JPH09260175A - Coil part and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable automation of bending and winding works of a flat strip conductor and enable stabilization of its shape and quality. SOLUTION: A series of operations such as tip end clamping of flat conductor 1 with respect to a winding spindle, bending of a lead part 45 as a winding start part, winding thereof by a predetermined number of turns and bending of a lead part 46 as a winding end part are carried out without reholding the flat conductor 1, whereby the flat conductor 1 is wound as overlapped on its wide face to form a wound cylinder 42, with a lead part 45 extended from an inner peripheral fold 43 located inside of the cylinder 42 in a first direction nearly parallel to an axial direction of the cylinder 42, and also with a lead part 46 extended from an outer peripheral fold 44 located outside of the cylinder 42 in a second direction nearly parallel to the axial direction of the cylinder 42 and opposite to the first direction.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil component in which a rectangular conductor wire (rectangular wire) is wound, which is suitable for use in a small-sized inductance element having a large current capacity, a transformer, and the like, and a manufacturing method thereof.

[0002]

20 and 21 are a perspective view and a plan view showing a conventional coil component using a rectangular conductor wire. In this coil component, a flat conductor wire 1 whose surface is insulated is wound in a cylindrical shape so that a wide surface forms a circumferential surface and overlaps with each other to form a cylindrical wound body 2. The folded portions 3 and 4 are formed and the lead portions 5 and 6 are drawn out in the same direction.

22 and 23 are a perspective view and a plan view showing a state in which lead parts 5 and 6 drawn out in the same direction are further bent in order to be incorporated in a magnetic material case such as ferrite. The same parts as those in FIGS. 20 and 21 are designated by the same reference numerals.

FIG. 24 is an exploded front sectional view showing an example of a coil device incorporating a coil component in which the lead portions 5 and 6 are bent as shown in FIGS. 22 and 23. Reference numeral 10 denotes the coil component described above. The coil component 10 is housed in a magnetic material case 11 such as ferrite, and the middle leg core 12 that is a magnetic material such as ferrite is inserted on the inner peripheral side of the coil component.
Further, the coil device is constructed by covering the upper opening of the magnetic material case 11 with a lid core 13 of a magnetic material such as ferrite to close the opening.

A method of manufacturing the above-mentioned conventional coil component will be described with reference to FIGS. First, the flat wire 1 whose surface is insulated from the wire supply bobbin (tension bobbin) of the winding device is pulled out as shown in FIG. 25, and the first bending is performed using the bending jig 15 as shown in FIG. I do. This first bending is performed in advance before the rectangular conductor 1 is clamped on the winding spindle 20 described in FIG. Then, as shown in FIG. 27, the outer shaft portion 21
And concentrically with it, protruding axially from its tip,
Also, the winding spindle 20 including the outer shaft portion 21 and the shaft center portion 22 that rotates integrally with the outer shaft portion 21 is used, and the folded tip portion of the rectangular conductor wire 1 is clamped by the clamping means to the flat clamp portion 23 of the outer shaft portion 21. Yes (clamp the shaded area). Then, as shown in FIG. 28, the winding spindle 20 is rotated a predetermined number of times to form the cylindrical wound body 2 having a predetermined number of turns. Then, as shown in FIG. 29, the clip 2 for the presser foot
5, the outer circumference of the cylindrical wound body 2 is clamped, taken out from the winding spindle 20, placed in an oven as it is and heated, and is fixed in a wound state by utilizing the heat fusion property of the insulating coating of the rectangular conductor 1. . Then, as shown in FIG. 30, the cylindrical wound body 2 is taken out of the oven, the clip 25 is removed, and the bending jig 15 is used again for bending. Thus, the winding process is completed, and the conventional coil component shown in FIGS. 20 and 21 is obtained.

[0006]

By the way, when considering the automation of the bending and winding work of the lead part of the coil component wound with this type of rectangular conductor wire, (1) the bending and winding work are continuously performed. It is necessary that (2) the bending and winding operations be as simple as possible, and (3) the shape and quality of the bent and wound coil components be stable.

However, the conventional coil component and the manufacturing method thereof are not satisfied with respect to (1) to (3) in the following points. That is, as shown in FIGS. 26 and 27, the method of first folding the folded-back portion 3 of the winding start side lead portion 5 of the rectangular conductor 1 and then grasping it by the clamp portion 23 of the winding spindle 20 is shown in FIGS. As shown in 32, it is necessary to change the holding pattern. That is, first, the diagonal line portion A behind the folded-back portion 3 of the rectangular conductor 1 is grasped by the wire chuck and moved to the clamp portion 23 of the winding spindle 20,
After that, since the lead portion 5 at the tip of the folded-back portion 3 is clamped and held by the clamp portion 23, there is a problem in that the clamp position varies due to holding (positional deviation in the X and Y directions in FIG. 32). Therefore, the setting of the rectangular conductor 1 on the winding spindle 20 is not stable.) Further, since the tip of the lead portion 5 of the flat conductor wire 1 cannot be pulled, a defective clamp may occur. Further, there is a problem in that the length of the lead portion 5 on the winding start side cannot be made too long (because tension is not applied to the portion beyond the wire chuck when held by the winding spindle 20).

FIGS. 33 (A) to 33 (D) show in detail the method of forming the lead portion 5 (or 6) at the winding start (or winding end) of the rectangular conductor 1, and FIG.
After pulling out as shown in (A), the oblique edge 15a of the bending jig 15 is applied onto the rectangular wire 1 as shown in (B), and tension is applied as shown in (C). While changing the direction of the rectangular conductor 1, the bending jig 15 is removed as shown in FIG. 3D, the folded portion 3 is squeezed, and the lead portion 5 is formed so as to be bent properly. All the operations shown in FIGS. 33 (A) to (D) are performed by hand. For accurate bending, the bending jig 15 is correctly applied to a predetermined position of the rectangular conductor 1, and tension is applied. Since it is necessary to move the rectangular conductor 1 while it is being hung, a problem arises in that the mechanism becomes complicated when attempting automation.

Further, as shown in FIG. 34, after the lead portion 5 is formed by folding back the flat conducting wire 1 on the winding start side, it is wound once and overlapped with the end portion of the folding portion 3 (dotted line circle B in the figure).
(Inside), the insulating coating of the flat conductor wire 1 of the second layer may be damaged. For this reason, as shown in FIG. 35, the insulating tape 30 has been attached to the folded-back portion 3 portion which comes into contact with the flat conductor wire second layer. However, since the insulating tape 30 is attached to the folded-back portion 3, it is difficult to attach due to the unevenness. There was also a problem of protruding from the width of the flat conductor wire 1.

A first object of the present invention is to provide a coil component capable of automatically bending and winding a rectangular conductor and stabilizing its shape and quality.

A second object of the present invention is that the bending and winding operations of the flat conductor wire are simple, and that the bending and winding operations can be performed continuously, and the shape and quality of the coil parts are stabilized by automation. Another object of the present invention is to provide a method of manufacturing a coil component that can achieve the above.

Other objects and novel features of the present invention will be clarified in embodiments described later.

[0013]

In order to achieve the above object, the coil component of the present invention has a tubular shape in which a rectangular conductor wire whose surface is insulated and coated is wound so that the wide surfaces overlap with each other so as to form a peripheral surface. A first winding member that constitutes a winding body and is substantially parallel to the axial direction of the tubular winding body by an inner peripheral side folding portion on the inner peripheral side of the cylindrical winding body.
On the outer peripheral side of the tubular winding body, the lead portion is formed in the direction of, and the outer peripheral side folded-back portion is substantially parallel to the axial direction of the cylindrical winding body and is on the side opposite to the first direction. The lead portion is formed in the direction of 2.

In the coil component, an insulating tape may be attached to a wide surface portion on the inner peripheral side of the flat conductor which faces the inner folded portion.

The method of manufacturing the coil component of the present invention is
Using a winding spindle composed of an outer shaft portion and a shaft core portion that projects in the axial direction from the tip of the outer shaft portion and rotates integrally with the outer shaft portion, a flat conductor wire whose surface is insulated After being clamped at the shaft portion, the winding conductor is swung by the winding guide to a direction perpendicular to the axial direction of the winding spindle and pulled, and the winding spindle is rotated at a predetermined rotation angle of one rotation or less. Only by rotating, the folded portion of the rectangular conductor is pressed against the outer periphery of the shaft core portion by a pressing member to form an inner peripheral folded portion, and thereafter, the winding spindle is rotated by a predetermined number of turns and then stopped. In this stopped state, the outer periphery of the tubular winding body formed by winding the flat conductor wire around the outer periphery of the shaft core is pressed by the winding pressing member, and then the flat conductor wire is swung by the winding guide to move the flat conductor wire. Is characterized in that to form the outer peripheral side folded portion against the said tubular winding body periphery of a member pushed against the folded portion of the conductor.

In the method for manufacturing the coil component, the insulating coating has a coating of a heat-fusible substance, and hot air is blown onto the cylindrical winding body after forming the outer peripheral side folded portion, and the rectangular conductor wire is formed. May be fixed in a wound state. Alternatively, the insulating coating may have a coating of a fusible substance that is melted by a solvent, and it is also possible to fix the rectangular conductor in a wound state by pre-adhering the solvent on the payout side of the rectangular conductor. is there.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of a coil component and a manufacturing method thereof according to the present invention will be described below with reference to the drawings.

1 to 3 show an embodiment of a coil component of the present invention. FIG. 1 is a perspective view thereof, FIG. 2 is a front view thereof, and FIG. 3 is a plan view thereof. As shown in these drawings, the coil component 40 has a structure in which a flat conductor wire 1 is wound, and the flat conductor wire 1 is a flat metal wire (strip-shaped metal body) such as copper whose surface is coated with an insulating coating. The insulating coating has a coating of a heat-fusible substance that melts with heat and is called a so-called cement wire. The heat-fusible substance is, for example, an adhesive resin that is melted by heat or a solvent. Then, the rectangular conductor 1 is formed into a cylindrical shape by winding the flat conductor 1 in a cylindrical shape so that the wide surfaces form a circumferential surface and overlap each other. The flat conductor 1 is formed on the inner peripheral side of the cylindrical conductor 42. 4 for the edge of
The lead portion 45 is formed in the first direction parallel to the axial direction of the cylindrical wound body 42 by the inner circumferential side folded portion 43 forming 5 degrees, and the flat angle is formed on the outer peripheral side of the cylindrical wound body 42. The lead portion 46 is arranged in the second direction, which is parallel to the axial direction of the cylindrical wound body 42 and is opposite to the first direction, by the outer peripheral side folded portion 44 forming 45 degrees with respect to the edge of the conductor wire 1. Is forming. The shape of the cylindrical wound body 42 can be fixed by melting the heat-fusible substance coated on the insulating coating with hot air to fix the respective layers of the flat rectangular conductive wire 1 to each other.

4 to 6 are perspective views and front views showing a state in which lead parts 45 and 46 folded back in mutually opposite directions are further bent in order to be incorporated in a magnetic material case such as ferrite. , And a plan view, respectively. In this case, the inner and outer fold-back portions 43, 44
Lead portions 45, which are pulled out in opposite directions by
Further, 46 is formed by bending in the extending direction of the diameter of the cylindrical wound body 42.

FIG. 7 shows the lead portion 4 as shown in FIGS.
FIG. 5 is a front cross-sectional view showing an example of a coil device that incorporates a coil component obtained by bending 5 and 46. The coil component 40 described above is housed in the magnetic body case 11 such as ferrite, the middle leg core 12 that is a magnetic body such as ferrite is inserted on the inner peripheral side of the coil component, and the upper opening of the magnetic body case 11 is further inserted. The coil device is configured by covering and closing the lid core 13 made of a magnetic material such as ferrite.

A method of manufacturing the coil component 40 will be described with reference to FIGS.

First, as shown in FIG. 8, for a winding wire composed of an outer shaft portion 51 and a shaft core portion 52 axially projecting from the tip of the outer shaft portion 51 and rotating integrally with the outer shaft portion 51. Using the spindle 50, the rectangular conductor 1 whose surface is insulated (coated with a heat-fusible substance) is parallel to the axial direction of the winding spindle 50 from a wire rod supply bobbin (tension bobbin) of the winding device. Pull out to the outside shaft part 5
Clamp at 1. That is, the flat conducting wire 1 is clamped on the flat clamp portion 51a of the outer shaft portion 51 by a clamp means (not shown) (the diagonal line portion is clamped). The tension is always applied as indicated by the arrow in the figure.

Then, while the winding spindle 50 is stopped, as shown in FIG. 9, the winding conductor 53 is turned 90 degrees as shown by an arrow C, so that the rectangular conductor 1 is attached to the winding spindle 20. Rotate with tension applied from the state parallel to the axial direction to the direction perpendicular to the axial direction.
The state is 0.

Similar to the turning of the winding guide 53,
Alternatively, after turning, the winding wire spindle 50 is rotated 90 degrees as shown in FIG. 11 in a state in which the flat conductor wire 1 is pulled to form a portion 43a where the flat conductor wire 1 is folded back, and as shown in FIG. The pressing member 54 having a curved concave surface corresponding to the outer peripheral surface on the tip surface presses the folded-back portion 43a of the rectangular conductor wire 1 (the portion to be the inner-circumferential-side folded-back portion 43 in FIG. 1) against the outer circumference of the shaft core portion. 45 for the edge of 1
The inner peripheral side turn-back portion 43 of FIG.

Thereafter, as shown in FIG. 13, the winding spindle 50 is rotated by a predetermined number of turns to produce the cylindrical wound body 42. Before that, the cylindrical wound body 42 is opposed to the tip end surface of the shaft core portion 52. The winding retainer 57 having an annular tip surface advances from the side as shown by the arrow and fits on the outer periphery of the shaft core portion 52 to be slightly larger than the width of the rectangular conductor 1 with respect to the tip surface of the outer shaft portion 51. Oppose at intervals. The winding retainer 57 is for preventing displacement in the front-rear direction when the rectangular conductor 1 is wound, and the forward end position of the winding retainer 57 is defined by a stopper (not shown). Adjustable according to the line width of the rectangular conductor. The winding spindle 5
When the cylindrical winding body 42 is obtained by rotating 0 for a predetermined number of turns, the winding spindle 50 is stopped, and in this stopped state, the rectangular conductor 1 is wound around the outer periphery of the shaft core portion 52. As shown in FIG. 14, the winding presser member 55 having a curved concave surface is pressed against the outer periphery of the formed cylindrical wound body 42. As shown in FIG. 14, while the flat wire 1 is kept pressed by the winding holding member 55, the flat wire 1 is swung by the winding guide until it becomes parallel to the axial direction of the winding spindle 20. As a result, the folded portion 44a of the flat conductor wire 1 is made. The winding presser member 55 can rotate integrally with the winding spindle 50.

After that, as shown in FIG. 16, the winding presser member 55 and the winding spindle 50 are rotated 90 degrees, and the pressing member 56 having a curved concave surface at its tip surface presses the flat portion 1 of the rectangular conductor wire 44a (FIG. 1). 1) is pressed against the outer periphery of the cylindrical winding body to form the outer peripheral side folded portion 44 of FIG. 1 forming 45 degrees with respect to the edge of the rectangular conductor 1. By forming two types of curved concave surfaces having different degrees of curvature on the pressing member 54 in FIG. 12, the pressing member 54 can also be used as the pressing member 56 used here.

In the state of FIG. 16, hot air is blown against the cylindrical wound body 42 by hot air generating means (air heater) (not shown) to melt the heat fusible substance coated on the insulating coating of the rectangular conductor 1. Each layer of the rectangular conductor 1 of the cylindrical wound body 42 is fixed in a wound state. This hot air blowing is
It continues for a while after the formation of the outer peripheral folded portion.

After that, the rectangular conductor wire 1 is cut while leaving the portion to be the lead portion 46, the clamp on the winding start side and the pressing of the winding pressing member 55 are released, and the completed coil component is discharged.

If the wire feeding side of the rectangular conductor 1 is held by a wire chuck in advance before cutting, it is possible to immediately shift to the step of clamping the winding spindle 50 in FIG. That is, as shown in FIG. 1, when the lead portion 45 and the lead portion 46 of the coil component 40 are in mutually opposite directions, the direction of drawing out the flat conductor 1 of the lead portion 46 on the winding end side (FIG. 16) and the next coil Since the drawing direction of the rectangular conductor 1 at the beginning of winding the component (FIG. 8) is the same, the coil component can be continuously manufactured.

If there is a possibility that the insulating coating may be damaged at the position where the inner peripheral side turn-back portion 43 of the coil component 40 and the inner side of the flat conductor wire of the second layer come into contact with each other, in order to solve this, an embodiment of the present invention is provided. In FIG. 1, in the stage before the bending by the winding spindle 50 and the winding process, the portion on the inner side of the second layer that comes into contact with the folded-back portion 43 on the winding start side is shown in FIG.
7, the insulating tape 60 is attached by using the jig 61 provided on the side for feeding the flat conductor wire to the winding spindle. That is, as shown in FIG. 18, the attachment position of the insulating tape 60 is the wide surface portion on the inner peripheral side of the flat conductor wire 1. When the tip of the flat conductor wire 1 is set on the spindle for winding and bent, the winding process is performed. In addition, as shown in FIG. 19, the insulating tape 60 is just in contact with the inner peripheral side bent portion 43.

According to the first embodiment, the following effects can be obtained.

(1) In the coil component 40, the flat conductor wire 1 whose surface is insulated and coated is wound so that the wide surface forms a peripheral surface and overlaps with each other to form a cylindrical wound body 42. Since it is a structure using 1, the size can be reduced and the current capacity can be increased. Further, on the inner peripheral side of the cylindrical wound body 42, the inner peripheral side turnback portion 43 forming 45 degrees with respect to the edge of the rectangular conductor 1 leads in the first direction parallel to the axial direction of the cylindrical wound body 42. The portion 45 is formed, and on the outer peripheral side of the cylindrical wound body 42, the outer peripheral side folded-back portion 44 forms 45 degrees with respect to the edge of the rectangular conductor 1.
The lead portion 46 is formed in the second direction which is parallel to the axial direction of the two and is opposite to the first direction, and has a structure suitable for automation of winding, and has a large number of coil components 40. The production (bending, winding) can be continuously performed.

(2) In manufacturing the coil component 40, the tip of the rectangular conductor 1 is clamped to the winding spindle 50, the winding start side lead portion 45 is bent, the winding is performed a predetermined number of times, and the winding end side lead portion 46 is bent. Since a series of operations leading to formation can be performed without changing the holding of the rectangular conductor 1, the shape and quality of the coiled coil component 40 is stable (there is no trouble due to changing the holding, the bending position is accurate, etc.).

(3) In the manufacture of the coil component 40, it is possible to easily bend the rectangular conductor wire 1 in a predetermined direction and position by changing the feeding direction, so that the mechanism for bending becomes simple.

(4) In the manufacture of the coil component 40, the fact that the insulating coating of the rectangular conductor 1 has a coating of a heat-fusible substance is used, and after the outer peripheral side turn-back portion 44 is formed, hot air is blown into the cylinder. Each layer of the rectangular conductor can be fixed in a wound state by spraying the coiled body 42.

(5) The insulating tape 60 for preventing a short circuit can be easily attached, and the insulation performance can be easily improved.

In the above-described embodiment, the axial core portion 52 of the winding spindle 50 has a circular columnar shape in cross section, but it has an elliptic cylindrical shape with an oval cross section, an elliptic cylindrical shape with an elliptical cross section, and a polygonal cylindrical shape. A rounded polygonal column with rounded corners may be used. Further, the shaft core portion 52 may be a winding frame (bobbin) itself made of resin or the like held by the outer shaft portion 51.

Further, in the above-described embodiment, the inner circumferential side turn-back portion 43 and the outer circumferential side turn-back portion 44 which form 45 degrees with respect to the edge of the rectangular conductor 1 are formed, and the cylindrical winding body 42 is oriented in the opposite direction. The lead portions 45 and 46 are formed in the axial direction of
Not limited to this, by changing the turning angle of the flat conductor wire 1 when forming the folded portion, the lead-out direction of the lead portion 45 and the lead portion 46 can be slightly changed with respect to the axial direction of the cylindrical winding body 42. . Further, the case where the rotation angle of the winding spindle 50 that is performed after the flat rectangular wire 1 is rotated when forming the inner peripheral side folded-back portion 43 is 90 degrees has been exemplified.
It is possible to set an appropriate rotation amount of one rotation or less (however, it is approximately 9
It can be said that around 0 degrees is preferable. ).

Further, in the above-described embodiment, hot air is blown to the cylindrical wound body 42 to melt the heat-fusible substance coated on the insulating coating of the rectangular conductor 1 to form the cylindrical wound body 42. Although fixed, a solvent is used instead of hot air to melt the fusible substance (adhesive resin or the like) coated on the insulating coating of the rectangular conductor 1 to wind each layer of the rectangular conductor 42 of the cylindrical winding body 42. It is also possible to fix them in a rotating state.
In this case, a solvent is attached to the rectangular conductor on the pay-out side of the rectangular conductor 1 (wet the solvent), and the tip end clamp of the rectangular conductor 1 to the winding spindle 50 and the winding start side in the solvent adhered state. Bending of the lead portion 45,
A series of operations up to a predetermined number of windings and bending of the winding end side lead portion 46 may be performed.

Although the embodiments of the present invention have been described above, it is obvious to those skilled in the art that the present invention is not limited to the embodiments and various modifications and changes can be made within the scope of the claims. There will be.

[0041]

As described above, according to the coil component of the present invention, a rectangular winding wire having a surface insulated by winding is wound so that the wide surfaces form a circumferential surface and overlap each other. In addition, since the structure uses the rectangular conductor, the size can be reduced and the current capacity can be increased. Further, on the inner peripheral side of the tubular winding body, the lead portion is formed in the first direction substantially parallel to the axial direction of the tubular winding body by the inner peripheral side folded portion, and the tubular winding body is formed. On the outer peripheral side, the outer peripheral side folded portion forms a lead portion in a second direction substantially parallel to the axial direction of the tubular winding body and opposite to the first direction. The structure is suitable for automation, and it is possible to continuously manufacture (bending, winding) many coil parts.

Further, in the manufacture of the above coil component,
A series of operations including clamping of the tip of a rectangular wire to the winding spindle, bending formation of the winding start side (inner circumference side) lead part, winding a predetermined number of times, bending formation of the winding end side (outer circumference side) lead part, Since it can be executed without changing over the holding of the rectangular conductor wire, the shape and quality of the wound coil component can be stabilized. In other words, there is an advantage that there is no trouble caused by changing the handle and the bending position becomes accurate. In addition, since the lead portion can be easily formed by bending the flat conductor wire in a predetermined direction and position by changing the feeding direction of the flat conductor wire, there is an advantage that the bending mechanism is simple.

[Brief description of drawings]

FIG. 1 is a perspective view showing a coil component in a completed state according to an embodiment of the present invention.

FIG. 2 is a front view of the same.

FIG. 3 is a plan view of the same.

FIG. 4 is a perspective view showing a coil component in which a lead portion is further bent for incorporation in a magnetic body case.

FIG. 5 is a front view of the same.

FIG. 6 is a plan view of the same.

FIG. 7 is a front sectional view showing an example of a coil device accommodating the coil component according to the embodiment.

FIG. 8 is a perspective view showing a state in which the tip end of the rectangular conductor wire is clamped in the method for manufacturing the coil component according to the embodiment.

[FIG. 9] Similarly, after clamping the rectangular conductor, 9
It is a perspective view which shows the process of making it rotate 0 degree.

FIG. 10 is a perspective view of the flat conductor wire after turning.

FIG. 11 is a perspective view showing a state in which the winding spindle is also rotated 90 degrees.

FIG. 12 is a perspective view showing a process for forming an inner peripheral side turnback portion of the flat conductor wire.

FIG. 13 is a perspective view showing a process of manufacturing a cylindrical wound body by winding a rectangular conductor wire a predetermined number of times.

FIG. 14 is a perspective view showing a state where the outer periphery of the cylindrical wound body is pressed by a winding pressing member.

FIG. 15 is a perspective view showing a state in which a rectangular wire has been swung to form an outer peripheral folded portion.

FIG. 16 is a perspective view showing a process for forming an outer peripheral side folded portion in the same manner.

FIG. 17 is a perspective view showing a step of attaching an insulating tape for securing insulation to an expected position of the rectangular conductor wire.

FIG. 18 is a plan view showing a position where the insulating tape is attached to the rectangular conductor.

FIG. 19 is a perspective view showing the position of the insulating tape when the flat conductor wire is wound once.

FIG. 20 is a perspective view showing a conventional coil component.

FIG. 21 is a plan view of the same.

FIG. 22 is a perspective view showing a conventional coil component in which a lead portion is further bent for incorporation in a magnetic body case.

FIG. 23 is a plan view of the same.

FIG. 24 is a conventional coil device that houses a coil component.
It is a disassembled front sectional view which shows an example.

FIG. 25 is a plan view showing a state in which a rectangular conductor has been pulled out in the conventional coil component manufacturing method.

FIG. 26 is a plan view showing a process of bending the flat conductor wire with a jig to form an inner peripheral side folded portion.

FIG. 27 is a perspective view showing a state where the tip of the lead portion is clamped to the winding spindle in the same manner.

FIG. 28 is a perspective view showing a process of manufacturing a cylindrical wound body by winding the rectangular conductor wire a predetermined number of times.

FIG. 29 is a perspective view showing a state in which the outer periphery of the cylindrical wound body is also held by a winding press clip.

FIG. 30 is a perspective view showing a process of forming the outer peripheral folded-back portion with a jig.

FIG. 31 is a perspective view illustrating a step of holding the flat rectangular wire in a conventional method for manufacturing a coil component.

FIG. 32 is a perspective view for explaining the positional displacement of the tip end of the rectangular conductor wire when the rectangular conductor wire is changed.

FIG. 33 is an explanatory diagram of a bending step for forming a folded portion of a rectangular conductor wire in a conventional method for manufacturing a coil component.

FIG. 34 is a perspective view showing a damaged portion of an insulating film of a rectangular conductor wire in a conventional coil component manufacturing method.

FIG. 35 is a perspective view showing an insulating tape attaching position in the same manner.

[Explanation of symbols]

 1 Flat conductor wire 2,42 Cylindrical winding body 3,4,43,44 Folding part 5,6,45,46 Lead part 10,40 Coil component 15 Bending jig 20,50 Winding spindle 21,51 Outside Shaft part 22,52 Shaft core part 30,60 Insulating tape 54,56 Pressing member 55 Winding pressing member

Claims (5)

[Claims] 1. A cylindrical winding body is constructed by winding a flat conductor wire whose surface is covered with insulation so that the wide surfaces form a circumferential surface and overlap each other, and at the inner circumference side of the cylindrical winding body. A lead portion is formed in the first direction substantially parallel to the axial direction of the tubular winding body by the inner peripheral side folding portion, and the outer peripheral side folding portion forms the tubular winding portion on the outer peripheral side of the tubular winding body. A coil component, wherein a lead portion is formed in a second direction that is substantially parallel to the axial direction of the revolving body and is opposite to the first direction. 2. The coil component according to claim 1, wherein an insulating tape is attached to a wide surface portion on the inner peripheral side of the rectangular conductor which faces the inner folded portion. 3. A winding spindle comprising an outer shaft portion and a shaft core portion axially protruding from the tip of the outer shaft portion and rotating integrally with the outer shaft portion, the surface of which is insulated and coated. After the flat wire is clamped by the outer shaft portion, the flat wire is turned by the winding guide to a direction perpendicular to the axial direction of the winding spindle and the winding spindle is rotated once while being pulled. Rotate by the following predetermined rotation angle, press the folded portion of the flat conductor wire against the outer circumference of the shaft core by a pressing member to form an inner circumferential folded portion, and then rotate the winding spindle by a predetermined number of turns. Then, in this stopped state, the outer periphery of the cylindrical winding body formed by winding the flat conductor wire around the outer periphery of the shaft core portion is pressed by the winding presser member, and then the flat conductor wire is wound by the winding guide. Turning Then, the folded portion of the flat conductor wire is pressed against the outer periphery of the cylindrical winding body by a pressing member to form an outer peripheral folded portion, the method for manufacturing a coil component. 4. The insulating coating has a coating of a heat-fusible material, and after the formation of the outer peripheral side folded portion,
The method for manufacturing a coil component according to claim 3, wherein hot air is blown onto the tubular winding body to fix the rectangular conductor wire in a wound state. 5. The insulating coating has a coating of a fusible substance that is melted by a solvent, and the solvent is attached on the payout side of the rectangular conductor to fix the rectangular conductor in a wound state. The method for manufacturing the coil component according to claim 3.