JP3737461B2 - Coil component and method for forming coil component - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a coil component and a method for forming a coil component.
[0002]
[Prior art]
An example of a conventional coil component will be described with reference to FIG. The coil component 110 includes two coil elements 111 and 112 arranged in parallel. Each coil element 111, 112 is formed by an individual winding 101, 102, respectively. Ends 101 a and 102 a on the connection side of the windings 101 and 102 are connected to each other via a connection terminal 115. The end portions 101a and 102a on each connection side and the connection terminal 115 are connected by welding means such as TIG welding or laser welding.
[0003]
[Problems to be solved by the invention]
However, according to the conventional coil component 110 described above, the windings 101 and 102 of both coil elements 111 and 112 are connected to each other via the communication terminal 115. For this reason, due to the welding involved in the connection between the coil elements 111 and 112 and the connecting terminal 115, the connecting terminal 115 and the end portions on the connecting side of the windings 101 and 102 (the connecting end portions of the coil elements). 101a and 102a protrude from the outer shape of the end surfaces of the coil elements 111 and 112 outward (forward in FIG. 12), and there is a problem that the space occupied by the coil component 110 is inevitably increased. This contributes to an increase in the size of electrical components such as a transformer in which the coil component 110 is incorporated. Therefore, improvement thereof is desired.
[0004]
There is also a coil component described in Japanese Patent Laid-Open No. 2000-10553. In the coil component, a plurality of coil elements arranged in parallel are formed by one winding without using a connecting terminal. However, since the connecting portion of the winding wire that extends between the coil elements protrudes outward from the outer shape of the end faces of the two coil elements, there is a problem that the occupied space of the coil parts is inevitably increased as described above. It was.
[0005]
Therefore, the problem to be solved by the present invention is to provide a coil component and a method for forming the coil component that can reduce the space occupied by the coil component.
[0006]
[Means for Solving the Problems]
In the coil component according to the first aspect of the present invention for solving the above-described problem, a plurality of coil elements arranged in parallel in the same winding direction are formed by edgewise winding of one rectangular wire. At the same time, the connecting portion of the flat wire extending between the two continuous coil elements is folded in half along the width direction orthogonal to the longitudinal direction, and is accommodated within the outer shape of the end faces of the two coil elements. Yes. With this configuration, the connection terminal and the connection side end of each coil element, which have been conventionally required, are eliminated, and the projecting portion that protrudes outward from the end faces of both coil elements is eliminated. The space occupied by parts can be reduced.
[0007]
According to a second aspect of the present invention, there is provided a method for forming a coil component, wherein a plurality of coil elements in the same winding direction are stepped in an axially eccentric state by edgewise winding of one rectangular wire. Form. Thereafter, by arranging the two coil elements in parallel so that the connecting portion of the flat wire between the two continuous coil elements is folded in two along the width direction orthogonal to the longitudinal direction, A coil component in which the connecting portion is housed in the outer shape of the end faces of both coil elements is formed. With this configuration, a plurality of coil elements in the same winding direction arranged in parallel are formed by edgewise winding of a single rectangular wire, and a rectangular wire connecting portion that spans between two mutually continuous coil elements. The coil component housed in the outer shape by the end faces of the two coil elements can be molded. Therefore, the connecting terminal and the connecting end of each coil element, which have been conventionally required, are eliminated, and the protruding portion that protrudes outward from the end faces of both coil elements is eliminated, thereby reducing the occupied space. The coil component which can be obtained can be obtained.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
[Embodiment 1]
Embodiment 1 of the present invention will be described. In the present embodiment, a coil component used for an automobile transformer is exemplified. In addition, the azimuth | direction which concerns on coil components is defined as shown by the arrow in each figure.
As shown in FIG. 1, the winding 1 forming the coil component 10 has, for example, a rectangular wire 1 having a predetermined width 1w and thickness 1t (the same reference numerals as those of the winding) 1 whose surface is insulated. Is used. For the winding 1, for example, a rectangular wire having a width 1w of 6.0 mm and a thickness 1t of 1.4 mm is used.
[0009]
As shown in FIGS. 1 and 2, the flat wire 1 is formed so that the surfaces forming the width 1w are in surface contact with each other in a state where the winding start end 1a of the flat wire 1 is drawn outward (forward). The first coil element 11 is formed by winding 1 upward in a stacked manner a predetermined number of times. Further, the connecting portion 1b of the winding 1 is folded back from the end of winding of the first coil element 11, and is extended to the right side. Subsequently, the rectangular wire 1 is wound downward in a stacked manner a predetermined number of times so that the surfaces forming the width 1 w of the rectangular wire 1 are in surface contact with each other in parallel on the right side of the first coil element 11. Thus, the second coil element 12 is formed. In the second coil element 12, the winding 1 is wound in the same winding direction as the winding 1 of the first coil element 11. Further, the winding end portion 1c of the winding 1 is drawn outward (forward) so as to be parallel to the winding start end portion 1a. Moreover, both the coil elements 11 and 12 are formed in the shape of a long rectangular cylinder with the short side in the left-right direction and the long side in the front-rear direction. The coil elements 11 and 12 are formed with a predetermined distance 10i (see FIG. 2) between them.
[0010]
That is, the coil component 10 is formed by edgewise winding two coil elements 11 and 12 in the same winding direction arranged in parallel with one winding 1. At the same time, the connecting portion 1b of the winding 1 that extends between the two coil elements 11 and 12 corresponds to the end surfaces 11a and 12a of the two coil elements 11 and 12 (in FIG. 1, the upper end surfaces of the two coil elements 11 and 12 correspond to each other). )). The connecting portion 1 b of the winding 1 is bent along the short side portions of the end faces 11 a and 12 a of the coil elements 11 and 12.
[0011]
The winding start end portion 1a and the winding end end portion 1c of the winding 1 are used as connection terminals by removing an insulating film formed by insulating treatment of the winding 1 by press working, machining, or the like. A magnetic core such as a transformer (not shown) is inserted into the hollow portion of each coil element 11, 12. Further, in the coil component 10, the directions of magnetic fluxes induced in the coil elements 11 and 12 when the winding 1 is energized are opposite to each other. For example, the direction of the magnetic flux in the first coil element 11 is If it is upward, the direction of the magnetic flux in the second coil element 12 is downward. Moreover, as described above, the coil component 10 having both the coil elements 11 and 12 formed by the winding 1 wound edgewise is suitable for a high frequency coil component.
[0012]
Next, a method for forming the coil component 10 will be described. First, as shown in FIG. 3 and FIG. 4, two coil elements 11, 12 are connected by one winding 1, and a connecting portion 1 b of the winding 1 is provided in the axial direction between the coil elements 11, 12. It is formed in a stepped shape in an eccentric state. That is, the second coil element 12 is formed on the upper left side with respect to the first coil element 11.
[0013]
At the start of winding of the winding 1, the winding start end 1a is drawn outward (forward). At the end of winding, the end portion 1c at the end of winding is drawn outward (forward) so as to be parallel to the end portion 1a. The winding method of the winding 1 is a so-called edgewise winding method as described above. Further, since the second coil element 12 is eccentric to the left by a predetermined eccentric amount 10e (see FIG. 4) with respect to the first coil element 11, the connecting portion of the winding 1 is corresponding to the eccentric amount 10e. 1b extends to the left. Moreover, since the coil | winding 1 is wound by the same winding direction in both the coil elements 11 and 12, it can be wound automatically using a well-known coil shaping | molding apparatus (it is also called a winding apparatus).
[0014]
After that, as shown in FIG. 5, the second coil element 12 is arranged in parallel on the right side of the first coil element 11 so that the connecting portion 1 b of the winding 1 is folded back. At this time, as shown in FIG. 4, the first pin member 41 is disposed on the upper end surface of the first coil element 11, and on the lower end surface (lower side in FIG. 4) of the second coil element 12. The second pin member 42 is disposed. The second pin member 42 is attached to an arm member 40 provided so as to be rotatable about the axis of the first pin member 41. In addition, each coil element 11 and 12 shall be hold | maintained by each holder (illustration omitted) so that each winding state may not collapse.
[0015]
Next, by rotating the arm member 40 in the clockwise direction in FIG. 4 (see arrow Y in FIG. 4) about the axis of the first pin member 41, the second pin member 42 is armed. It is rotated integrally with the member 40. As a result, as shown in FIG. 5, the connecting portion 1b of the winding 1 between the coil elements 11 and 12 is folded back, and the coil elements 11 and 12 that are continuous to each other are arranged in parallel, that is, the first coil element. The second coil elements 12 are arranged on the right side of 11. At the same time, the coil component 10 (see FIG. 1) in which the connecting portion 1b of the winding 1 is housed in the outer shape of the end surfaces 11a and 12a of the coil elements 11 and 12 can be formed. In addition, the shaping | molding of the coil component 10 is completed by taking out both the pin members 41 and 42 from the coil component 10. FIG. Further, a roller member (not shown) is rotatably provided on each pin member 41, 42, and the roller is contacted and rotated with respect to the winding 1, whereby the pin member 41, 42 and the winding 1 are interposed between each pin member 41, 42. Sliding resistance can be reduced.
[0016]
According to the coil component 10 (see FIG. 1 and FIG. 2) described above, a connection terminal (refer to reference numeral 115 in FIG. 12) and an end portion on the connection side of the coil elements 11 and 12 that are conventionally required (in FIG. 12). , Reference numerals 101a and 102a) are eliminated. At the same time, the protruding portions that protrude outward from the end faces 11a, 12a of both coil elements 11, 12 are eliminated. Thereby, the occupied space of the coil component 10 can be reduced.
Moreover, according to the above-described forming method, the coil component 10 that can reduce the occupied space can be obtained.
[0017]
Further, the contact terminal (refer to reference numeral 115 in FIG. 12) that has been required in the past is unnecessary, the process of removing the insulation film from the winding for connecting the contact terminal, and welding between the contact terminal and the winding. The process can be omitted. Therefore, it is possible to reduce the number of parts and the work process, thereby realizing a reduction in cost. Moreover, since the problem of the welding strength dispersion | variation in the said welding process is also eliminated, the dispersion | variation in quality can be reduced. Moreover, since the welding equipment concerning the said welding becomes unnecessary, installation cost can also be reduced.
[0018]
Moreover, in the coil component 10 of the said embodiment, as shown in FIG. 5, the connection part 1b of the coil | winding 1 between the both coil elements 11 and 12 is the site | part (code | symbol 1 code | symbol 11 side). 1b1) is bent substantially in a semicircular shape, and the portion on the second coil element 12 side (reference numeral 1b2) is bent in a gentle "<" shape. The bent shape of the connecting portion 1b can be appropriately changed as illustrated below.
[0019]
For example, in the case shown in FIG. 6, the portion 1b11 on the first coil element 11 side of the connecting portion 1b of the winding 1 is bent into a substantially channel shape and the portion 1b21 on the second coil element 12 side is substantially crank-shaped. It is bent.
7, the portion 1b12 on the first coil element 11 side of the connecting portion 1b of the winding 1 is bent substantially in the shape of a channel, and the portion 1b22 on the second coil element 12 side has a gentle “く”. It is bent in the shape of "".
8, the portion 1b13 on the first coil element 11 side of the connecting portion 1b of the winding 1 is bent in a substantially C shape, and slightly on the portion 1b23 on the second coil element 12 side. It is folded in the shape of the letter “ku”.
[0020]
[Embodiment 2]
A second embodiment of the present invention will be described. In the second embodiment, the coil elements 11 and 12 of the first embodiment described above are wound around the bobbin. Therefore, the changed portion will be described in detail, and redundant description will be omitted.
As shown in FIG. 9, the bobbin 30 is made of, for example, a resin, and includes a main body portion 31 that has a substantially rectangular tube shape, and upper and lower ends that are annularly projected on the outer peripheral portions of both upper and lower ends of the main body portion 31. And flange portions 32 and 33. Thus, the left half of the front edge portion of the upper flange portion 32 is cut away to form an opening groove 32a. An end portion 32b on the opening groove 32a side at the front edge of the upper flange portion 32 serves as a bending reference, and a guide convex portion 32c projects on the end portion 32b.
[0021]
Next, a method for forming a coil component according to the second embodiment will be described. First, in the same manner as in the first embodiment, as shown in FIG. 10, two coil elements 11 and 12 are wound in the axial direction and between the coil elements 11 and 12 by one winding 1. It is formed in a stepped shape in an eccentric state via the connecting portion 1b of the line 1. At this time, the winding 1 is wound around the main portion 31 (see FIG. 9) of each bobbin 30 of each coil element 11, 12. Further, the bobbin 30 of the second coil element 12 is disposed such that the flange portion 32 having the opening groove 32a faces downward. The connecting portion 1b of the winding 1 between the coil elements 11 and 12 is drawn from the opening groove 32a side of the bobbin 30 in the first coil element 11, and the opening of the bobbin 30 in the second coil element 12. It is drawn from the groove 32a side.
Thereafter, as in the first embodiment, the connecting portion 1b of the winding 1 is folded back, and the coil elements 11 and 12 that are continuous with each other are arranged in parallel (see FIG. 11).
[0022]
Also according to the second embodiment described above, the same effects as those of the first embodiment can be obtained.
Further, since the end portion 32b on the opening groove 32a side at the front edge portion of the flange portion 32 of each bobbin 30 is a bending reference, each pin member 41, 42 in the first embodiment (see FIGS. 4 and 5). Can be omitted.
Further, the connecting portion 1 b of the winding 1 can be gently bent by the guide convex portion 32 c provided on the flange portion 32 in each bobbin 30. Note that the guide protrusion 32c can be omitted.
[0023]
Further, as shown in FIG. 11, the windings 1 of both the coil elements 11 and 12 are respectively held by the bobbins 30. When both the coil elements 11 and 12 are arranged in parallel, both the bobbins 30 face each other. The end surfaces of the upper flange portion 32 are in contact with each other, and the end surfaces of the lower flange portion 32 are also in contact with each other. Thereby, the dimensional accuracy of the distance 10d between the centers of the coil elements 11 and 12 can be improved.
[0024]
The present invention is not limited to the embodiment described above, and can be modified without departing from the gist of the present invention. For example, the coil component 10 of the present invention can be applied not only to a transformer but also to a motor, other electrical components, and the like. The coil component 10 may include three or more coil elements .
[0025]
【The invention's effect】
As described above, according to the coil component and the molding method of the coil component of the present invention, the connection terminal and the connection side end of each coil element that have been conventionally required are eliminated, and the end surfaces of both coil elements are removed. By eliminating the protruding portion that protrudes outward from the coil, the space occupied by the coil component can be reduced.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a coil component according to a first embodiment of the present invention.
FIG. 2 is a perspective view of a coil component viewed from the lower surface side.
FIG. 3 is a perspective view showing a semi-molded product of coil parts.
FIG. 4 is a front view showing a semi-molded product of coil parts.
FIG. 5 is a front view showing a molding method from a semi-molded product to a coil component.
FIG. 6 is a front view showing a modification example 1 of a folded shape of a connecting portion of a winding.
FIG. 7 is a front view showing a second modification of the folded shape of the connecting portion of the winding.
FIG. 8 is a front view showing a third modified example of the folded shape of the connecting portion of the winding.
FIG. 9 is a perspective view showing a bobbin according to a second embodiment of the present invention.
FIG. 10 is a front view showing a semi-molded product of coil parts.
FIG. 11 is a front view showing a coil component.
FIG. 12 is a perspective view showing a coil component according to a conventional technique.
[Explanation of symbols]
1 Winding (flat wire)
DESCRIPTION OF SYMBOLS 1a Winding end part 1b Connection part 1c End of winding part 10 Coil component 11 1st coil element 11a End surface 12 2nd coil element 12a End surface

Claims (2)

A plurality of coil elements in the same winding direction arranged in parallel are formed by edgewise winding of a single rectangular wire, and the connecting portions of the rectangular wires extending between the two continuous coil elements are orthogonal to the longitudinal direction. A coil component that is housed in an outer shape by end faces of both coil elements so as to be folded in two along the width direction . A plurality of coil elements in the same winding direction are formed in a stepped shape in the axial direction and in an eccentric state by edgewise winding of one flat wire, and thereafter, between the coil elements that are mutually continuous. By arranging both coil elements in parallel so that the connecting portion of the flat wire to be folded is folded in two along the width direction orthogonal to the longitudinal direction, the connecting portion is accommodated in the outer shape by the end faces of both coil elements. A method for forming a coil component, comprising forming the coil component.

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