Coil arrangement and method of manufacturing the same

Abstract

Provided is a coil device in which a terminal portion for external connection is optimized in structure or the like, and a manufacturing method thereof. The coil device (10) includes a coil (12) composed of a wire wound to form a winding portion (17), a core (11) having the winding portion (17) in which the coil (12) is wound, a base (13) that fixes the core (11), and a terminal portion (19) that is electrically connected to the coil (12). Further, the terminal portion (19) has a first front side terminal portion (191) or the like that is connected to a lower end (124) or the like of the coil (12) and disposed on a front side, and a first rear side terminal portion (193) or the like that is connected to an upper end (123) or the like of the coil (12) and disposed on a rear side. Furthermore, the first front side terminal portion (191) or the like and the first rear side terminal portion (193) or the like differ in length.

Description

Technical Field

[0001] This invention relates to a coil device and a method for manufacturing the same, and particularly to a coil device and a method for manufacturing the same having a terminal portion for external connection. Background Technology

[0002] In the past, coil devices were used as electronic components such as noise filters.

[0003] FIG. 8 (A) is an exploded perspective view showing the structure of the noise filter 100 described in Patent Document 1. FIG. 8 (B) is a three-dimensional view showing the structure of the noise filter 100.

[0004] Reference FIG. 8 (A) and FIG. 8 (B) The noise filter 100 has a base 102, a magnetic core 101 fixed on the base 102, and windings 104 wound on the magnetic core 101. Here, two windings 104 are wound on the magnetic core 101.

[0005] like FIG. 8 As shown in (A), the lower end 105 is formed by shaping the area near the lower end of the winding 104 into a straight line, and the upper end 106 is formed by shaping the area near the upper end of the winding 104 into a straight line.

[0006] Four conductive pins 103 are arranged at the four corners of the lower end of the base 102. The conductive pins 103 are used as terminals when mounting the noise filter 100.

[0007] The magnetic core 101 is fixed to the base 102 in a flat, upright wound state as a flat wire winding 104. Furthermore, the lower end 105 is brazed to a conductive pin 103 disposed on the front side of the base 102. Conversely, the upper end 106 is brazed to a conductive pin 103 disposed on the rear side of the base 102.

[0008] Patent Document 1: Japanese Patent Application Publication No. 2019-110186 Summary of the Invention

[0009] The problem that the invention aims to solve

[0010] However, from the viewpoint of its structure and manufacturing method, there is room for improvement in the noise filter 100 with the above-described structure.

[0011] Specifically, such as FIG. 8(B) shown, the length differs between the lower end portion 105 and the upper end portion 106 which are the ends of the wire 104. That is, the upper end portion 106 which is led from the upper end of the wire 104 to the lower side is formed longer than the lower end portion 105. Due to this, the leading process and the like of the upper end portion 106 is not simple.

[0012] Further, in order to make the longer upper end portion 106 linear, a forming work of uncoiling the wire 104 which is bent in a circular arc shape is required, and there is a problem that the manufacturing process becomes complicated and the manufacturing cost rises.

[0013] Furthermore, the temporary connection of the upper end portion 106 and the lower end portion 105 to the conductive needle 103 is performed by winding, but there is a problem that the work of winding the flat wire to the conductive needle 103 is not simple.

[0014] The present application has been made in view of the above circumstances, and an object thereof is to provide a coil device and a manufacturing method thereof in which the structure of a terminal portion for external connection and the like is optimized.

[0015] Means for solving the problem

[0016] Hereinafter, technical solutions of the present application made to solve the above problem are described. In addition, the constituent elements employed in each of the technical solutions described below can be employed in any combination as much as possible. Further, the technical solutions or features of the present application are not limited to those described below, but are identified based on the ideas of the present application described throughout the specification and the drawings, or which can be grasped by those skilled in the art from these descriptions.

[0017] The first technical solution of the present application regarding a coil device has: a coil having a coil portion composed of a wire wound; a core having a winding portion in which the coil is wound; a base which fixes the core; and a terminal portion which is electrically connected to the coil; the terminal portion has a front side terminal portion connected to a lower end of the coil and disposed on a front side, and a rear side terminal portion connected to an upper end of the coil and disposed on a rear side; and the front side terminal portion and the rear side terminal portion differ in length.

[0018] Further, in another technical solution of the present application regarding a coil device, the base has a pedestal and a back panel; the core is fixed to the pedestal along the back panel; and the length from the coil portion of the coil to the upper end of the rear side terminal portion is less than half of the outer circumference of the coil portion of the coil.

[0019] Further, in another technical solution of the present application regarding a coil device, the rear side terminal portion is inserted inside the back panel of the base.

[0020] Further, in another aspect of the present invention regarding the coil device, the winding portion is formed in a straight line shape; and the coil is formed by winding a flat wire in a flat vertical manner.

[0021] Further, in another aspect of the present invention regarding the coil device, the terminal portion has a vertical portion and a horizontal portion; and the end of the coil is inserted between the horizontal portion and the base.

[0022] Further, in another aspect of the present invention regarding the coil device, the horizontal portion of the terminal portion faces the back panel of the base.

[0023] Further, in another aspect of the present invention regarding the coil device, the core is a closed magnetic core having a first winding portion and a second winding portion formed in a straight line shape without a joint; the coil has a first coil wound on the first winding portion and a second coil wound on the second winding portion in a direction opposite to the first coil; the front-side terminal portion has a first front-side terminal portion connected to a lower end of the first coil and a second front-side terminal portion connected to a lower end of the second coil; and the rear-side terminal portion has a first rear-side terminal portion connected to an upper end of the first coil and a second rear-side terminal portion connected to an upper end of the second coil.

[0024] Further, the first aspect of the present invention regarding a manufacturing method of a coil device is a method of manufacturing a coil device having a coil having a coil portion formed by winding a wire, a core having a winding portion in which the coil is wound, a base fixing the core, and a terminal portion electrically connected to the coil, the terminal portion having a front-side terminal portion connected to a lower end of the coil and disposed on a front side, and a rear-side terminal portion connected to an upper end of the coil and disposed on a rear side, the front-side terminal portion and the rear-side terminal portion being different in length, the method including a step of preparing the core in which the coil is wound and the base in which the front-side terminal portion and the rear-side terminal portion are fitted; a step of fitting the core to the base; and a step of electrically connecting the front-side terminal portion and the rear-side terminal portion to the coil.

[0025] Effects of the Invention

[0026] According to the coil device of the present invention, by making the front-side terminal portion and the rear-side terminal portion different in length, and by extending the terminal portion formed longer to the end of the coil, the connection reliability of the front-side terminal portion and the rear-side terminal portion to the end of the coil can be improved.

[0027] According to the coil device of the present application, by making the length of the upper end of the coil be less than half the outer circumference of the coil portion, the upper end can be shortened, and the forming work for unwinding the upper end of the coil can be eliminated.

[0028] According to the coil device of the present application, by inserting the rear-side terminal portion inside the back panel of the base, the relatively long rear-side terminal portion can be protected by the back panel.

[0029] According to the coil device of the present application, the end of the coil formed by flat-to-stand winding of a flat wire can be easily connected to the terminal portion, and the connection reliability of the end of the coil to the terminal portion can be improved.

[0030] According to the coil device of the present application, by inserting the end of the coil between the horizontal portion of the terminal portion and the base, the end of the coil can be easily connected to the terminal portion. Further, in the manufacturing process of the coil device, by temporarily fixing the end of the coil by inserting it between the horizontal portion of the terminal portion and the base, soldering connection can be performed in this state.

[0031] According to the coil device of the present application, by opposing the horizontal portion of the terminal portion to the back surface side of the back panel of the base, the insulation of the horizontal portion can be improved. Further, when soldering connecting the upper end of the coil to the horizontal portion of the terminal portion, the horizontal portion and the upper end can be pressed on the back panel by a soldering iron, and soldering connection can be reliably and easily performed.

[0032] According to the coil device of the present application, by having a closed magnetic core, a first coil, and a second coil, it can be used as a line filter.

[0033] According to the manufacturing method of the coil device of the present application, by making the front-side terminal portion and the rear-side terminal portion different in length, and making the relatively long terminal portion extend to the end of the coil, the forming work for unwinding the end of the coil for connection can be eliminated, and the connection work of the coil can be simplified. BRIEF DESCRIPTION OF DRAWINGS

[0034] FIG. 1 is a diagram showing a coil device relating to an embodiment of the present application, FIG. 1 (A) is a perspective view of the coil device viewed from the front, FIG. 1 (B) is a perspective view of the coil device viewed from the rear.

[0035] FIG. 2 is a diagram showing a coil device relating to an embodiment of the present application, and is a perspective view of a core and a coil after winding of the coil.

[0036] FIG. 3 is a diagram showing a base of a coil device relating to an embodiment of the present application,FIG. 3 (A) is a perspective view of the base viewed from the front, FIG. 3 (B) is a perspective view of the base viewed from the rear.

[0037] FIG. 4 is a view showing a coil device relating to an embodiment of the present application, FIG. 4 (A) is a perspective view showing a connection structure of an upper end of a 2nd coil and a horizontal portion of a 2nd rear side terminal portion, FIG. 4 (B) is a perspective view showing a connection structure of a lower end of the 2nd coil and a horizontal portion of a 2nd front side terminal portion.

[0038] FIG. 5 is a view showing a coil device relating to an embodiment of the present application, and is a plan view showing an example of a wire length of an upper end as an end portion of a coil.

[0039] FIG. 6 is a view showing a coil device relating to an embodiment of the present application, FIG. 6 (A), FIG. 6 (B), FIG. 6 (C), and FIG. 6 (D) are views showing each structure of the base at a connection portion of a terminal portion.

[0040] FIG. 7 is a view showing a coil device relating to an embodiment of the present application, and is a view showing a structure of a base.

[0041] FIG. 8 is a view showing a coil device relating to the background art, FIG. 8 (A) is an exploded perspective view, FIG. 8 (B) is a perspective view.

[0042] Explanation of Reference Signs

[0043] 10 coil device; 11 core; 12 coil; 121 first coil; 122 second coil; 123 upper end; 124 lower end; 125 upper end; 126 lower end; 127 coil portion; 128 coil portion; 13 base; 131 pedestal; 132 back panel; 133 protruding portion; 134 hollow portion; 135 opposing surface; 136 protruding portion; 137 recessed portion; 138 left support portion; 139 right support portion; 17 winding portion; 171 first winding portion; 172 second winding portion; 19 terminal portion; 191 first front side terminal portion; 192 second front side terminal portion; 193 first rear side terminal portion; 194 second rear side terminal portion; 195 vertical portion; 196 horizontal portion; 197 vertical portion; 198 horizontal portion; 100 noise filter; 101 magnetic core; 102 pedestal; 103 conductive needle; 104 wire; 105 lower end portion; 106 upper end portion. DETAILED DESCRIPTION

[0044] Hereinafter, a coil device 10 and a manufacturing method thereof according to an embodiment of the present application will be described in detail based on the drawings. In the following description, the same reference numerals are assigned to the same components, and repetitive description will be omitted.

[0045] FIG. 1 (A) is a perspective view of the coil device 10 viewed from the front, FIG. 1 (B) is a perspective view of the coil device 10 viewed from the rear.

[0046] Referring to FIG. 1 (A) and FIG. 1 (B), the coil device 10 mainly has a core 11, a coil 12, a base 13, and a terminal portion 19. The coil device 10 can be used as, for example, a line filter, a noise filter, a common mode noise filter, a transformer, or the like. Further, the coil device 10 is a mounting component mounted with respect to a mounting surface of a mounting substrate or the like. As a mounting structure of the coil device 10, insertion or soldering fusion or the like can be employed. Furthermore, as will be described later, the first coil 121 and the second coil 122 are wound with a wire substantially perpendicularly with respect to the mounting surface of the coil device 10.

[0047] The core 11 has a substantially rectangular frame shape viewed from the front. As a material of the core 11, a magnetic body such as amorphous alloy, silicon steel sheet, ferrite, or the like can be employed. Details of the core 11 will be described later with reference to FIG. 2

[0048] ​The coil 12 is composed of a wire wound in a coil. Specifically, the coil 12 is composed of a flat wire wound vertically. The surface of the wire constituting the coil 12 is covered with a thin resin film, such as a film composed of polyurethane resin. Here, the coil 12 is composed of a first coil 121 and a second coil 122, the details of which will be described later. FIG. 2 The details will be described later.

[0049] The base 13 is a member composed of synthetic resin or the like configured to fix the core 11, the structure of which will be described later. FIG. 3 The details will be described later.

[0050] The terminal portion 19 is electrically connected to the coil 12 and is a connection mechanism provided at the lower end of the coil device 10. The terminal portion 19 is formed by bending a wire composed of copper, aluminum, or the like. Specifically, the terminal portion 19 has a first front side terminal portion 191 connected to the lower end 126 of the first coil 121, a second front side terminal portion 192 connected to the lower end 124 of the second coil 122, a first rear side terminal portion 193 connected to the upper end 125 of the first coil 121, and a second rear side terminal portion 194 connected to the upper end 123 of the second coil 122. The details of these terminal portions will be described later with reference to FIG. 4 and the like.

[0051] In the present embodiment, the first front side terminal portion 191 and the second front side terminal portion 192 are different in length from the first rear side terminal portion 193 and the second rear side terminal portion 194. Here, the first rear side terminal portion 193 and the second rear side terminal portion 194 are formed longer than the first front side terminal portion 191 and the second front side terminal portion 192. By so doing, as will be described later, the upper ends of the first coil 121 and the second coil 122 can be shortened. The details will be described later with reference to FIG. 2 The details will be described later.

[0052] FIG. 2 is a perspective view of the core 11 and the coil 12.

[0053] The core 11 is a closed magnetic core having no joint, which has a first winding portion 171 and a second winding portion 172 having a straight line shape as the winding portion 17. The first winding portion 171 and the second winding portion 172 are substantially perpendicular to the mounting surface of the coil device 10, which is not shown, here.

[0054] The coil 12 has a first coil 121 wound on the first winding portion 171, and a second coil 122 wound on the second winding portion 172 and wound in the opposite direction to the first coil 121. In the first coil 121 and the second coil 122, the cross-sectional shape of the wire (conductor width, conductor thickness) and the number of turns are the same. By so doing, the coil device 10 including the first coil 121 and the second coil 122 can be used as a noise filter or the like as described above. Further, the coil portion 127 and the coil portion 128 are here substantially perpendicular with respect to the mounting surface of the coil device 10 not shown.

[0055] The first coil 121 has a coil portion 127 constituted by a wire wound on the first winding portion 171, an upper end 125 in which the wire of the upper end portion of the coil portion 127 is unwound, and a lower end 126 in which the wire of the lower end portion of the coil portion 127 is unwound.

[0056] The second coil 122 has a coil portion 128 constituted by a wire wound on the second winding portion 172, an upper end 123 in which the wire of the upper end portion of the coil portion 128 is unwound, and a lower end 124 in which the wire of the lower end portion of the coil portion 128 is unwound. Further, the coil portion 127 and the coil portion 128 have substantially the same outer diameter and outer circumference.

[0057] FIG. 3 (A) is a perspective view of the base 13 viewed from the front, FIG. 3 (B) is a perspective view of the base 13 viewed from the rear.

[0058] Referring to FIG. 3 (A), the base 13 has a pedestal 131 and a back panel 132. FIG. 2 The core 11 shown is fixed on the pedestal 131 along the back panel 132.

[0059] The protruding portion 133 is formed by making the front surface central portion of the back panel 132 protrude toward the front so as to be elongated along the up-and-down direction. The protruding portion 133 is fitted in the central opening of the above-mentioned core 11.

[0060] The hollowed portion 134 is formed by making the front surface portion of the back panel 132 partially recessed substantially in an elliptical shape. Here, in the front surface of the back panel 132, the hollowed portion 134 is formed in the left upper portion, the right upper portion, and the central lower portion. By forming the hollowed portion 134, the amount of resin required for the manufacture of the base 13 can be reduced, achieving cost reduction.

[0061] The left support portion 138 and the right support portion 139 are portions in which the left and right ends of the base 131 protrude upward. The inner side surfaces of the left support portion 138 and the right support portion 139 are curved surfaces that conform to the shape of the core 11. The core 11 described above is held in the left and right directions by the left support portion 138 and the right support portion 139.

[0062] Referring to FIG. 3 (B), the vertically extending portions of the first rear-side terminal portion 193 and the second rear-side terminal portion 194 (see FIG. 4 (A) the vertical portion 195 described later) pass through the inside of the back surface plate 132 of the base 13. By so doing, the first rear-side terminal portion 193 and the second rear-side terminal portion 194 are securely supported by the base 13, and the insulation of the first rear-side terminal portion 193 and the second rear-side terminal portion 194 can be ensured.

[0063] FIG. 4 (A) is a perspective view that shows the connection structure of the upper end 123 of the second coil 122 and the horizontal portion 196 of the second rear-side terminal portion 194, FIG. 4 (B) is a perspective view that shows the connection structure of the lower end 124 of the second coil 122 and the horizontal portion 198 of the second front-side terminal portion 192.

[0064] Referring to FIG. 4 (A), the second rear-side terminal portion 194 is composed of the vertical portion 195 and the horizontal portion 196. In other words, the middle portion of the second rear-side terminal portion 194 is bent to be substantially at right angles. The lower end of the vertical portion 195 is exposed downward from the lower end of the base 13. Further, the horizontal portion 196 opposes the rear surface (the opposing surface 135) of the back surface plate 132 of the base 13. Further, the second rear-side terminal portion 194 is formed longer than the first front-side terminal portion 191 and the like described above. Thus, the horizontal portion 196 that is the upper end of the second rear-side terminal portion 194 can be disposed near the upper end of the second coil 122, and the wire length of the upper end 123 can be shortened.

[0065] The upper end 123 of the second coil 122 is inserted through or held between the horizontal portion 196 and the back surface of the back surface plate 132. Further, the connection portion of the upper end 123 and the horizontal portion 196 is brazed here. The structure in which the upper end 123 is inserted through or held is described with reference to FIG. 6 and FIG. 7 described later.

[0066] By so doing, the upper end 123 can be firmly connected to the horizontal portion 196. Further, since the horizontal portion 196 of the second rear-side terminal portion 194 is disposed in the vicinity of the upper end portion of the second coil 122, the upper end 123 can be shortened to the same degree as the lower end 124 described later. In addition, FIG. 1 the connection structure of the upper end 125 of the first coil 121 to the first rear-side terminal portion 193 shown in (B) and FIG. 4 (A) are the same.

[0067] Referring to FIG. 4 (B), the second front-side terminal portion 192 has a vertical portion 197 and a horizontal portion 198. In addition, the lower end 124 of the second coil 122 is sandwiched or inserted between the horizontal portion 198 and the front surface (opposite surface 135) of the pedestal 131. Further, the connecting portion of the horizontal portion 198 to the lower end 124 is brazed here with a solder not shown. Such a connection structure is the same as FIG. 1 the first front-side terminal portion 191 and the lower end 126 of the first coil 121 shown in (A).

[0068] FIG. 5 is a view showing an example of the length of the upper end 123. The length L11 of the upper end 123 unwound from the upper end of the second coil 122 is preferably one-half or less of the outer circumference L10 of the coil portion 128. Here, the length L11 of the upper end 123 is the length from the unwound portion P1 of the second coil 122 to the portion P2 where the upper end 123 is connected to the horizontal portion 196 of the second rear-side terminal portion 194. This length is substantially the same as the distance L13 from the end surface of the second winding portion 172 in the vicinity of the upper end of the coil portion 128 to the horizontal portion 196.

[0069] This is the same as the other ends, i.e., the upper end 125, the lower end 124, and the lower end 126. By so doing, the unwound length can be shortened to make the upper end 123 and the like substantially linear, and the manufacturing process can be simplified to reduce the manufacturing cost.

[0070] More preferably, by making the length L11 of the upper end 123 unwound from the upper end of the second coil 122 one-third or less of the outer circumference L10 of the coil portion 128, the effect can be made significant. This is the same as the other ends, i.e., the upper end 125, the lower end 124, and the lower end 126.

[0071] FIG. 6 (A), FIG. 6 (B), FIG. 6 (C), and FIG. 6(D) is a view showing each form of the associated structure of the horizontal portion of each terminal and the opposing surface 135 of the horizontal portion of the base 13. In FIG. 6 In each view, the lower side end 126 is shown as being sandwiched between the opposing surface 135 and the horizontal portion 198. FIG. 4 In each view, the upper side end 125 and the lower side end 126 are shown as being sandwiched between the opposing surface 135 and the horizontal portion 198.

[0072] Referring to FIG. 6 (A), the opposing surface 135 of the front surface of the base 13 and the horizontal portion 198 are set to be substantially parallel. The distance L12 of the opposing surface 135 and the horizontal portion 198 is set to be FIG. 4 (B) or less. By doing so, the lower side end 126 can be sandwiched between the opposing surface 135 and the horizontal portion 198.

[0073] Referring to FIG. 6 (B), here the opposing surface 135 of the front surface of the base 13 is inclined with respect to the horizontal portion 198. Specifically, the opposing surface 135 is an inclined surface inclined toward the rear in the left direction as the outer side in the left-right direction. By doing so, the lower side end 126 can be appropriately sandwiched between the opposing surface 135 as the inclined surface and the horizontal portion 198.

[0074] Referring to FIG. 6 (C), here a protruding portion 136 is formed by partially protruding the opposing surface 135 of the portion facing the horizontal portion 196 toward the rear. The protruding portion 136 can be formed in a dot shape or in a line shape extending continuously and elongatedly along the left-right direction. The tip of the protruding portion 136 can be disposed in the vicinity of the horizontal portion 196 or can be in contact with the horizontal portion 196. By doing so, the upper side end 123 shown in FIG. 4 (A) can be more firmly sandwiched between the protruding portion 136 and the horizontal portion 196.

[0075] Referring to FIG. 6 (D), here a concave portion 137 is formed by recessing the opposing surface 135 of the portion facing the horizontal portion 196 toward the front. By doing so, the upper side end 125 is sandwiched in a curved state between the horizontal portion 196 and the concave portion 137, so the upper side end 125 can be more firmly sandwiched.

[0076] FIG. 6 The structures shown in (A) to FIG. 6 (D) can be applied to all of the connection portions shown in FIG. 1 That is, they can be applied to the connection structure of the lower side end 124 and the 2nd front side terminal portion 192 shown in FIG. 1 (A), the connection structure of the lower side end 126 and the 1st front side terminal portion 191, FIG. 1The connection structure of the first rear-side terminal portion 193 to the upper end 125 and the connection structure of the second rear-side terminal portion 194 to the upper end 123 are shown in (B).

[0077] Referring to FIG. 7 , another configuration of the portion connecting the horizontal portion 198 to the lower end 126 will be described. Here, the distance L12 between the facing surface 135 of the front surface of the base 13 and the rear face of the horizontal portion 198 is set to be longer than the width (thickness) of the lower end 126. By so doing, the lower end 126 is inserted between the facing surface 135 and the horizontal portion 198. If this structure, the horizontal portion 198 and the lower end 126 can be electrically connected and the position of the lower end 126 can be fixed by brazing, too. Further, if this structure, the lower end 126 can be temporarily fixed by being inserted between the facing surface 135 and the horizontal portion 198 in the manufacturing process, too.

[0078] Based on FIG. 1 to FIG. 4 , a manufacturing method of the coil device 10 having the structure shown in (A) to (C) will be described with reference to the above-described drawings. FIG. 1

[0079] Referring to FIG. 2 , the first coil 121 and the second coil 122 are wound on the core 11. Further, the upper end 125 and the lower end 126 are formed by unwinding the wire at the upper end and the lower end of the first coil 121. The upper end 123 and the lower end 124 are formed by unwinding the wire at the upper end and the lower end of the second coil 122.

[0080] The core 11 is loaded into the base 13 shown in (A) from the front. At this time, the protruding portion 133 of the base 13 is inserted into the central opening of the core 11. Further, the lower end portion of the core 11 is supported from the left and right outer sides by the left support portion 138 and the right support portion 139. Further, on the base 13, the terminal portion 19 for connecting each end of the coil 12 is assembled in advance, and a prescribed interval is provided between each horizontal portion (196, 198) of each terminal and the facing surface 135 of the base. FIG. 3 Referring to

[0081] (B), the lower end 124 is sandwiched or inserted between the horizontal portion 198 of the second front-side terminal portion 192 and the front surface of the pedestal 131, and the horizontal portion 198 and the lower end 124 are pushed by a soldering iron to melt the resin film covering the periphery of the lower end 124, and further brazing is performed. Thereby, the lower end 124 and the horizontal portion 198 are electrically connected. Further, by the same procedure, the horizontal portion 198 of the first front-side terminal portion 191 shown in (A) is electrically connected to the lower end 126. FIG. 4 FIG. 1 (A) are electrically connected. ​​

[0082] Referring to FIG. 1 (B), as with the case of the horizontal portion 198 of the 2nd front side terminal portion 192 described above, the horizontal portion 196 of the 2nd rear side terminal portion 194 is connected to the upper end 123. Further, the horizontal portion 196 of the 1st rear side terminal portion 193 is connected to the upper end 125.

[0083] By the above-described procedure, the coil device 10 shown in FIG. 1 is manufactured.

[0084] By the above-described embodiment, the following main effects can be achieved.

[0085] Referring to FIG. 1 (B), according to the coil device 10 of the present application, by making the lengths of the 1st front side terminal portion 191 and the 2nd front side terminal portion 192 different from those of the 1st rear side terminal portion 193 and the 2nd rear side terminal portion 194, the 1st rear side terminal portion 193 and the 2nd rear side terminal portion 194, which are formed longer, are extended to the vicinity of the upper end of the coil 12. Thereby, referring to FIG. 4 (A), the upper end 123 can be shortened, and the connection reliability can be improved. Further, since the upper end 123 of the 2nd coil 122 does not need to be connected to the horizontal portion 196 after the post-processing such as terminal bending is applied to the horizontal portion 196, the production cost can be reduced by omitting these operations.

[0086] Referring to FIG. 5 Further, by making the length of the upper end 123 of the coil 12 be less than half of the outer circumference of the coil portion 128, the upper end 123 can be shortened, and the forming operation of unwinding the upper end 123 of the coil 12 can be simplified or can not be needed.

[0087] Referring to FIG. 3 (B), further, by inserting the 1st rear side terminal portion 193 and the 2nd rear side terminal portion 194 inside the back panel 132 of the base 13, the 1st rear side terminal portion 193 and the 2nd rear side terminal portion 194, which are formed relatively long, can be protected by the back panel 132 and the insulation can be improved.

[0088] Referring to FIG. 1 (A), further, the ends of the 1st coil 121 and the 2nd coil 122, which are formed by flatly and vertically winding the flat wire, can be simply connected to the 1st front side terminal portion 191 or the 2nd rear side terminal portion 194, and the connection reliability can be improved.

[0089] Referring to FIG. 4(A), and by sandwiching the upper end 123 of the second coil 122 between the horizontal portion 196 of the second rear-side terminal portion 194 and the base 13, the upper end 123 and the terminal portion 19 can be firmly connected. Further, in the manufacturing process of the coil device 10, by temporarily fixing by sandwiching or inserting the upper end 123 between the horizontal portion 196 and the base 13, soldering connection can be performed in this state.

[0090] Referring to FIG. 4 (A), and by the horizontal portion 196 of the second rear-side terminal portion 194 opposing the back panel 132 of the base 13, the insulation of the horizontal portion 196 can be improved. Further, when soldering connecting the upper end 123 and the horizontal portion 196, the horizontal portion 196 and the upper end 123 can be pressed against the back panel 132 with a soldering iron, and soldering connection can be reliably and easily performed.

[0091] Referring to FIG. 1 (A), and by having the closed magnetic core, the first coil 121, and the second coil 122, the coil device 10 can be used as a line filter.

[0092] Referring to FIG. 1 (B), and by extending the first rear-side terminal portion 193 and the second rear-side terminal portion 194, which are formed longer, to the vicinity of the upper end of the coil 12 in the manufacturing method, the forming work of unwinding the end portion of the coil 12 for connection can not be needed, and the connection structure and the connection work of the coil 12 can be simplified.

[0093] The embodiments of the present application have been described above, but the present application is not limited to this, and can be changed within the scope of the gist of the present application. Further, each of the above-described modes can be combined with each other.

[0094] For example, referring to FIG. 3 (B), in the above-described embodiment, the first rear-side terminal portion 193 and the second rear-side terminal portion 194 are inserted inside the back panel 132 of the base 13, but the first rear-side terminal portion 193 and the second rear-side terminal portion 194 can be fitted to the back panel 132 by other configurations. For example, a groove-shaped region extending in the up-down direction can be formed on the back surface of the back panel 132, and the first rear-side terminal portion 193 and the second rear-side terminal portion 194 can be fitted into this groove-shaped region.

[0095] Further, referring to FIG. 1 (A), in the present embodiment, a rectangular core is used as the core 11, but other shapes of cores can also be used as the core 11, for example, a ring-shaped core can also be used as the core 11. Further, only one coil can be designed as an inductor.

Claims

1. A coil device comprising: a coil having a coil portion formed by winding a wire; a core having a winding portion in which the coil is wound; a base that fixes the core; and a terminal portion electrically connected to the coil, characterized in that the terminal portion has a front side terminal portion connected to a lower end of the coil and disposed on a front side, and a rear side terminal portion connected to an upper end of the coil and disposed on a rear side, the front side terminal portion and the rear side terminal portion differ in length, the terminal portion has a vertical portion and a horizontal portion, the base has a pedestal and a back panel, the core is fixed to the pedestal along the back panel, the horizontal portion and the back panel of the base face each other with a prescribed distance therebetween, the prescribed distance is equal to or less than a thickness of the end of the coil, and the end of the coil is sandwiched between the horizontal portion and the back panel of the base.

2. A coil device comprising: a coil having a coil portion formed by winding a wire; a core having a winding portion in which the coil is wound; a base that fixes the core; and a terminal portion electrically connected to the coil, characterized in that the terminal portion has a front side terminal portion connected to a lower end of the coil and disposed on a front side, and a rear side terminal portion connected to an upper end of the coil and disposed on a rear side, the front side terminal portion and the rear side terminal portion differ in length, the terminal portion has a vertical portion and a horizontal portion, the base has a pedestal and a back panel, the core is fixed to the pedestal along the back panel, the horizontal portion and the back panel of the base face each other with a prescribed distance therebetween, the prescribed distance is greater than a thickness of the end of the coil, a gap having the prescribed distance is formed between the horizontal portion and the back panel of the base for temporarily fixing the end of the coil, and the end of the coil is inserted through the gap only once.

3. The coil device according to claim 1 or 2, characterized in that a length from the coil portion of the coil to the upper end of the rear side terminal portion is equal to or less than half of an outer circumference of the coil portion of the coil.

4. The coil device according to claim 3, characterized in that the rear side terminal portion is inserted inside the back panel of the base.

5. The coil device according to claim 1 or 2, characterized in that the winding portion is formed in a straight line shape, and the coil is formed by winding a flat wire in a vertical direction.

6. The coil device according to claim 1 or 2, characterized in that the core is a closed magnetic core having a first winding portion and a second winding portion in a straight line shape without a joint, the coil has a first coil wound on the first winding portion and a second coil wound on the second winding portion in a direction opposite to the first coil, the front side terminal portion has a first front side terminal portion connected to a lower end of the first coil and a second front side terminal portion connected to a lower end of the second coil, and the first front side terminal portion and the second front side terminal portion differ in length. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ The rear side terminal portion has a first rear side terminal portion connected to the upper end of the first coil and a second rear side terminal portion connected to the upper end of the second coil.

7. The coil device according to claim 6, wherein The rear side terminal portion is inserted into the inside of the back panel of the base.

8. The coil device according to claim 6, wherein The winding portion is formed in a straight line shape. The coil is formed by standing flat wire.

9. A method of manufacturing the coil device according to any one of claims 1 to 8, wherein The method comprises: a step of preparing the core on which the coil is wound and the base into which the front side terminal portion and the rear side terminal portion are fitted; a step of fitting the core into the base; a step of temporarily fixing by sandwiching or inserting the end of the coil between the horizontal portion and the base; and a step of electrically connecting the front side terminal portion and the rear side terminal portion to the coil.

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