Coil member manufacturing apparatus and coil member manufacturing method

Abstract

The present invention relates to a coil member manufacturing apparatus and a coil member manufacturing method. The present invention provides a coil member manufacturing apparatus capable of winding a twisted portion of a wire at a desired position of a core. The coil member manufacturing apparatus includes a nozzle through which a plurality of wires can be inserted; a wire twisting mechanism that holds the core, relatively rotates the core with respect to the nozzle in a direction in which the plurality of wires are twisted, and can form a twisted portion in which the plurality of wires are twisted between the nozzle and the core; a wire winding mechanism that holds the core, relatively rotates the core with respect to the nozzle in a direction in which the twisted portion is wound on the core, and can wind the twisted portion on the core; and a guide member that is located closer to the core than the nozzle, and can guide the twisted portion to a predetermined position of the core when the twisted portion is wound on the core.

Description

TECHNICAL FIELD

[0001] The present application relates to a coil member manufacturing apparatus and a coil member manufacturing method. BACKGROUND

[0002] Conventionally, as a coil member manufacturing method, there is a method described in Japanese Patent Application Publication No. 2010-147132 (Patent Literature 1). The coil member manufacturing method has a first step of passing a plurality of wires through a nozzle and connecting the front ends of the wires to an external electrode portion of a core, a second step of rotating the nozzle a predetermined number of times to form a twisted portion of the wires between the nozzle and the core, and a third step of rotating the core to wind the twisted portion of the wires around the core.

[0003] Patent Literature 1: Japanese Patent Application Publication No. 2010-147132

[0004] However, in the above-described coil member manufacturing method, in order to reduce the number of steps, a relatively large number of wires are sometimes wound around the core at once. In this case, the twisted portion is formed in a relatively long wire at once. That is, the distance between the nozzle and the core is made as far as possible, and the wire is made relatively long between the nozzle and the core to form the twisted portion between the nozzle and the core.

[0005] However, since the nozzle and the core are separated, when the twisted portion of the wire is wound around the core in this state, it is difficult to wind the twisted portion of the wire around the desired position of the core. In particular, when the distance from the nozzle to the core is long, it is difficult to wind the twisted portion of the wire around the core with good positional accuracy. SUMMARY

[0006] Therefore, an object of the present application is to provide a coil member manufacturing apparatus and a coil member manufacturing method capable of winding a twisted portion of a wire around a desired position of a core.

[0007] In order to solve the above-described problem, a coil member manufacturing apparatus according to one embodiment of the present disclosure includes a nozzle through which a plurality of wires can be inserted; a wire twisting mechanism that holds a core and relatively rotates the core with respect to the nozzle in a direction in which the plurality of wires are twisted, and can form a twisted portion in which the plurality of wires are twisted between the nozzle and the core; a wire winding mechanism that holds the core and relatively rotates the core with respect to the nozzle in a direction in which the twisted portion is wound around the core, and can wind the twisted portion around the core; and a guide member that is located closer to the core than the nozzle, and can guide the twisted portion to a predetermined position of the core when the twisted portion is wound around the core.

[0008] Here, the prescribed position of the core refers to a position required for winding the twisted portion spirally along the axial direction in the circumferential direction of the core. According to the above-described manner, since the twisted portion is wound around the core while being guided to the prescribed position of the core by the guide member positioned closer to the core than the nozzle, the twisted portion can be wound around the desired position of the core.

[0009] Preferably, the guide member is positioned between the nozzle and the core when winding the twisted portion around the core.

[0010] According to the above-described embodiment, the guide member can be present at a position where a load is not easily applied to the wire, while guiding the twisted portion to the core.

[0011] Preferably, in one embodiment of the coil member manufacturing apparatus, the guide member has a groove with a V-shaped cross section through which the twisted portion passes.

[0012] Here, the V-shaped refers to a shape in which the width narrows from the opening of the groove toward the bottom of the groove, and is not limited to a complete V-shaped shape, and can be a substantially V-shaped shape such as a trapezoidal shape in which the bottom of the groove is flat.

[0013] According to the above-described embodiment, the guide member has a groove with a V-shaped cross section, and thus the twisted portion can be wound around the core while being positioned in the groove of the guide member. Thus, the position accuracy of the winding of the twisted portion around the core can be further improved.

[0014] Preferably, in one embodiment of the coil member manufacturing apparatus, the guide member is a cylindrical body, and the groove extends in the circumferential direction on the side surface of the cylindrical body.

[0015] According to the above-described embodiment, since the groove extends in the circumferential direction on the side surface of the cylindrical body, the twisted portion is guided in the circumferential direction on the side surface of the cylindrical body. Thus, the twisted portion can be smoothly guided to the core without applying excessive burden to the twisted portion.

[0016] Preferably, in one embodiment of the coil member manufacturing apparatus, the guide member is held so as to be rotatable around the axis of the cylindrical body.

[0017] According to the above-described embodiment, since the guide member is held so as to be rotatable, the guide member guides the twisted portion to the core while rotating. Thus, the resistance of the guide member to the twisted portion can be reduced, and the twisted portion can be more smoothly guided to the core.

[0018] Preferably, in one embodiment of the coil member manufacturing apparatus, a guide driving mechanism that can move the guide member in the axial direction of the core when winding the twisted portion along the axial direction of the core is further provided.

[0019] According to the above embodiment, the guide driving mechanism is further provided, so that the guide member can be used to wind the twisted portion around the core at a desired position. Thus, the position accuracy of the twisted portion around the core can be further improved.

[0020] Preferably, in one embodiment of the coil member manufacturing apparatus, two guide members are provided, and the two guide members are located on opposite sides of the twisted portion when the twisted portion is wound around the core, so that the twisted portion can be guided to a desired position of the core.

[0021] According to the above embodiment, since the two guide members are located on opposite sides of the twisted portion, and the twisted portion is guided to a desired position of the core, the position accuracy of the twisted portion around the core can be further improved.

[0022] Preferably, in one embodiment of the coil member manufacturing apparatus, a nozzle height adjustment mechanism is further provided, which can adjust the distance between the nozzle and the core.

[0023] According to the above embodiment, the distance between the nozzle and the core can be adjusted according to the size of the product when the twisted portion is formed, or / and when the twisted portion is wound around the core. In addition, the twist pitch of the twisted portion can be adjusted by adjusting the distance between the nozzle and the core when the twisted portion is formed.

[0024] Preferably, in one embodiment of the coil member manufacturing apparatus, the nozzle has a plurality of nozzle portions through which the plurality of wires can be respectively inserted, and the coil member manufacturing apparatus further comprises a nozzle distance adjustment mechanism which can adjust the distance between the plurality of nozzle portions.

[0025] According to the above embodiment, the twist pitch of the twisted portion can be adjusted by adjusting the distance between the plurality of nozzle portions when the twisted portion is formed.

[0026] In addition, the coil member manufacturing method according to one embodiment of the present disclosure comprises the following steps: a step of connecting the starting ends of the plurality of wires to the external electrode of the core by passing the plurality of wires through the nozzle; a step of relatively rotating the nozzle and the core in a direction in which the plurality of wires are twisted, so as to form a twisted portion around the nozzle and the core; and a step of relatively rotating the nozzle and the core in a direction in which the twisted portion is wound around the core, while guiding the twisted portion to a desired position of the core by using a guide member located closer to the core than the nozzle, and winding the twisted portion around the core.

[0027] According to the above-described configuration, the twisted portion is guided to a predetermined position of the core while being guided to the predetermined position of the core by the guide member located closer to the core than the nozzle, and thus the twisted portion can be wound around the core at a desired position.

[0028] Preferably, in one embodiment of the method of manufacturing the coil member, in the process of winding the twisted portion around the core, the guide member is rotated around the axis of the guide member while guiding the twisted portion to the predetermined position of the core.

[0029] According to the above-described embodiment, the twisted portion is guided to the core while the guide member is rotated, and thus the resistance of the guide member to the twisted portion can be reduced, and the twisted portion can be more smoothly guided to the core.

[0030] Preferably, in one embodiment of the method of manufacturing the coil member, in the process of winding the twisted portion around the core, the guide member is moved in the axial direction of the core while guiding the twisted portion to the predetermined position of the core.

[0031] According to the above-described embodiment, the guide member is moved in the axial direction of the core while guiding the twisted portion to the predetermined position of the core, and thus the twisted portion can be wound around the core while the guide member is aligned with a desired position of the core. Thus, the position accuracy of the winding of the twisted portion around the core can be further improved.

[0032] Preferably, in one embodiment of the method of manufacturing the coil member, there are two guide members, and in the process of winding the twisted portion around the core, the twisted portion is guided to the predetermined position of the core by the two guide members located on opposite sides with respect to the twisted portion.

[0033] According to the above-described embodiment, the twisted portion is guided to the predetermined position of the core by the two guide members located on opposite sides with respect to the twisted portion, and thus the position accuracy of the winding of the twisted portion around the core can be further improved.

[0034] Preferably, in one embodiment of the method of manufacturing the coil member, in at least one of the process of forming the twisted portion and the process of winding the twisted portion around the core, the distance between the nozzle and the core is adjusted.

[0035] According to the above-described embodiment, in at least one of the process of forming the twisted portion and the process of winding the twisted portion around the core, the distance between the nozzle and the core can be adjusted according to the size of the product. In addition, in the process of forming the twisted portion, the twist pitch of the twisted portion can be adjusted by adjusting the distance between the nozzle and the core.

[0036] Preferably, in one embodiment of the manufacturing method of the coil member, the above-described nozzle has a plurality of nozzle portions through which the above-described plurality of wires are respectively inserted, and in the process of forming the twisting portion, the distance between the plurality of nozzle portions is adjusted.

[0037] According to the above-described embodiment, in the process of forming the twisting portion, by adjusting the distance between the plurality of nozzle portions, the twisting pitch of the twisting portion can be adjusted.

[0038] According to the manufacturing device of the coil member and the manufacturing method of the coil member according to one embodiment of the present disclosure, the twisting portion of the wire can be wound at a desired position of the core. BRIEF DESCRIPTION OF DRAWINGS

[0039] Figure 1 is a schematic configuration view of a first embodiment of a manufacturing device of a coil member.

[0040] Figure 2 is a plan view of the coil member.

[0041] Figure 3A is a perspective view of a guide member.

[0042] Figure 3B is a cross-sectional view of the guide member including a shaft.

[0043] Figure 4 is a plan view of a core provided with an external electrode.

[0044] Figure 5A is an explanatory view of a manufacturing method of a coil member.

[0045] Figure 5B is an explanatory view of a manufacturing method of a coil member.

[0046] Figure 5C is an explanatory view of a manufacturing method of a coil member.

[0047] Figure 5D is an explanatory view of a manufacturing method of a coil member.

[0048] Figure 5E is an explanatory view of a manufacturing method of a coil member.

[0049] Figure 5F is an explanatory view of a manufacturing method of a coil member.

[0050] Figure 5G is an explanatory view of a manufacturing method of a coil member.

[0051] Figure 5H is an explanatory view of a manufacturing method of a coil member.

[0052] Figure 6 is a schematic perspective view showing a second embodiment of the manufacturing apparatus of the coil component.

[0053] Figure 7 is a schematic structural view showing a third embodiment of the manufacturing apparatus of the coil component.

[0054] Figure 8 is a schematic structural view showing a fourth embodiment of the manufacturing apparatus of the coil component.

[0055] BRIEF DESCRIPTION OF DRAWINGS

[0056] 1, 1A, 1B, 1C... manufacturing apparatus of the coil component; 10... nozzle; 11... first nozzle portion; 12... second nozzle portion; 20... wire twisting mechanism; 21... twisting chuck portion; 30... wire winding mechanism; 31... winding chuck portion; 40... guide member; 40a... shaft; 41... groove; 50... guide driving mechanism; 52... guide position adjustment portion; 61... nozzle height adjustment mechanism; 62... nozzle-to-nozzle distance adjustment mechanism; 100... coil component; 110... core; 110a... shaft; 111... first flange portion; 112... second flange portion; 113... winding core portion; 120... coil; 121... first wire; 122... second wire; 125... twisted portion; 131... first external electrode; 132... second external electrode; 133... third external electrode; 134... fourth external electrode. DETAILED DESCRIPTION

[0057] Hereinafter, the manufacturing apparatus of the coil component and the manufacturing method of the coil component according to the illustrated embodiments as one mode of the present disclosure will be described in detail. In addition, the drawings include a part of the component that is schematic, and there is a case where the actual size, ratio is not reflected.

[0058] (First Embodiment)

[0059] Figure 1 is a schematic structural view showing a first embodiment of the manufacturing apparatus of the coil component. As shown in Figure 1 the manufacturing apparatus of the coil component 1 is provided with: a nozzle 10 through which a first wire 121 and a second wire 122 can be inserted; a wire twisting mechanism 20 that can form a twisted portion in which the first wire 121 and the second wire 122 are twisted; a wire winding mechanism 30 that can wind the twisted portion on a core 110; a guide member 40 that can guide the twisted portion to a prescribed position of the core 110 when the twisted portion is wound on the core 110; and a guide driving mechanism 50 that can move the guide member 40 in a direction of a shaft 110a of the core 110 when the twisted portion is wound in the direction of the shaft 110a of the core 110. Using the manufacturing apparatus of the coil component 1, the coil component can be manufactured.

[0060] Here, the coil component is described. Figure 2 is a bottom view of the coil component. As shown in Figure 2 the coil component 100 includes a core 110, a coil 120 wound around the core 110, and a first external electrode 131, a second external electrode 132, a third external electrode 133, and a fourth external electrode 134 provided to the core 110 and electrically connected to the coil 120.

[0061] The core 110 has a winding core portion 113, a first flange portion 111 provided to a first end of the winding core portion 113, and a second flange portion 112 provided to a second end of the winding core portion 113. As a material of the core 110, a magnetic body such as a sintered body of ferrite, a molded body of a magnetic powder-containing resin, or the like is preferable, and a non-magnetic body such as alumina or a resin can also be used.

[0062] The winding core portion 113 has a shape such as a rectangular parallelepiped. Further, a cross-sectional shape of the winding core portion 113 orthogonal to the axis 110a can be a curved surface such as a circular shape, or can also be a polygonal shape such as a hexagonal shape or an octagonal shape.

[0063] The first flange portion 111 and the second flange portion 112 have a shape such as a rectangular flat plate. The first external electrode 131 and the second external electrode 132 are provided to a bottom surface of the first flange portion 111, and the third external electrode 133 and the fourth external electrode 134 are provided to a bottom surface of the second flange portion 112. The first external electrode 131 to the fourth external electrode 134 are composed of, for example, a conductive material such as silver. The first external electrode 131 to the fourth external electrode 134 are electrically connected to electrodes of a mounting substrate, not shown.

[0064] The coil 120 includes a first wire 121 and a second wire 122 wound around the winding core portion 113. That is, the first wire 121 and the second wire 122 are wound around the core 110 along the axis 110a (an extension direction of the winding core portion 113) of the core 110.

[0065] The first wire 121 and the second wire 122 are insulated-coated wires in which a wire composed of, for example, a metal such as copper is covered with a coating film composed of a resin such as polyurethane or polyamide-imide. A first end of the first wire 121 is electrically connected to the first external electrode 131, and a second end of the first wire 121 is electrically connected to the third external electrode 133. A first end of the second wire 122 is electrically connected to the second external electrode 132, and a second end of the second wire 122 is electrically connected to the fourth external electrode 134. The first wire 121 and the second wire 122 are connected to the first external electrode 131 to the fourth external electrode 134, for example, by thermal compression bonding, brazing, welding, or the like.

[0066] The first wire 121 and the second wire 122 are wound in the same direction relative to the core portion 113. Therefore, in the coil component 100, if an inverted signal, such as a differential signal, is input to the first wire 121 and the second wire 122, the magnetic flux generated by the first wire 121 and the second wire 122 cancels each other out, weakening the inductor effect and allowing the signal to pass. On the other hand, if an in-phase signal, such as external noise, is input to the first wire 121 and the second wire 122, the magnetic flux generated by the first wire 121 and the second wire 122 reinforces each other, strengthening the inductor effect and blocking the noise from passing through. Therefore, the coil component 100 functions as a common-mode choke coil, which reduces the transmission loss of differential-mode signals such as differential signals and attenuates common-mode signals such as external noise.

[0067] The first wire 121 and the second wire 122 are twisted together to form a twisted portion 125. The twisted portion 125 exists in the region of the core portion 113, but it may also exist in at least one of the regions between the first flange portion 111 and the core portion 113 and between the second flange portion 112 and the core portion 113. In the twisted portion 125, the relative differences between the two wires (such as line length and stray capacitance deviation) are reduced, thus reducing the mode conversion output, such as the differential mode signal being converted into a common mode signal for output within the coil component 100, or vice versa, resulting in good mode conversion characteristics.

[0068] like Figure 1 As shown, in the coil component manufacturing apparatus 1, the nozzle 10 is positioned above the wire winding mechanism 20 in the vertical direction. Furthermore, the wire winding mechanism 30 and the guide member 40 are positioned between the nozzle 10 and the wire winding mechanism 20 in the vertical direction. Here, "above" refers to the upper side in the direction of gravity when the manufacturing apparatus 1 is placed on the ground.

[0069] The nozzle 10 includes: a first nozzle portion 11 through which a first wire 121 can be inserted; a second nozzle portion 12 through which a second wire 122 can be inserted; and a support plate 15 supporting the first nozzle portion 11 and the second nozzle portion 12. The first nozzle portion 11 and the second nozzle portion 12 are integrally connected by the support plate 15.

[0070] The wire twisting mechanism 20 holds the core 110 and rotates the core 110 relative to the nozzle 10 in the direction of twisting the first wire 121 and the second wire 122, so that a twisting part 125 can be formed between the nozzle 10 and the core 110.

[0071] The wire twisting mechanism 20 has a twisting chuck portion 21 that holds the core 110, a rotating table 22 that supports and fixes the twisting chuck portion 21, a motor 23 that rotates the rotating table 22 about a vertical axis, a support table 24 that supports the rotating table 22 so as to be rotatable, a first air cylinder 25 that reciprocally moves the support table 24 in a horizontal direction, a base table 26 that supports the support table 24 so as to be reciprocally movable, and a second air cylinder 27 that reciprocally moves the base table 26 in a vertical direction.

[0072] The twisting chuck portion 21 is rotated in the Rl direction about the vertical axis together with the rotating table 22 by driving of the motor 23. Then, the core 110 held by the twisting chuck portion 21 is rotated in the Rl direction about the vertical axis orthogonal to the axis 110a of the core 110 and passing through the center of the core 110 by driving of the motor 23.

[0073] The twisting chuck portion 21 and the rotating table 22 are reciprocally moved in the horizontal direction together with the support table 24 by driving of the first air cylinder 25. That is, the twisting chuck portion 21 is reciprocally moved in the left-right direction (Xl direction) by driving of the first air cylinder 25, and approaches or moves away from the wire winding mechanism 30.

[0074] The twisting chuck portion 21, the rotating table 22, and the support table 24 are reciprocally moved in the vertical direction together with the base table 26 by driving of the second air cylinder 27. That is, the twisting chuck portion 21 is reciprocally moved in the up-down direction (Zl direction) by driving of the second air cylinder 27, and approaches or moves away from the wire winding mechanism 30.

[0075] The wire winding mechanism 30 holds the core 110 so that the core 110 is relatively rotated in a direction in which the twisted portion 125 is wound on the core 110 with respect to the nozzle 10, and can wind the twisted portion 125 on the core 110.

[0076] The wire winding mechanism 30 has a winding chuck portion 31 that holds the core 110, and a motor 32 that rotates the winding chuck portion 31 about a horizontal axis. Then, the core 110 held by the winding chuck portion 31 is rotated in the R2 direction about the axis 110a of the core 110 coinciding with the horizontal axis by driving of the motor 32. Further, the core 110 is selectively held in the twisting chuck portion 21 or the winding chuck portion 31, and in the Figure 1 In the state in which the core 110 is held by the winding chuck portion 31 is shown.

[0077] The guide driving mechanism 50 can move the guide member 40 in the axis 110a direction of the core 110 when winding the twisted portion 125 on the core 110.

[0078] The guide drive mechanism 50 has a guide support portion 51 that supports the guide member 40, a guide position adjustment portion 52 that reciprocally moves the guide support portion 51 in the horizontal direction, and a cylinder 53 that reciprocally moves the guide position adjustment portion 52 in the horizontal direction.

[0079] The guide position adjustment portion 52 has, for example, a ball screw that is screwed with the guide support portion 51, and moves the guide support portion 51 in the horizontal direction by rotation of the ball screw. The guide member 40 is reciprocally moved in the horizontal direction with the guide support portion 51 by driving of the guide position adjustment portion 52. That is, the guide member 40 is reciprocally moved in the left-right direction (X2 direction) by driving of the guide position adjustment portion 52, and approaches or moves away from the wire winding mechanism 30.

[0080] The guide member 40 and the guide support portion 51 are reciprocally moved in the horizontal direction with the guide position adjustment portion 52 by driving of the cylinder 53. That is, the guide member 40 is reciprocally moved in the left-right direction (X3 direction) by driving of the cylinder 53, and approaches or moves away from the wire winding mechanism 30.

[0081] The guide member 40 is positioned closer to the core 110 held by the winding chuck portion 31 than the nozzle 10, and is able to guide the twisted portion 125 to a prescribed position of the core 110 when winding the twisted portion 125 on the core 110.

[0082] Specifically, the guide member 40 is positioned between the nozzle 10 and the core 110 when winding the twisted portion 125 on the core 110. That is, the guide member 40 is positioned on the wire 121, 122 between the nozzle 10 and the core 110. It is preferable that the guide member 40 be positioned on a line segment that connects the nozzle 10 and the core 110. The guide member 40 is positioned between the nozzle 10 and the core 110 held by the winding chuck portion 31 in the vertical direction.

[0083] Furthermore, the guide member 40 can also not be positioned on the line segment that connects the nozzle 10 and the core 110. In addition, the guide member 40 can also not be positioned between the nozzle 10 and the core 110 in the vertical direction, and can be positioned at the same height as the core 110, for example.

[0084] The guide member 40 winds the twisted portion 125 in a helical shape in the axial direction on the circumference of the core 110. In other words, the guide member 40 winds the twisted portion 125 on the circumference of the core 110 while shifting little by little in the axial direction of the core 110. In this way, the guide member 40 guides the twisted portion 125 to a position of winding with respect to the core 110, and the guide member 40 is able to move in the axial direction of the core 110 in cooperation with the shift of the twisted portion 125 in the axial direction of the core 110.

[0085] According to the above structure, while guiding the twisted portion 125 to a predetermined position on the core 110 using the guide member 40 located closer to the core 110 than the nozzle 10, the twisted portion 125 is wound around the core 110. Therefore, the twisted portion 125 can be guided to the core 110 at a position close to the core 110, and as a result, the twisted portion 125 can be wound around the core 110 at the desired position.

[0086] In addition, when the twisted portion 125 is wound around the core 110, the guide member 40 is located between the nozzle 10 and the core 110. Therefore, the guide member 40 can be located in a position where it is not easy to apply load to the wires 121 and 122, while guiding the twisted portion 125 to the core 110.

[0087] Furthermore, since it also has a guide drive mechanism 50, the twisting portion 125 can be wound around the core 110 while the guide member 40 is moved to align with the core 110 at the desired position. As a result, the positional accuracy of the twisting portion 125 relative to the core 110 can be further improved.

[0088] Figure 3A This is a three-dimensional view of the guide component 40. Figure 3B It is a sectional view of the guide member 40 including the shaft 40a.

[0089] like Figure 3A and Figure 3B As shown, the guide member 40 has a V-shaped groove 41 through which the twisting portion 125 passes. The V-shape refers to a shape where the width H narrows from the opening of the groove 41 towards the bottom of the groove 41; it is not limited to a perfect V-shape, but can also be a substantially V-shaped groove, such as a trapezoid with a flat bottom. In this embodiment, the bottom of the groove 41 is flat.

[0090] According to the above structure, the twisted portion 125 can be positioned in the V-shaped groove 41 while being wound around the core 110. This further improves the positional accuracy of the twisted portion 125 relative to the core 110.

[0091] Furthermore, the guide member 40 is a cylinder, and the groove 41 extends circumferentially along the side of the cylinder. According to the above structure, the twisted portion 125 is guided circumferentially along the side of the cylinder. Thus, the twisted portion 125 can be smoothly guided to the core 110 without placing excessive burden on it.

[0092] Furthermore, the guide member 40 is maintained so as to be able to rotate about the axis 40a of the cylinder. That is, the guide member 40 is... Figure 1The guide support 51 shown is rotatable about the axis 40a. According to this structure, the guide member 40 guides the twisted portion 125 towards the core 110 while rotating. This reduces the resistance of the guide member 40 to the twisted portion 125, allowing the twisted portion 125 to be guided more smoothly to the core 110.

[0093] Preferably, the width H of the opening side of the groove 41 is more than twice and less than three times the diameter of the wires 121 and 122. If the width H is more than twice, the twisted portion 125 can be accommodated in the groove 41 even when the two wires 121 and 122, which are the largest in the twisted portion 125, are arranged in a transverse direction parallel to the axis 40a. On the other hand, if the width H is less than three times, when the twisted portion 125 accommodated in the groove 41 is wound onto the core portion 113, the clearance allowance for the twisted portion 125 to move within the groove 41 can be reduced. As a result, the twisted portion 125 in the groove 41 can be wound onto the core portion 113 at the desired position.

[0094] Next, the manufacturing method of the coil component will be explained.

[0095] First, such as Figure 4 As shown, a first external electrode 131 and a second external electrode 132 are provided on the bottom surface of the first flange portion 111 of the core 110, and a third external electrode 133 and a fourth external electrode 134 are provided on the bottom surface of the second flange portion 112 of the core 110.

[0096] Then, as Figure 5A As shown, the first flange 111 of the core 110 is held by the winding chuck portion 31. Furthermore, wires 121 and 122 (not shown) are led out from the winding tube, with the first wire 121 passing through the first nozzle portion 11 and the second wire 122 passing through the second nozzle portion 12. The starting end of the first wire 121 is connected to the first external electrode 131 of the core 110, and the starting end of the second wire 122 is connected to the second external electrode 132 of the core 110. For example, a heating element is used to press the starting ends of the wires 121 and 122 onto the external electrodes 131 and 132. At this time, the winding chuck portion 21 is in the first position (retracted position).

[0097] After that, as Figure 5B As shown, the rod of the first cylinder 25 is extended, causing the winding chuck section 21 to approach the winding chuck section 31 together with the rotary table 22 and the support table 24. Additionally, the... Figure 1 The rod of the second cylinder 27 shown extends, causing the winding chuck section 21, along with the rotary table 22, support table 24, and base 26, to approach the winding chuck section 31. That is, the winding chuck section 21 is moved from... Figure 5A The first position shown is towards Figure 5BThe second position (core handover position) shown is moved. Then, the core 110 held by the winding chuck portion 31 is moved to the twisting chuck portion 21.

[0098] After that, as shown in Figure 5C the rod of the first cylinder 25 is retracted, and the twisting chuck portion 21 is separated from the winding chuck portion 31 together with the rotation stage 22 and the support stage 24. At this time, the twisting chuck portion 21 is located at the third position (twisted portion forming position).

[0099] Then, as shown in Figure 5D the nozzle 10 and the core 110 are relatively rotated in the direction in which the two wires 121, 122 are twisted, and a twisted portion 125 in which the two wires 121, 122 are twisted is formed between the nozzle 10 and the core 110. Specifically, the nozzle 10 is fixed, and the rotation stage 22 is rotated around the vertical axis by driving the motor 23, and the twisting chuck portion 21 (core 110) is rotated in the Rl direction. Figure 1

[0100] In addition, the core 110 can be fixed, and the nozzle 10 can be rotated around the core 110, or the core 110 can be rotated, and the nozzle 10 can be rotated in the direction opposite to the rotation of the core 110, or the core 110 can be rotated, and the nozzle 10 can be rotated faster than the core 110 in the same direction as the rotation of the core 110.

[0101] After that, as shown in Figure 5E the rod of the first cylinder 25 is extended, and the twisting chuck portion 21 approaches the winding chuck portion 31 together with the rotation stage 22 and the support stage 24, that is, the twisting chuck portion 21 is moved toward Figure 5B the second position shown, and as shown in Figure 5F the core 110 held by the twisting chuck portion 21 is moved to the winding chuck portion 31. Then, the rod of the first cylinder 25 is retracted, and the twisting chuck portion 21 is separated from the winding chuck portion 31 together with the rotation stage 22 and the support stage 24. In addition, the rod of the second cylinder 27 shown is retracted, and the twisting chuck portion 21 is separated from the winding chuck portion 31 together with the rotation stage 22, the support stage 24, and the base stage 26. That is, the twisting chuck portion 21 is moved toward Figure 1 the first position shown. Figure 5A

[0102] After that, as shown in Figure 5G the rod of the cylinder 53 is extended, and the guide member 40 approaches the winding chuck portion 31 together with the guide support portion 51 and the guide position adjustment portion 52. At this time, the guide member 40 approaches the core 110 held by the winding chuck portion 31, and the twisted portion 125 is housed in the groove 41 of the guide member 40 and is entangled.

[0103] Then, as shown in​​Figure 5H As shown, the nozzle 10 and the core 110 are relatively rotated in a direction in which the twisted portion 125 is wound around the core 110, and the twisted portion 125 is guided to a prescribed position of the core 110 by the guide member 40 located closer to the core 110 than the nozzle 10 while being wound around the core 110. Specifically, the nozzle 10 is fixed, and the winding chuck portion 31 is rotated around the horizontal axis by the driving of the motor 32, and the core 110 held by the winding chuck portion 31 is rotated in the R2 direction around the axis 110a of the core 110.

[0104] Thus, the twisted portion 125 is wound around the core 110 while being guided to a prescribed position of the core 110 by the guide member 40 located closer to the core 110 than the nozzle 10, and therefore the twisted portion 125 can be guided to the core 110 at a position close to the core 110, and as a result, the twisted portion 125 can be wound around the core 110 at a desired position. Further, since the twisted portion 125 is wound around the core 110 while advancing in the groove 41 of the guide member 40, the twisted portion 125 is less likely to be deviated and can be wound around a more accurate position.

[0105] It is preferable that the distance between the guide member 40 and the core 110 be shorter than the distance between the nozzle 10 and the guide member 40 when the twisted portion 125 is wound around the core 110, and thus the twisted portion 125 can be wound around a more accurate position.

[0106] Further, when the twisted portion 125 is wound around the core 110, the guide member 40 is rotated around the axis 40a of the guide member 40 while guiding the twisted portion 125 to a prescribed position of the core 110. Thus, the resistance of the guide member 40 to the twisted portion 125 can be reduced, and the twisted portion 125 can be more smoothly guided to the core 110. For example, the friction of the guide member 40 against the wires 121, 122 can be reduced, and thus the breakage of the wires 121, 122 can be suppressed.

[0107] Further, when the twisted portion 125 is wound around the core 110, the guide member 40 is moved in the direction of the axis 110a of the core 110 to guide the twisted portion 125 to a prescribed position of the core 110. Specifically, the guide member 40 is moved together with the guide support portion 51 along the axis 110a of the core 110 from the first flange portion 111 to the second flange portion 112 by the driving of the guide position adjustment portion 52. Thus, the twisted portion 125 can be wound around the core 110 while the guide member 40 is moved to align with a desired position of the core 110. Thus, the position accuracy of the winding of the twisted portion 125 with respect to the core 110 can be further improved.

[0108] After that, the terminal of the first wire 121 is connected to the third external electrode 133 of the core 110, and the terminal of the second wire 122 is connected to the fourth external electrode 134 of the core 110, as shown in Figure 2 to manufacture the coil member 100.

[0109] Further, in the case where the twist pitch of the twisted portion 125 of the coil member 100 is changed, when the nozzle 10 and the core 110 are relatively rotated to form the twisted portion 125, the twist pitch of the twisted portion 125 can be changed by changing the rotation speed of the twist chuck portion 21.

[0110] Here, the twist pitch of the twisted portion 125 refers to the length from a specific relative position of the first wire 121 and the second wire 122 to the first return to the next same relative position in the state where the first wire 121 and the second wire 122 are twisted with each other. That is, it refers to the length when the positional relationship of the plurality of wires twisted with each other is rotated from 0° to 360°.

[0111] (Second Embodiment)

[0112] Figure 6 is a schematic perspective view showing a second embodiment of a manufacturing apparatus of a coil member. The second embodiment differs from the first embodiment in the number of guide members. The different structure will be described below. The other structures are the same structures as those of the first embodiment, the same reference numerals are attached and the description thereof is omitted.

[0113] As shown in Figure 6 , in the manufacturing apparatus 1A of the coil member of the second embodiment, there are two guide members 40. When the twisted portion 125 is wound around the core 110, the two guide members 40 are located on opposite sides of each other with respect to the twisted portion 125, and can guide the twisted portion 125 to the prescribed position of the core 110. Specifically, the two guide members 40 are located on opposite sides of each other with respect to the twisted portion 125, and are arranged up and down along the twisted portion 125. The twisted portion 125 travels in the grooves 41 of the two guide members 40 respectively.

[0114] According to the above structure, the two guide members 40 sandwich the twisted portion 125 in the grooves 41, and guide to the prescribed position of the core 110, so that the positional accuracy of the winding of the twisted portion 125 with respect to the core 110 can be further improved.

[0115] Next, the second embodiment of the manufacturing method of the coil member will be described. In the first embodiment, the twisted portion 125 is wound around the core 110 using one guide member 40, but in the second embodiment, the twisted portion 125 is wound around the core 110 using two guide members 40. Further, the other processes are the same as those of the first embodiment, and thus the description thereof is omitted.

[0116] That is, in the process of winding the twisted portion 125 around the core 110, the twisted portion 125 is guided to a prescribed position of the core 110 by the two guide members 40 located on opposite sides of the twisted portion 125. Thereby, the position accuracy of the winding of the twisted portion 125 around the core 110 can be further improved.

[0117] Further, in the above-described second embodiment, there are two guide members 40, but there can be three or more, in which case the plurality of guide members 40 can be arranged along the twisted portion 125, alternately located on opposite sides with respect to the twisted portion 125.

[0118] (Third Embodiment)

[0119] Figure 7 is a schematic configuration view of a third embodiment of the coil member manufacturing apparatus. The third embodiment differs from the first embodiment in that a nozzle height adjustment mechanism is provided. The different configuration will be described below. The other configurations are the same as those of the first embodiment, and the same reference numerals are assigned and the description thereof is omitted.

[0120] As shown in Figure 7 , in the coil member manufacturing apparatus IB of the third embodiment, a nozzle height adjustment mechanism 61 capable of relatively adjusting the distance between the nozzle 10 and the core 110 is further provided. That is, the nozzle height adjustment mechanism 61 is capable of relatively adjusting the distance between the nozzle 10 and the wire twisting mechanism 20. In the present embodiment, as indicated by an arrow of Figure 7 , the nozzle height adjustment mechanism 61 is capable of bringing the nozzle 10 closer to or separating from the twisting chuck portion 21. Specifically, the nozzle 10 is moved downward to approach the core 110 held by the twisting chuck portion 21, and on the other hand, the nozzle 10 is moved upward to move away from the core 110 held by the twisting chuck portion 21.

[0121] Further, the nozzle height adjustment mechanism can also be capable of bringing the twisting chuck portion 21 closer to or separating from the nozzle 10, or the nozzle height adjustment mechanism can also be capable of bringing the nozzle 10 and the twisting chuck portion 21 closer to or separating from each other.

[0122] According to the above-described configuration, in forming the twisted portion 125, the distance between the nozzle 10 and the core 110 can be adjusted according to the size of the product. In addition, in forming the twisted portion 125, by adjusting the distance between the nozzle 10 and the core 110, the twist pitch of the twisted portion 125 can be adjusted. Specifically, if the distance between the nozzle 10 and the core 110 is increased, the twist pitch becomes larger, and if the distance between the nozzle 10 and the core 110 is decreased, the twist pitch becomes smaller.

[0123] Meanwhile, the nozzle height adjustment mechanism 61 is capable of relatively adjusting the distance between the nozzle 10 and the wire winding mechanism 30. In the present embodiment, the nozzle height adjustment mechanism 61 is capable of bringing the nozzle 10 closer to or separating the nozzle 10 from the winding chuck portion 31. Specifically, the nozzle 10 is moved downward to approach the core 110 held by the winding chuck portion 31, and on the other hand, the nozzle 10 is moved upward to separate from the core 110 held by the winding chuck portion 31.

[0124] Further, the nozzle height adjustment mechanism can also bring the winding chuck portion 31 closer to or separate the winding chuck portion 31 from the nozzle 10, or the nozzle height adjustment mechanism can also bring the nozzle 10 and the winding chuck portion 31 closer to or separate the nozzle 10 and the winding chuck portion 31 from each other.

[0125] According to the above structure, when winding the twist portion 125 on the core 110, the distance between the nozzle 10 and the core 110 can be adjusted according to the size of the product.

[0126] Next, a third embodiment of the manufacturing method of the coil member will be described. In the first embodiment, the distance between the nozzle 10 and the core 110 is constant in the forming process of the twist portion 125 and the winding process of the twist portion 125, but in the third embodiment, the distance between the nozzle 10 and the core 110 is varied. Further, the other processes are the same as those of the first embodiment, and thus the description thereof will be omitted.

[0127] That is, in at least one of the process of forming the twist portion 125 and the process of winding the twist portion 125 on the core 110, the distance between the nozzle 10 and the core 110 is relatively adjusted. Thereby, in at least one of the process of forming the twist portion 125 and the process of winding the twist portion 125 on the core 110, the distance between the nozzle 10 and the core 110 can be adjusted according to the size of the product. In addition, in the process of forming the twist portion 125, by adjusting the distance between the nozzle 10 and the core 110, the twist pitch of the twist portion 125 can be adjusted.

[0128] Further, the nozzle height adjustment mechanism can also relatively adjust the distance between the nozzle and the wire twisting mechanism, or the distance between the nozzle and the wire winding mechanism.

[0129] (Fourth Embodiment)

[0130] Figure 8 is a schematic configuration view of a fourth embodiment of a manufacturing apparatus of a coil member. The fourth embodiment differs from the first embodiment in that a nozzle-to-nozzle distance adjustment mechanism is provided. The different configuration will be described below. The other configurations are the same configurations as those of the first embodiment, and the same reference numerals are attached thereto and the description thereof will be omitted.

[0131] As Figure 8 shown in FIG. 4, in the coil member manufacturing apparatus 1C of the fourth embodiment, the nozzle 10 is configured such that the first nozzle portion 11 and the second nozzle portion 12 can approach or separate from each other. The coil member manufacturing apparatus 1C further has a nozzle distance adjustment mechanism 62 that can adjust the distance between the first nozzle portion 11 and the second nozzle portion 12. In the present embodiment, as indicated by an arrow of Figure 8 , the nozzle distance adjustment mechanism 62 moves the first nozzle portion 11 and the second nozzle portion 12 in the horizontal direction with respect to each other. That is, the nozzle distance adjustment mechanism 62 causes the first nozzle portion 11 and the second nozzle portion 12 to approach or separate from each other. In addition, the nozzle distance adjustment mechanism 62 can also enable either of the first nozzle portion 11 or the second nozzle portion 12 to move.

[0132] According to the above-described structure, in the formation of the twisted portion 125, by adjusting the distance between the first nozzle portion 11 and the second nozzle portion 12, it is possible to adjust the twist pitch of the twisted portion 125. Specifically, if the distance between the first nozzle portion 11 and the second nozzle portion 12 is increased, the twist pitch becomes smaller, and if the distance between the first nozzle portion 11 and the second nozzle portion 12 is decreased, the twist pitch becomes larger.

[0133] Next, the fourth embodiment of the coil member manufacturing method will be described. In the first embodiment, the distance between the first nozzle portion 11 and the second nozzle portion 12 is constant in the formation process of the twisted portion 125, but in the fourth embodiment, the distance between the first nozzle portion 11 and the second nozzle portion 12 is varied. In addition, the other processes are the same as those of the first embodiment, and thus the description thereof will be omitted.

[0134] That is, in the process of forming the twisted portion 125, the distance between the first nozzle portion 11 and the second nozzle portion 12 is adjusted. Thereby, in the process of forming the twisted portion 125, by adjusting the distance between the first nozzle portion 11 and the second nozzle portion 12, it is possible to adjust the twist pitch of the twisted portion 125.

[0135] In addition, the present disclosure is not limited to the above-described embodiments, and design changes can be made within the scope of the gist of the present disclosure. For example, the respective features of the first to fourth embodiments can also be variously combined.

[0136] In the above-described embodiments, the coil member is used as a common mode choke coil, but for example, it can also be used as a winding type coil in which a plurality of wires are wound around a winding core portion, such as a transformer, a coupled inductor array, and the like. In these winding type coils, reduction of the inter-wire capacitance is also useful.

[0137] In the above embodiment, the coil includes two wires, but the coil can include more than two wires, and can include three or more wires. In this case, the twisting portion is not limited to a structure in which two wires are twisted, and can be a structure in which three or more wires are twisted. In addition, in the case where the number of wires is three or more, the number of nozzle portions is three or more, and the three wires can be respectively inserted through the three nozzle portions.

[0138] In the above embodiment, the guide driving mechanism has a cylinder, but the cylinder can be omitted and only the guide position adjusting portion can be provided. In addition, in the above embodiment, the guide driving mechanism is provided, but the guide driving mechanism can not be provided.

[0139] In the above embodiment, the nozzle has a first nozzle portion through which the first wire is inserted and a second nozzle portion through which the second wire is inserted, but the nozzle can have one nozzle portion through which the plurality of wires are inserted.

[0140] In the above embodiment, when the twisting portion is formed, the nozzle is fixed and the twisting chuck portion is rotated, but the nozzle can be rotated and the twisting chuck portion can be fixed, or the nozzle and the twisting chuck portion can be rotated in the same direction or in opposite directions, respectively.

[0141] In the above embodiment, when the winding portion is formed, the nozzle is fixed and the winding chuck portion is rotated, but the nozzle can be rotated and the winding chuck portion can be fixed, or the nozzle and the winding chuck portion can be rotated in the same direction or in opposite directions, respectively.

[0142] In the above embodiment, after the twisting portions are formed together, the twisting portions are wound together on the core, but the twisting portions can be wound on the core after the twisting portions are formed in multiple times. That is, after a predetermined number of twisting portions are formed, the twisting portions can be wound on the core, and then, after a predetermined number of twisting portions are formed again, the twisting portions can be wound on the core.

Claims

1. An apparatus for manufacturing a coil component, wherein, Possessing: a nozzle capable of allowing a plurality of wires to be inserted therethrough; a wire twisting mechanism that holds a core so that the core relatively rotates with respect to the nozzle in a direction in which the plurality of wires are twisted, and is capable of forming a twisted portion in which the plurality of wires are twisted between the nozzle and the core; a wire winding mechanism that holds the core so that the core relatively rotates with respect to the nozzle in a direction in which the twisted portion is wound on the core, and is capable of winding the twisted portion on the core; and a guide member that is located closer to the core than the nozzle, and is capable of guiding the twisted portion to a prescribed position of the core when the twisted portion is wound on the core, the nozzle has a plurality of nozzle portions capable of allowing the plurality of wires to be inserted therethrough, the coil member manufacturing apparatus further possesses a nozzle distance adjusting mechanism that is capable of adjusting a distance between the plurality of nozzle portions, the guide member is a cylindrical body having a groove that is V-shaped in cross section and extends in a circumferential direction of the cylindrical body.

2. The coil member manufacturing apparatus according to claim 1, wherein the guide member is located between the nozzle and the core when the twisted portion is wound on the core.

3. The coil member manufacturing apparatus according to claim 1, wherein the groove allows the twisted portion to pass therethrough.

4. The coil member manufacturing apparatus according to claim 2, wherein the groove allows the twisted portion to pass therethrough.

5. The coil member manufacturing apparatus according to claim 1, wherein the guide member is held so as to be rotatable about an axis of the cylindrical body.

6. The coil member manufacturing apparatus according to any one of claims 1 to 5, wherein the coil member manufacturing apparatus further possesses a guide drive mechanism that is capable of moving the guide member in an axial direction of the core when the twisted portion is wound on the core in the axial direction of the core.

7. The coil member manufacturing apparatus according to any one of claims 1 to 5, wherein there are two guide members, the two guide members are located on opposite sides of the twisted portion with respect to each other when the twisted portion is wound on the core, and are capable of guiding the twisted portion to a prescribed position of the core.

8. The coil member manufacturing apparatus according to claim 6, wherein there are two guide members, the two guide members are located on opposite sides of the twisted portion with respect to each other when the twisted portion is wound on the core, and are capable of guiding the twisted portion to a prescribed position of the core.

9. The coil member manufacturing apparatus according to any one of claims 1 to 5, wherein the coil member manufacturing apparatus further possesses a nozzle height adjusting mechanism that is capable of relatively adjusting a distance between the nozzle and the core.

10. The coil member manufacturing apparatus according to claim 6, wherein the coil member manufacturing apparatus further possesses a nozzle height adjusting mechanism that is capable of relatively adjusting a distance between the nozzle and the core. Possessing:

11. A method of manufacturing a coil component, wherein, ​ a step of passing a plurality of wire rods through the nozzle and connecting starting ends of the plurality of wire rods to the outer electrode of the core; a step of relatively rotating the nozzle and the core in a direction in which the plurality of wire rods are twisted, and forming a twisted portion in which the plurality of wire rods are twisted, between the nozzle and the core; and a step of relatively rotating the nozzle and the core in a direction in which the twisted portion is wound around the core, and winding the twisted portion around the core while guiding the twisted portion to a predetermined position of the core by a guide member located closer to the core than the nozzle, the nozzle has a plurality of nozzle portions through which the plurality of wire rods are respectively inserted, in the step of forming the twisted portion, the distance between the plurality of nozzle portions is adjusted, the guide member is a cylindrical body having a groove extending in a V-shape in cross section in a circumferential direction of the cylindrical body.

12. The method of manufacturing a coil member according to claim 11, wherein in the step of winding the twisted portion around the core, the guide member is rotated around an axis of the guide member while guiding the twisted portion to the predetermined position of the core.

13. The method of manufacturing a coil member according to claim 11, wherein in the step of winding the twisted portion around the core, the guide member is moved in an axial direction of the core while guiding the twisted portion to the predetermined position of the core.

14. The method of manufacturing a coil member according to claim 12, wherein in the step of winding the twisted portion around the core, the guide member is moved in an axial direction of the core while guiding the twisted portion to the predetermined position of the core.

15. The method of manufacturing a coil member according to any one of claims 11 to 14, wherein there are two guide members, in the step of winding the twisted portion around the core, the twisted portion is guided to the predetermined position of the core by the two guide members located on opposite sides of the twisted portion.

16. The method of manufacturing a coil member according to any one of claims 11 to 14, wherein in at least one of the step of forming the twisted portion and the step of winding the twisted portion around the core, the distance between the nozzle and the core is relatively adjusted.

17. The method of manufacturing a coil member according to claim 15, wherein in at least one of the step of forming the twisted portion and the step of winding the twisted portion around the core, the distance between the nozzle and the core is relatively adjusted.

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