JP6519437B2 - Coil component and method of forming coil component - Google Patents

Description

  The present invention relates to a coil component used as a reactor or the like, and a method of forming the coil component, and more particularly, a coil formed of two rectangular coils in the form of closely spaced rectangular cylinders formed by a single flat wire. The present invention relates to a part and a method of forming the coil part.

A coil component such as a reactor can generate an inductance by adopting a configuration in which a winding coil is wound around a magnetic core.
As the reactor, various types of reactors are known depending on the purpose of use, ranging from large-capacity ones for transmission systems to communication device parts. Such a reactor is accommodated in a metal case or the like together with other insulating members and the like.

  By the way, in a reactor used for a boost circuit for a vehicle, two stacked coil elements are formed in parallel, and both coil elements are formed so as to obtain a high inductance value when a high current flows. A configuration is known in which the directions of flowing current are connected in opposite directions to each other.

As a conventional example of such a reactor, one in which two coil elements arranged in parallel are formed by edgewise winding of one flat wire is known (see, for example, Patent Documents 1 and 2 below) ).
That is, in Patent Documents 1 and 2 below, as shown in FIG. 7, a flat wire is wound while forming a bent portion by edgewise winding, at a position opposite to the magnetic core F forming the closed loop. A first coil element 211 and a second coil element 212 are formed. Between these two coil elements 211, 212 there is a coil connection where a flat wire is passed.

  And in the said coil connection part, as shown to FIG. 2 (B) and FIG. 6 (B) by the time it transfers to the 2nd coil element 212 from the 1st coil element 211, a flat angle is only about 90 degrees 2 It is folded over the turn. That is, the flat wire is bent in a crank shape without being twisted.

  According to the reactor of patent documents 1 and 2 constituted in this way, the welding part and return part for connection between two coil elements 211 and 212 become unnecessary. Furthermore, the end on the connection side does not protrude outward from the outer shape of the end face of both coil elements, and it is possible to prevent an increase in the space occupied by the coil. In addition, if the flat wire is twisted between the two coil elements in the connecting portion, the flat wire will enter between the two coil elements, and the space area between the coil elements must be made larger than necessary. Although the above-mentioned reactors of Patent Documents 1 and 2 do not cause such twisting of the flat wire, it is possible to prevent the upsizing of the entire product.

Patent No. 4951272 gazette Patent No. 4812641

By the way, in the market in recent years, in particular, the power
High inductance) is required. In order to satisfy the above requirements, it is necessary to shorten the coil length as much as possible to reduce the DCR (direct current resistance) component, and efforts to shorten the design even at a ratio of 0.1% with respect to the coil length every day It is done.
The present invention has been made in view of such circumstances, and it is a compact coil component capable of reducing the DC resistance component of the entire coil by shortening the length of the flat wire of the coil connection portion between two elements and It is an object of the present invention to provide a method of manufacturing a coil component.

In order to solve the said subject, the manufacturing method of the coil component which concerns on this invention, and a coil component is equipped with the following characteristics.
The coil component according to the present invention is
The first and second coil elements are formed parallel to each other in a rectangular tube shape by laminating edgewise wound using a rectangular wire, and the corresponding one side sides are arranged along each other,
The first coil element is formed so as to wind and laminate the flat wire from one end side of one flat wire, and the second coil element is formed by the single flat wire. The flat wire is formed so as to be wound and laminated in the same lamination direction in the same winding direction as the first coil element from the other end side of
In the final turn of the first coil element, the end on one side of the side of the first coil element serves as a first coupling end, and in the final turn of the second coil element, the second The other end of the side of the coil element is a second connection end, and a flat wire is linearly formed between the first connection end and the second connection end. It is characterized in that a winding connection portion is provided in a stretched state.

  Moreover, it is preferable that the said flat wire in the said winding connection part is contained in one plane.

Further, the method for forming a coil component of the present invention is
A first coil element forming step of forming the first coil element into a rectangular tube shape by laminating the rectangular wire by edgewise winding from one end of the rectangular wire using one rectangular wire; Simultaneously or sequentially performing a second coil element forming step of forming a second coil element into a rectangular tube shape by laminating the rectangular wire by edgewise winding from the other end of the rectangular wire;
After this, with the first and second coil elements arranged such that the side portions of the corresponding two elements extend along each other, one end of the side portion of the first coil element A flat wire stretching step of linearly stretching the flat wire between the lower portion and the other end of the side portion of the second coil element.

  Here, the “edgewise winding” or the “edgewise winding” mentioned above means that the short side of the flat wire is wound longitudinally with the inner diameter surface.

  According to the coil component of the present invention, in the state where the first and second coil elements are arranged such that one side of the two elements is along each other, the side of the first coil element The flat wire is linearly stretched between an end on one side of the portion and an end on the other side of the side portion of the second coil element.

  As a result, the winding connection of the flat wire between the first coil element and the second coil element is delivered at the shortest distance in a straight line, not in a crank shape as in the prior art described above. Since the coil length of the above-mentioned winding connection part can be shortened as much as possible, the total length of the flat wire can be shortened, and the DCR (direct current resistance) component can be reduced.

  Moreover, as in the prior art described above, it is possible to prevent an increase in the space occupied by the coil, and to prevent an increase in the overall size of the product.

  Further, according to the method for manufacturing a coil component of the present invention, the winding connecting portion is not particularly formed in this portion, and the last remaining unwound portion of the flat wire is the winding portion. Since the connecting portion is formed, the manufacturing process can be simplified and the molding efficiency can be improved.

  In addition, since both coil elements can be formed at the same time by winding one flat wire inwardly from both ends, the forming efficiency can be further improved in this case.

It is the perspective view which looked at the coil component which concerns on embodiment of this invention from diagonally front upper direction. It is the schematic for demonstrating the comparison of the length of a winding connection part in embodiment (A) of this invention, and a prior art (B). It is a 1st figure for demonstrating the formation method of the coil components which concern on embodiment of this invention. It is a 2nd figure for demonstrating the formation method of the coil components which concern on embodiment of this invention. It is the perspective view which looked at the coil component concerning the modification of the present invention from diagonally front upper. It is the schematic for demonstrating the comparison of the length of the specific winding connection part (expansion winding connection part) in the modification (A) of this invention, and a prior art (B). It is the schematic which shows the structure of a common reactor coil.

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

  The reactor is used, for example, as an electric circuit element of various devices mounted in a car, and includes a core and a reactor coil wound around the core, and usually, a reactor core is inserted in the reactor coil, These components are accommodated in a case and fixed by a filler or the like.

  The reactor coil 10 of the present embodiment is formed in parallel to each other in the form of a rectangular tube by laminating the rectangular wire rod 1 by edgewise winding as shown in FIG. 1, and corresponding one side 11C, 12C Are configured to include first and second coil elements 11 and 12 disposed along each other.

  The first coil element 11 is formed so as to wind and laminate the flat wire 1 from one end side of one flat wire 1 and the second coil element 12 is the other of the flat wire 1 described above. The flat wire 1 is wound from the end side of the first coil element 11 in the same winding direction as the first coil element 11 and stacked in the same stacking direction.

  The end of one side of the side 11C of the first coil element 11 is the first connection end 11A in the final turn of the first coil element 11 (the nearest turn in the drawing), and the second coil In the final turn of the element 12, the other end of the side 12C of the second coil element 12 is used as the second connecting end 12A, and these first connecting end 11A and the second connecting end A winding connecting portion 20 in which the flat wire 1 is linearly stretched is formed between the portions 12A.

That is, the flat wire 1 is configured to be linearly connected in one plane without twisting from the first coil element 11 to the second coil element 12.
Further, the first coil element 11 is wound counterclockwise from the back side to the front side in the drawing, and is stacked from the back side to the front side in the drawing. On the other hand, the second coil element 12 is also wound counterclockwise from the back side to the front side in the drawing, and is stacked from the back side to the front side in the drawing.
However, since one of the terminals 11a and 12a is an input terminal and the other is an output terminal, the currents flow in opposite directions in the respective coil elements 11 and 12, considering the flow of the current, The currents flowing in the coil elements 11, 12 will rotate in opposite directions.
As a result, the magnetic fields passing through the inside of the magnetic core also become opposite to each other between the coil elements 11 and 12.

  Then, in the winding connecting portion 20 of the present embodiment, as described above, the flat rectangular wire 1 is linearly passed between the first connecting end 11A and the second connecting end 12A. Therefore, the length of the flat wire 1 in the winding connecting portion 20 can be made shortest as compared with the above-described prior art, and hence the total length of the flat wire 1 can be shortened. The direct current resistance component (DCR) of the reactor coil 10 can be reduced, which can contribute to increasing the inductance.

FIG. 2A is a schematic diagram for explaining the length of the winding connection portion 20 of the reactor coil 10 in the present embodiment, and FIG. 2B is a winding connection of the reactor coil 210 in the prior art. FIG. 7 is a schematic view for explaining the length of a portion 220.
That is, the length of the winding connection portion 20 of the reactor coil 10 according to the present embodiment is represented by the length R of the rectangular wire 1 in the winding connection portion 20 from the first coil element 11 to the second coil element 12 Ru.

The first connecting end of the first coil element 11 (actually the middle point therein) 11A is taken as the first vertex, and the second connecting end of the second coil element 12 (actually there) Center point 12A is a second vertex, and a straight line 15A extending along the long side of the second coil element 12 from the second connection end 12A, and a first coil element 11 from the first connection end 11A When a right triangle is formed with a third vertex at an intersection point 12B with a straight line 15B extending along the short side of the above, the distance R is the distance P between the second vertex and the third vertex, the first vertex and the third vertex It is represented by following Formula (1) using the distance Q of.
R = (P ² + Q ² ) ^1/2 ... (1)

On the other hand, in the prior art described above, as shown in FIG. 2 (B), the length of the winding connection portion 220 of the reactor coil 210 is the length of the winding connection portion 220 from the first coil element 211 to the second coil element 212. The rectangular wire 201 at a length R ′ (not shown) is represented.
Here, a straight line 215A extending along the long side of the second coil element 212 from the second connecting end 212A, and a straight line extending along the short side of the first coil element 211 from the first connecting end 211A. When the point of intersection 212B with 215B is defined as shown in FIG. 2B, the distance R 'is the length P' of the second end for connection 212A and the point of intersection 212B, and the first end for connection 211A. And the length Q ′ of the intersection point 212B are expressed by the following equation (2).
R '= P' + Q '... (2)

As understood from the comparison of the above equation (1) and the above equation (2), the length R of the winding connecting portion 20 of the reactor coil 10 according to this embodiment is a right angle as shown in FIG. While the length R 'of the winding connection portion 220 of the reactor coil 210 in the prior art is the length corresponding to the oblique side of the triangle, it is the sum of the lengths of the two sides sandwiching the right angle of the right triangle. It is apparent that the length of the winding connecting portion 20 of the reactor coil 10 according to the embodiment can be shortened as compared with the length of the winding connecting portion 220 of the reactor coil 210 in the prior art.

  FIG. 3 and FIG. 4 are diagrams for explaining a method of molding the reactor coil 10. As shown in FIG. In this method of molding reactor coil 10, as shown in FIGS. 3A to 3F and 4A to 4F, a winding jig 30 for the first coil element 11 is used. And winding jigs 40 for the second coil element 12 are used to wind the windings. The winding jig 30 and the winding jig 40 are pulley-like head members which can move in position. In each of FIGS. 3A to 3F, the flat wire 1 is omitted at the central portion.

As shown in FIG. 3A, a wire winding jig 30 for the first coil element 11 is used, using a long rectangular wire 1 long enough to wind the first coil element 11 and the second coil element 12; The winding jigs 40 for the second coil element 12 abut each other on the opposite surface of the flat wire 1.
The first coil element 11 is formed by winding the left portion in the drawing, and the second coil element 12 is formed by winding the right portion in the drawing.

  Next, as shown in FIG. 3B, in preparation of the first coil element 11, the left end of the flat wire 1 is bent 90 degrees in the arrow direction (clockwise direction) with the winding jig 30 as a fulcrum, And in preparation of the 2nd coil element 12, the winding jig 40 is used as a fulcrum, and the left end part of the rectangular wire 1 is bent 90 degrees in the arrow direction (clockwise direction).

  Next, as shown in FIG. 3C, each of the winding jig 30 and the winding jig 40 is arranged along the rectangular wire 1 by a predetermined distance (the length of the inner side of the short side of the rectangular tube shape). Move it inwards.

  Next, as shown in FIG. 3D, in forming the first coil element 11, the left end portion of the flat wire 1 is further bent 90 degrees in the arrow direction (clockwise direction) with the winding jig 30 as a fulcrum (The tip of the bending portion is parallel to the original flat wire 1), and in the preparation of the second coil element 12, with the winding jig 40 as a fulcrum, the right end of the flat wire 1 is in the arrow direction (clockwise) (Bent end is parallel to original flat wire 1).

  Next, as shown in FIG. 3 (E), the winding jig 30 and the winding jig 40 are respectively arranged along the rectangular wire 1 by a predetermined distance (the length of the inner side of the long side of the rectangular cylinder shape). Move to

  Next, as shown in FIG. 3 (F), in the preparation of the first coil element 11, the left end of the flat wire 1 is further bent 90 degrees in the direction of the arrow (clockwise) with the winding jig 30 as a fulcrum (The tip of the bent portion is bent by 270 degrees with respect to the original flat wire 1), and in the preparation of the second coil element 12, with the winding jig 40 as a fulcrum, The right end is bent 90 degrees in the direction of the arrow (clockwise) (the tip of the bent portion is bent by 270 degrees with respect to the original flat wire 1). As shown in FIG. 3F, in both of the first coil element 11 and the second coil element 12, the lead portions 11a and 12a are formed in a shape which is protruded from the rectangular tube shape.

When the above-described operation is repeated, as shown in FIG. 4A, each of the coil elements 11 and 12 is rotated by (n + 1/4) turns from the first stage, and the flat wire 1 is not wound. The length becomes shorter (one turn remains).

  After this, as shown in FIG. 4B, along the rectangular wire 1 by a predetermined distance (the length of the inner side of the short side of the rectangular tube shape), each of the winding jig 30 and the winding jig 40 Move it inwards.

Next, as shown in FIG. 4C, in forming the second coil element 12, the right end portion of the flat wire 1 is bent 90 degrees in the arrow direction (clockwise direction) with the winding jig 40 as a fulcrum.
At this time, the winding jig 40 is moved inward along the rectangular wire 1 by a predetermined distance (inside length of the long side of the rectangular cylinder shape).

  Next, as shown in FIG. 4D, in forming the second coil element 12, the right end portion of the flat wire 1 is bent 90 degrees in the arrow direction (clockwise direction) with the winding jig 40 as a fulcrum. At this time, the length of the flat wire 1 located between the coil elements 11 and 12 corresponds to the length of the winding connecting portion 20 finally located between the coil elements 11 and 12.

  Thereafter, as shown in FIG. 4E, the winding jig 40 is moved inward along the rectangular wire 1 by a predetermined distance (interior length of the rectangular tube short side).

  Finally, as shown in FIG. 4 (F), in the preparation of the first coil element 11, with the winding jig 30 as a fulcrum, the left end of the flat wire 1 is further 90 degrees in the arrow direction (clockwise). Bending by less than a predetermined angle θ, and in forming the second coil element 12, the predetermined angle of less than 90 degrees in the direction of the arrow (clockwise) with the winding jig 40 as a fulcrum Bend only θ. Bending (rotation) of these two coil elements 11 and 12 is performed with the flat wire 1 between the two coil elements 11 and 12 stretched.

As described above, in the method for forming a coil component according to the present embodiment, both coil elements 11 and 12 can be simultaneously formed by winding one flat rectangular wire 1 inwardly from both ends thereof, It is efficient. Moreover, with regard to the winding connection portion 20, even if this portion is not specially formed, the last extended portion left unwound in the rectangular wire 1 is configured to be the winding connection portion 20. Therefore, the manufacturing process can be simplified and the efficiency is extremely high.
Furthermore, in the winding connecting portion 20, the rectangular wire 201 needs to be bent 90 ° twice for two times in the above prior art, which may make it difficult to reduce the space in which the corner portion R is located. Although it may be prevented from making the elements 211 and 212 approach, in the coil component of this embodiment, since the bending angle of the flat wire 1 may be less than 90 °, it is easy to reduce the space where the corner R is located. As a result, it is easy to bring the two coil elements 211 and 212 close to each other, and the downsizing of the entire coil component can be promoted.

  The core part of the present invention and the method of molding the same are not limited to those of the above embodiment, but can be modified in various manners. In particular, the method of forming the core part according to the above-described embodiment is not limited to the forming method shown in FIGS. 3 and 4 and, for example, a long flat rectangular wire in the same direction from one end to the other end A method of sequentially forming the first core element, the winding connection portion, and the second core element during winding can also be adopted.

  Also, for example, in the coil component (reactor) of the above embodiment, as shown in FIG. 1, the first coil element 11 is wound counterclockwise from the back side to the front side of the paper surface, and The coil element 12 is also formed so as to be wound counterclockwise from the back side to the front side in the drawing.

On the other hand, as shown in a modification of FIG. 5 (the parts corresponding to the respective parts of the embodiment of FIG. 1 are represented by the reference numerals of the embodiment of FIG. 1 plus 100), the first coil element 111 The second coil element 112 may also be formed to be wound clockwise from the back of the paper surface to the front of the paper surface.
Further, the winding connecting portion 120 is linearly stretched from a first connecting end 111A located at the upper left in the drawing to a second connecting end 112A located at the lower right in the drawing.

In the above embodiment, the comparison of the length of the winding connecting portion with the above-described prior art is described using FIG. 2, but this modification is also described using FIG. 6. The comparison of the length of the winding connecting portion (the enlarged winding connecting portion (the winding connecting portion (straight line portion) plus this R portion before and after this) with the prior art will be described.
The description using FIG. 6 is different from the description using FIG. 2 in the point of comparison of the enlarged winding connecting portion, but the length of the winding connecting portion is compared with the prior art described above. The conclusion is that they can be shortened.

That is, the length of the enlarged winding connecting portion 120 a of the reactor coil 110 according to the present embodiment is the length A − of the flat rectangular wire 101 in the expanded winding connecting portion 120 a from the first coil element 111 to the second coil element 112. It is represented by A '.
The cross-sectional shape of the flat wire 101 is 1.0 mm × 6.0 mm, and the direct current resistance of the flat wire 101 specified by the wire manufacturer is 3.013 Ω / km (at 20 ° C.). And the boundary position of In addition, the inner method of each coil element 111, 112 in the longitudinal direction is 30 mm, the inner method in the short side direction is 20 mm, the distance between each coil element 111, 112 is 3 mm, and the inner diameter of the R portion of each coil element 111, 112 is 6 mm. I assume.
At this time, the length A-A 'of the enlarged winding connecting portion 120a is 48 mm, and the direct current resistance is 0.149 m ?.

On the other hand, the length of the enlarged winding connection portion 220a of the reactor coil 210 according to the prior art is the length B-B of the flat rectangular wire 201 in the expanded winding connection portion 220a from the first coil element 211 to the second coil element 212. It is represented by '.
As in the above modification, the cross-sectional shape of the flat wire 201 is 1.0 mm × 6.0 mm, and the DC resistance of the flat wire 201 specified by the wire manufacturer is 3.013 Ω / km (at 20 ° C.). Let 'be the boundary position between the straight part and the R part. Further, as in the above modification, the inner method of each coil element 211, 212 is 30 mm, the inner method of the short direction is 20 mm, the distance between each coil element 211, 212 is 3 mm, each coil element 211, 212 The inner diameter of the R portion of the is 6 mm.
At this time, the length B-B 'of the enlarged winding connecting portion 220a is 55 mm, and the direct current resistance is 0.171 m ?.

As a result, the direct current of the length A-A 'of the enlarged winding connection portion 120a of the reactor coil 110 according to the present modification and the length B-B' of the enlarged winding connection portion 220a of the reactor coil 210 according to the prior art The difference in resistance is 0.022 mΩ, and in this modification, the direct current resistance can be reduced by 12.7% as compared with the prior art.
Also, when a direct current of 20 A is supplied to the flat wire 101, 201,
Power consumption = square of current value × DC resistance, the power consumption between A and A ′ is 59.6 mW, and the power consumption between B and B ′ is 68.4 mW. The power consumption can be reduced by 8.8 mW as compared with the prior art.

In addition, the coil element of the coil component of the present invention is applicable regardless of the number of turns, and can also be applied to cases where the number of turns is extremely small (for example, one turn). Even if it exists, it shall be called "square tube shape".
In addition, although the reactor (coil component) according to the above embodiment shows one applied to a vehicle-mounted reactor, the coil component according to the present invention is not limited to vehicle-mounted but can be applied to various products. For example, it is possible to apply also to the reactor etc. which are used in a solar energy power generation panel.

DESCRIPTION OF SYMBOLS 1, 101, 201 Square wire 10, 110, 210 Reactor 11, 111, 211 1st coil element 11A, 111A, 211A 1st connection end 11C, 12C, 111C, 112C Side 11a, 12a, 111a, 112a , 211a, 212a lead part 12, 112, 212 second coil element 12A, 112A, 212A second connection end part 12B, 212B intersection point 15A, 15B, 215A, 215B straight line 20, 120, 220 winding connection part 30, 40 Winding jig 120a, 220a Expanded winding connection F Magnetic core

Claims (3)

The first and second coil elements are formed parallel to each other in a rectangular tube shape by laminating edgewise wound using a rectangular wire, and the corresponding one side sides are arranged along each other,
The first coil element is formed so as to wind and laminate the flat wire from one end side of one flat wire, and the second coil element is formed by the single flat wire. The flat wire is formed so as to be wound and laminated in the same lamination direction in the same winding direction as the first coil element from the other end side of
In the final turn of the first coil element, the end on one side of the side of the first coil element serves as a first coupling end, and in the final turn of the second coil element, the second The other end of the side of the coil element is a second connection end, and a flat wire is linearly formed between the first connection end and the second connection end. A coil component characterized by comprising a wound wire connecting portion.   The coil component according to claim 1, wherein the flat wire in the winding connection portion is included in one plane. A first coil element forming step of forming the first coil element into a rectangular tube shape by laminating the rectangular wire by edgewise winding from one end of the rectangular wire using one rectangular wire; Simultaneously or sequentially performing a second coil element forming step of forming a second coil element into a rectangular tube shape by laminating the rectangular wire by edgewise winding from the other end of the rectangular wire;
Thereafter, in a state where the first and second coil elements are arranged in parallel so that one side of the corresponding two elements is parallel to each other, the side of the first coil A flat wire stretching step of linearly stretching the flat wire between an end on one side and an end on the other side of the side portion of the second coil element Part molding method.

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