component 100 according to the present embodiment uses a single rectangular wire 101 and is wound in one direction by edgewise winding between one end 101 </ b> A and the other end 101 </ b> B serving as connection terminals. The first coil element 111 and the second coil element 112, which are formed in parallel in a rectangular tube shape, are formed by bending and folding into two at a predetermined position (usually approximately an intermediate position) of the laminated coils. In addition to being provided, a connecting portion 113 that connects both coil elements 111 and 112 is provided.
It winds so that the margin of the flat wire 101 for using for the connection part 113 may arise in the said predetermined position of this coil wound and laminated | stacked.
The flat wire 101 has a rectangular cross section, and for example, an insulating coating is applied to the surface of a copper wire.

The first coil element 111 and the second coil element 112 are arranged in parallel so that one side face 111D, 112D facing each other is parallel to each other and spaced along a predetermined dimension D.
The connecting portion 113 includes an inter-element connecting portion 113A disposed between the opposing side surfaces between the two coil elements 111 and 112, and an inter-element connecting portion 113A and a winding start portion 112C of the second coil element 112. And a loop coupling portion 113B formed along the side surface 112A (the upper surface in the present embodiment) of the coil element 112.

  The inter-element coupling portion 113A includes a first inter-element flatwise bent portion 123A in which the flat wire 101 is bent by flat-wise bending on the winding end side of the first coil element 111, and a winding of the second coil element 112. On the start side, the flat wire 101 is provided with a second inter-element flat-wise bent portion 123D that is bent by flat-wise bending, and an intermediate portion 123C that extends between these two inter-element flat-wise bent portions 123A and 123D. . An inter-element edgewise winding portion 123B bent by edgewise winding is disposed between the first inter-element flatwise bending portion 123A and the intermediate portion 123C. Thereby, the inter-element connecting portion 113A drawn in the horizontal direction is shaped to rise in the vertical direction.

  The loop connection portion 113B includes an extension portion 123E extending from the second inter-element flatwise bending portion 123D of the inter-element connection portion 113A, a loop portion edgewise winding portion 123F bent by edgewise winding, and a flatwise width. A loop portion flatwise bent portion 123G that is bent by bending and connected to the rectangular wire 112C at the winding start portion of the second coil element is provided.

  According to the coil component according to the present embodiment, the inter-element connecting portion 113A and the loop connecting portion 113B that connect the two coil elements 111 and 112 are bent by approximately 90 degrees by flatwise bending and by edgewise winding. The flat wire 101 is not twisted and is connected in a flat state so as to be disposed between the coil elements 111 and 112 using a bending of approximately 90 degrees. It can be avoided that the torsion-shaped portion of the connecting portion 113 fits between the two coil elements 111 and 112 to increase the distance between the two coil elements. Thereby, the enlargement of a core can be prevented and the deterioration of a magnetic characteristic can be avoided.

In particular, since the intermediate portion 123C of the inter-element coupling portion 113A is positioned so as to stand in parallel with the two opposing side surfaces 111D and 112D of the two coil elements 111 and 112, the two coil elements 111 and 112 The interval D can be set to a small distance.
Further, unlike the prior art, there is no portion where the flat wire is twisted or bent at an angle greater than 90 degrees, so that problems such as peeling of the electric wire film are unlikely to occur.
Further, if manufacturing is performed so that the end surfaces of the two coil elements folded back at the position of the connecting portion 113 face each other, an edgewise winding manufacturing process is formed by winding a rectangular wire in the same direction. Therefore, man-hours can be reduced and the mechanism of the winding machine can be simplified.

For the coil component 100 shown in FIG. 1, as shown in FIG. 2, the left and right legs of the pair of U-shaped cores 151 and 152 are inserted into the hollow portions 111F and 112F of the two coil elements 111 and 112, The reactor main body is configured by abutting each other inside the hollow portion.

3 and 4 are attached to the combination of the coil component 100 and the pair of cores 151 and 152 (reactor body) shown in FIG. 2 with a pair of legs 161A and 161B.
A coil device is shown in which the coil component 100 is disposed at a position where the coil component 100 is lifted upward with respect to the attachment portions 161C and 161D of the leg portions 161A and 161B to the housing or the like.
The legs 161A and 161B are screwed by screwing screws (not shown) into the housing or the like through the screw holes 161E, 161F, 161G, and 161H.
A pair of legs 161A and 161B is a metal band 1 that tightens around the cores 151 and 152.
62 and the cores 151 and 152 are sandwiched and fixed. The metal band 162 is formed in a loop shape with a part cut along the periphery of the cores 151 and 152. Cylindrical fasteners 163A and 163B are provided at end portions of the loop. In addition, screw holes 165A and through-holes 165B are provided in a direction orthogonal to the axes of the fasteners 163A and 163B. Between the peripheral surfaces of the cores 151 and 152 and the metal band 162 along the peripheral surface The metal band 162 is tightened by inserting screws 164 into the screw holes 165A and through-holes 165B of the fasteners 163A and 163B while sandwiching the back plates of the pair of legs 161A and 161B.

Thereby, both leg parts 161A and 161B are fixed to the peripheral surfaces of the cores 151 and 152, and the vertical position of the reactor body is a mounting plate 161C for attaching both leg parts 161A and 161B.
, 161D can be placed upward by a predetermined distance from the mounting position of the housing or the like to maintain insulation.
In addition, the screw 164 is inserted from the outside in the vicinity of both ends of the metal band 162, and is sequentially inserted into the inner fastener 163B and the fastener 163A, and the screw 164 is tightened so that the periphery of the cores 151 and 152 of the metal band 162 The tightening to the surface becomes strong, and the holding force of both leg portions 161A and 161B increases.

  In the inter-element coupling portion 113A, the two coil elements 111 are interposed via a first inter-element flatwise bent portion 123A that is bent by a flat-wise bend from a winding end portion (indicated by 111E) of the first coil element 111. , 112, and is pulled out from between the two coil elements 111, 112 via a second inter-element flatwise bent portion 123D bent by flatwise bending. In the inter-element connecting portion 113A, the coil elements 111 and 112 that are oriented in the front-rear direction rise in the vertical direction via the inter-element edgewise winding portion 123B that is bent by edgewise winding.

Referring to FIG. 4 showing a plan view, it is drawn between two coil elements 111 and 112 by flat-wise bending, rises vertically by edge-wise winding between the two coil elements 111 and 112, and further flat. It is pulled out from between the two coil elements 111 and 112 to the upper side of the coil element 112 (loop connecting portion 113B) by the wise bending.
As described above, in the present embodiment, the thickness of the inter-element connecting portion 113A in the coil element arrangement direction is minimized between the two coil elements 111 and 112 (in this direction, the thickness direction of the flat wire 101). Therefore, the distance D between the coil elements 111 and 112 can be minimized.

By the way, various attachment structures of the leg portions 161A and 161B in the reactor using the coil component as in the present embodiment are conceivable, and the attachment structures shown in FIGS. 3 and 4 are given as an example.
However, although this mounting structure has an advantage that the distance between the coil elements 111 and 112 can be reduced, the structure is slightly complicated and the number of manufacturing steps is increased, so that a simpler mounting structure is desired.
As a simple mounting structure, as shown in FIG. 5, in the upper valley between the coil elements 711, 712 (valley between corners with R between the coil elements 711, 712), the entire length before and after that A structure in which both leg portions 761A and 761B are fastened by a long screw 762A and a nut 762B that have been passed over is known. In such a reactor, it may be desirable to have a fastening structure as shown in FIG. 1 depending on the application and purpose, but it is often desired to have a simple fastening structure as shown in FIG. It is important that both the fastening structure shown in FIG. 1 and the fastening structure shown in FIG.

  In the present embodiment, the radius of curvature of the second inter-element flatwise bent portion 723D is made larger than that shown in FIG. 1 in the final portion of the inter-element coupling portion 713A, and the R portion at the corner of the coil element 712 is taken. , The space in the upper valley between the coil elements 711 and 712 is expanded, and even if the long screw 762A is passed through the valley, the long screw 762A is a flat wire 701. The inconvenience of interfering with the flatwise bent portion 723D between the second elements can be avoided.

On the other hand, in the coil devices described in Patent Documents 2 and 3 described above, at the end of the rising portion of the inter-element connecting portion, it is bent forward by 90 degrees again by edgewise winding, and thereafter, Since it is structured to be drawn out in front of the coil element, it is difficult to follow the rectangular wire with the R shape at the corner of the coil element, and a space for passing a long screw through the upper valley portion between the coil elements. It is difficult to ensure.
As described above, according to the coil component of this embodiment, the radius of curvature of the second element flatwise bent portion 723D can be easily adjusted, and by this adjustment, the upper valley between the coil elements 711 and 712 can be adjusted. A space for passing the long screw 762A can be secured, and the distance D between the coil elements 711 and 712 can be reduced to a level close to the thickness of the flat wire 701, thereby reducing the overall size of the coil component and the reactor device. While being able to make it small, deterioration of a magnetic characteristic can be avoided.
In addition, about the following embodiment, since the effect is the same as that of the coil apparatus incorporating the coil component according to the present embodiment, and the shape is also displayed in substantially the same manner as in FIG. The drawing corresponding to FIG. 5 is omitted, and FIG. 5 is used as an alternative drawing in the description requiring the drawing.

<Second Embodiment>
Since this second embodiment has many members that are common to those of the first embodiment described above, such common members are numbered by adding 100 to the numbering of the members in the first embodiment. The number is the numbering of the members of the present embodiment, and detailed description thereof is omitted.
That is, as shown in FIG. 6, the coil component 200 of the present embodiment uses a single rectangular wire 201 and is wound and laminated by edgewise winding between one end 201A and the other end 201B serving as connection terminals. Then, the first coil element 211 and the second coil element 212, which are formed in parallel in a rectangular tube shape, are provided by bending them into two at a predetermined position (usually substantially an intermediate position) of the wound and laminated coils. And it is the same as that of the coil component 100 of the said 1st Embodiment in the point that the connection part 213 which connects both the coil elements 211 and 212 is provided.
The coil component 100 according to the first embodiment is also wound in such a manner that a margin of the flat wire 201 for use in the connecting portion 213 is generated at the predetermined position of the wound and laminated coil. It is the same.

The first coil element 211 and the second coil element 212 are arranged in parallel so that one side surface 211D, 212D facing each other is parallel to each other with a predetermined dimension D therebetween.
The connecting portion 213 includes an inter-element connecting portion 213A disposed between the opposing side surfaces 211D and 212D between the two coil elements 211 and 212, and a flat wire 211C on the winding end side of the first coil element 211. And a loop coupling portion 213B that is interposed between the inter-element coupling portions 213A and formed along the lower side surface 212A (the lower surface in this embodiment) of the coil element 211.

  The loop connecting portion 213B includes a loop portion flatwise bent portion 223A where the flat wire 211C on the winding end side of the first coil element 211 is bent by flatwise bending, and a loop portion edgewise wound portion 223B bent by edgewise winding. And an extending portion 223C extending to the first inter-element flatwise bent portion 223D of the inter-element connecting portion 213A.

In addition, the inter-element connecting portion 213A includes a first inter-element flatwise bent portion 223D in which the flat wire 201 is bent by flatwise bending on the winding end side of the first coil element 211, and a second coil element 212. On the winding start side, the flat wire 201 includes a second inter-element flat-wise bent portion 223G bent by flat-wise bending, and an intermediate portion 223E extending between the two inter-element flat-wise bent portions 223D and G. ing. An inter-element edgewise winding portion 223F that is bent by edgewise winding is provided between the intermediate portion 213A and the second inter-element flatwise bending portion 223G.

  According to the coil component according to the present embodiment, the inter-element connecting portion 213A and the loop connecting portion 213B that connect the two coil elements 211 and 212 are bent by approximately 90 degrees by flatwise bending and by edgewise winding. The flat wire 201 is not twisted and is connected to be arranged between the coil elements 211 and 212 in a flat state by using a bending of approximately 90 degrees. It can be avoided that the torsion-shaped portion of the connecting portion 213 fits between the two coil elements 211 and 212 to increase the distance between the two coil elements 211 and 212. Thereby, the enlargement of a core can be prevented and the deterioration of a magnetic characteristic can be avoided.

In particular, since the intermediate portion 223C of the inter-element coupling portion 213A is positioned so as to stand in parallel with the two opposing side surfaces 211D and 212D of the two coil elements 211 and 212, the two coil elements 211 and 212 The interval can be set to a small distance D.
Further, unlike the prior art, there is no portion where the flat wire is twisted or bent at an angle greater than 90 degrees, so that problems such as peeling of the electric wire film are unlikely to occur.
In addition, if manufacturing is performed so that the end surfaces of the two coil elements 211 and 212 folded back at the position of the connecting portion 213 face each other, the manufacturing process of edgewise winding is performed by winding the rectangular wire 201 in the same direction. Therefore, it is possible to reduce man-hours and simplify the mechanism of the winding machine.

  Further, according to the coil device of the present embodiment, the radius of curvature of the first inter-element flatwise bent portion 223D can be easily adjusted, and by this adjustment, a long screw is formed between the lower valleys between the coil elements 211 and 212. (Attached 762A in FIG. 5) can be secured, and the distance D between the coil elements 211 and 212 can be reduced to a level close to the thickness of the flat wire 201, whereby the coil The overall size of the parts and the reactor device can be reduced, and deterioration of the magnetic characteristics can be avoided.

<Third Embodiment>
Since this third embodiment has many members in common with those of the first embodiment described above, such common members are numbered by adding 200 to the member numbering in the first embodiment. The number is the numbering of the members of the present embodiment, and detailed description thereof is omitted.
That is, as shown in FIG. 7, the coil component 300 according to the present embodiment uses a single rectangular wire 301, and is wound by edgewise winding between one end portion 301A and the other end portion 301B serving as connection terminals. Then, the first coil element 311 and the second coil element 312 that are formed in parallel in a rectangular tube shape are provided by bending the coil that is wound and laminated into two at a predetermined position (usually approximately an intermediate position). In addition, it is the same as the coil component 100 of the first embodiment in that it is configured by providing a connecting portion 313 for connecting both the coil elements 311 and 312.
The coil component 100 according to the first embodiment is also wound in such a manner that a margin of the flat wire 301 for use in the connecting portion 313 is generated at the predetermined position of the wound and laminated coil. It is the same.

The first coil element 311 and the second coil element 312 are arranged in parallel so that one side surface 311D and 312D facing each other are parallel to each other and are spaced by a predetermined dimension D.
The connecting portion 313 includes an inter-element connecting portion 313A disposed between the side surfaces 311D and 312D facing each other between the two coil elements 311 and 312 and a rectangular wire on the winding end side of the first coil element 311. 311C and the inter-element connecting portion 313A, and the coil element 31
Between the first loop connecting portion 313B1 formed along the lower side surface 311A of the first wire, the inter-element connecting portion 313A, and the rectangular wire 312C on the winding start side of the second coil element 312; And a second loop coupling portion 313B2 formed along the side surface 312A. That is, the connecting portion 313 has a structure in which loop connecting portions 313B1 and 313B2 are provided before and after the inter-element connecting portion 313A.

The first loop connecting portion 313B1 includes a first loop portion flatwise bent portion 323A in which a flat wire 311C on the winding end side of the first coil element 311 is bent by flatwise bending, and a first loop bent by edgewise winding. Edge wise winding portion 323B and an extending portion 323C extending to the first inter-element flatwise bending portion 323D of the inter-element coupling portion 313A are provided in this order.
The second loop coupling portion 313B2 includes an extension portion 323G extending from the second inter-element flatwise bending portion 323F of the inter-element coupling portion 313A, a second loop portion edgewise winding portion 323H bent by edgewise winding, A second loop portion flatwise bent portion 323I that is bent by flatwise bending and connected to the flat wire 312C at the winding start portion of the second coil element is provided in this order.

  The inter-element connecting portion 313A includes a first inter-element flatwise bent portion 323D in which the flat wire 301 is bent by flatwise bending and a second loop connecting portion 313B2 on the arrangement side of the first loop connecting portion 313B1. The flat wire 301 includes a second inter-element flatwise bent portion 323F bent by flatwise bending, and an intermediate portion 323E extending between the two inter-element flatwise bent portions 323D and F. ing.

  According to the coil component according to the present embodiment, the inter-element connecting portion 313A and the loop connecting portions 313B1 and 313B2 that connect the two coil elements 311 and 312 are bent by about 90 degrees by flatwise bending, and edgewise. It is designed to be connected so as to be arranged between the coil elements 311 and 312 in a flat state without twisting the flat wire 301 by using a bending of approximately 90 degrees by winding. It can be avoided that the torsion-shaped portion of the connecting portion 313 fits between the two coil elements 311 and 312 to increase the distance between the two coil elements. Thereby, the enlargement of a core can be prevented and the deterioration of a magnetic characteristic can be avoided.

In particular, the intermediate portion 323E of the inter-element coupling portion 313A is positioned so as to stand in parallel with the two opposing side surfaces 311D and 312D of the two coil elements 311 and 312. The interval D can be set to a small distance.
Further, unlike the prior art, there is no portion where the flat wire is twisted or bent at an angle greater than 90 degrees, so that problems such as peeling of the electric wire film are unlikely to occur.
In addition, if manufacturing is performed so that the end surfaces of the two coil elements 311 and 312 folded back at the position of the connecting portion 313 face each other, the manufacturing process of edgewise winding is performed by winding the rectangular wire 301 in the same direction. Therefore, it is possible to reduce man-hours and simplify the mechanism of the winding machine.

  Further, according to the coil device of the present embodiment, the radii of curvature of the first inter-element flatwise bent portion 323D and the second inter-element flatwise bent portion 323F can be easily adjusted. A space for passing a long screw (indicated by 762A in FIG. 5) between the upper and lower valleys between the elements 311 and 312 can be secured, and the interval D between the coil elements 311 and 312 is the thickness of the rectangular wire 301. Thus, the overall size of the coil component and the reactor device can be reduced, and deterioration of the magnetic characteristics can be avoided.

<Fourth Embodiment>
Since this fourth embodiment has many members that are common to those of the first embodiment described above, such common members are numbered by adding 300 to the member numbering in the first embodiment. The number is the numbering of the members of the present embodiment, and detailed description thereof is omitted.
That is, as shown in FIG. 8, the coil component 400 of the present embodiment uses a single rectangular wire 401 and is wound and laminated by edgewise winding between one end 401A and the other end 401B that serve as connection terminals. Then, a first coil element 411 and a second coil element 412 that are formed in parallel in a rectangular tube shape are provided by bending the coil that is wound and laminated into two at a predetermined position (usually approximately an intermediate position). And it is the same as that of the coil component 400 of the said 1st Embodiment in the point that the connection part 413 which connects both the coil elements 411 and 412 is provided.

The coil component 100 according to the first embodiment is also wound in such a manner that a margin of the flat wire 401 for use in the connecting portion 413 is generated at the predetermined position of the wound and laminated coil. It is the same.
In other words, the fourth embodiment is formed in the same manner as the first embodiment, but the intermediate portion 423D of the inter-element coupling portion 413A approaches the second coil element 412 as it rises. It has an inclined configuration. Thereby, although the space | interval D of both the coil elements 411 and 412 becomes large compared with the said 1st Embodiment, the other effect is the same as that of 1st Embodiment.

<Fifth Embodiment>
Since the fifth embodiment has many members that are common to those of the third embodiment described above, such common members are numbered by adding 200 to the member numbering in the third embodiment. The number is the numbering of the members of the present embodiment, and detailed description thereof is omitted.
That is, as shown in FIG. 9, the coil component 500 of the present embodiment uses a single rectangular wire 501 and is wound by edgewise winding between one end 501A and the other end 501B serving as connection terminals. The first coil element 511 and the second coil element 512, which are formed in parallel in a rectangular tube shape, are formed by bending and folding into two at a predetermined position (usually approximately an intermediate position) of the laminated coils. It is the same as that of the coil component 300 of the said 3rd Embodiment in the point that it provides and the connection part 513 which connects both the coil elements 511 and 512 is provided.

The coil component 300 according to the third embodiment is also wound in such a manner that a margin of the flat wire 501 for use in the connecting portion 513 is generated at the predetermined position of the coil that is wound and laminated. It is the same.
In other words, the fifth embodiment is formed in the same manner as the third embodiment, but the intermediate portion 523E of the inter-element coupling portion 513A approaches the second coil element 512 as it rises. It has an inclined configuration. Thereby, although the space | interval D of both the coil elements 511 and 512 becomes large compared with the said 3rd Embodiment, the other effect is the same as that of 3rd Embodiment.

<Sixth Embodiment>
Since this sixth embodiment has many members that are common to those of the third embodiment described above, such common members are numbered by adding 300 to the numbering of the members in the third embodiment. The number is the numbering of the members of the present embodiment, and detailed description thereof is omitted.
That is, as shown in FIG. 10, the coil component 600 of this embodiment uses a single rectangular wire 601 and is wound and laminated by edgewise winding between one end portion 601A and the other end portion 601B serving as connection terminals. Then, the first coil element 611 and the second coil element 612 that are formed in parallel in a rectangular tube shape are provided by bending the coil that is wound and laminated into two at a predetermined position (usually approximately an intermediate position). And it is the same as that of the coil component 300 of the said 3rd Embodiment in the point that the connection part 613 which connects both the coil elements 611 and 612 is provided.

The coil coil 300 of the third embodiment is also wound at the predetermined position of the wound and laminated coil so that a margin of the flat wire 601 for use in the connecting portion 613 is generated. It is the same.
That is, in the sixth embodiment, the first loop coupling portion 613B1, the inter-element coupling portion 613A, and the second loop coupling portion 613B2 are configured to draw an S-curve as a whole. In other words, the radii of curvature of the first inter-element flatwise bent portion 623D and the second inter-element flatwise bent portion 623F are formed to be somewhat larger than the radii of curvature of the corners of both coil elements 611 and 612. The inter-element coupling portion 613A stands upright between the coil elements 611 and 612 at the intermediate portion 623E, and is coupled so as to draw a gentle curve between the front and rear loop coupling portions 613B1 and 613B2.
The operational effects are almost the same as in the third and fifth embodiments.

Note that the coil component and the coil device of the present invention are not limited to those of the above-described embodiment, and may take other various aspects. For example, a linear part or a bent part may be added to each part constituting the inter-element coupling part or the loop coupling part in the above embodiment, or a part of each part constituting the inter-element coupling part or the loop coupling part may be omitted. Is possible.
Moreover, in the said embodiment, although the aspect at the time of providing the apparatus leg part which supports a coil apparatus main body is shown, as a coil apparatus of this invention, it can of course be used as an aspect which does not provide an apparatus leg part. Is possible.

In addition, since the outer surface of the coil component is covered with an insulating coating, the coil device body can be held so that the outer surface of the coil and the leg portion are in contact with each other in the case of low voltage.
Moreover, although the reactor (coil component) which concerns on the said embodiment has shown what was applied to the reactor for vehicle mounting, the coil component and coil apparatus which concern on this invention are not restricted to vehicle mounting, and can apply to various things For example, it can be applied to a reactor or the like used in a photovoltaic power generation panel.

100, 200, 300, 400, 500, 600, coil components 101, 201, 301, 401, 501, 601, 701 rectangular wire 101A, B, 201A, B, 301A, B, 401A, B, 501A, B, 601A , B, 701A, B End 111, 211, 311, 411, 511, 611, 711 First coil element 111D, 211D, 311D, 411D, 511D, 611D, 112D, 212D, 312D, 412D, 512D, 612D 112, 212, 312, 412, 512, 612, 712 Second coil element 113, 213, 313, 413, 513, 613, 713 Connecting portion 113A, 213A, 313A, 413A, 513A, 613A, 713A
Inter-element connecting portion 113B, 213B, 313B1, 313B2, 413B, 513B1, 513B2, 613B1, 613B2, 713B
Loop connection portion 123A, D, G, 223A, D, G, 323A, D, F, I, 423A, D, G, 523A, D, F, I, 623A, D, F, I, 723D, G Flatwise Bending portion 123B, F, 223B, F, 323B, H, 423B, F, 523B, H, 623B, H, 723F Edgewise winding portion 123C, 223E, 323E, 423C, 523E, 623E Intermediate portion 123E, 223C, 323C, G, 423E, 523C, G, 623C, G
Extension part 151, 152, 751, 752 Core 161A, B, 761A, B Leg part 164, 762A Screw

Claims (7)

A coil winding body formed by laminating a single rectangular wire into a rectangular shape having corners R by edgewise winding is divided into two at a predetermined position and folded, and the opposing side surfaces are A first coil element and a second coil element arranged so as to be parallel to each other, and a connecting portion that connects both the coil elements;
The connecting portion includes an inter-element connecting portion disposed between the opposing side surfaces, the inter-element connecting portion, a winding end portion of the first coil element, and a winding start portion of the second coil element. A loop coupling portion that is formed along a side surface that is interposed between at least one of the coil element side and that is adjacent to the opposing side surface of the corresponding coil element side,
The inter-element connecting portion does not have a twisted shape of a flat wire, and the flat wire is formed at the winding end side end of the first coil element and the winding start side end of the second coil element. A flatwise bent portion between the first and second elements bent by flatwise bending, and an intermediate portion extending between the flatwise bent portions between these two elements,
The loop connecting portion is extended by extending from an inter-element flatwise bent portion of the inter-element connecting portion, a loop portion bent by edgewise winding, an edgewise winding portion, and bent by flatwise bending. A loop portion flatwise bent portion connected to at least one of the flat wire on the winding end side of the first coil element and the flat wire on the winding start side of the second coil element, from the inter-element connecting portion side A coil component characterized by being provided in this order.   The coil component according to claim 1, wherein the intermediate portion has an inter-element edgewise winding portion bent by edgewise winding.   3. The coil component according to claim 1, wherein the intermediate portion is disposed in parallel between the opposing side surfaces between the two coil elements.   Second intermediate flatwise bent portion where the intermediate portion is located on the winding start side of the second coil element from the first interelement flatwise bent portion located on the winding end side of the first coil element The coil component according to claim 1, wherein the coil component is arranged so as to be inclined so as to approach the second coil element as it goes to.   Of the first and second inter-element flat-wise bent portions where the flat wire is bent by flat-wise bending, the radius of curvature of the inter-element flat-wise bent portion connected to the loop connecting portion is the flat width. 5. The coil component according to claim 1, wherein the coil component is formed to have a radius of curvature greater than or equal to the corner of the coil element along the bent portion.   A coil device comprising: the coil component according to any one of claims 1 to 5; and a magnetic core portion that forms a closed magnetic path by inserting a leg portion into each hollow portion of the coil component. .   The coil device according to claim 6, further comprising a device leg portion that holds a coil device body in which the coil component and the magnetic core portion are combined in a predetermined position.

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