Coil framework, coil component and manufacturing method of coil framework

Abstract

The bobbin (10) has a winding (120), a first bobbin (111), and a second bobbin (112). The first frame (111) and the second frame (112) are arranged side by side so as to follow each other in the axial direction. The winding (120) is continuously wound across the first frame (111) and the second frame (112), and transitions from the first frame (111) to the second frame (112) through an inner space (130) sandwiched between the first frame (111) and the second frame (112) in a horizontal row. In addition, the winding (120) has a slack portion (121) in the inner space (130).

Description

Technical Field

[0001] The present invention relates to a coil bobbin having a plurality of bobbins on which windings are continuously wound, a coil component including the coil bobbin, and a method for manufacturing the coil bobbin. Background Art

[0002] Some coil components have two bobbins arranged side by side in an axial direction, with a winding wound continuously across the two bobbins. Specifically, after the winding is wound from one end to the other end of one of the two bobbins arranged side by side, the winding is then wound directly from the other end to the one end of the other adjacent bobbin.

[0003] Regarding this technology, Patent Document 1 below discloses an inductor component in which a single winding (9, 10) is continuously wound around two bobbins (21, 22) arranged side by side so as to follow each other in the axial direction.

[0004] As in Patent Document 1 Figure 1 As shown in FIG. (b), the windings (9, 10) are wound from the lower end toward the upper end of the coil bobbin (21) on one side (for example, the left side), transition from the left coil bobbin (21) to the right coil bobbin (22), and are wound from the upper end toward the lower end of the right coil bobbin (22). More specifically, the windings (9, 10) wound from the lower end toward the upper end of the left coil bobbin (21) are led to the flange portion (24) on the upper end side of the left coil bobbin (21). The windings (9, 10) pass along the outer circumference of the inductor component while passing over the flange portion (24) and transition from the left coil bobbin (21) to the right coil bobbin (22), and are wound from the upper end toward the lower end of the right coil bobbin (22).

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Laid-Open No. 2000-182844 Summary of the Invention

[0008] Problems to be solved by the invention

[0009] A winding device is typically used to wind the wire around a bobbin. Specifically, the wire feeding unit (such as a nozzle that unwinds the wire) or the bobbin (which serves as the winding core) is rotated to wind the wire around the bobbin's outer circumference. Simultaneously with the winding of the wire, the wire feeding unit or the bobbin is moved axially to arrange the windings on the bobbin.

[0010] When the winding is wound continuously around two coil bobbins (21, 22) arranged horizontally in a manner that follows each other axially, as in Patent Document 1, when winding the wire around one coil bobbin, the other coil bobbin close to the coil bobbin may interfere with a part of the winding device, such as the wire supply unit. For example, when the position of the wire supply unit of the winding device is fixed and one coil bobbin is rotated while winding, the other coil bobbin that is close to the first coil bobbin in the radial direction of the first coil bobbin rotates around the axis of the first coil bobbin as the first coil bobbin rotates, and therefore interferes with the wire supply unit of the winding device. In addition, when the position of the coil bobbin is fixed and the wire supply unit is moved around the axis of the first coil bobbin to wind the winding, the wire supply unit that moves circumferentially on the first coil bobbin interferes with the other coil bobbin that is close to it. In order to prevent the wire supply unit from interfering with the coil bobbin, a gap needs to be provided between the two coil bobbins so that the wire supply unit can pass between the two coil bobbins when winding the winding. However, when gaps are provided between the coil bobbins, the overall size of the coil component increases. In order to miniaturize the coil component by eliminating gaps between the coil bobbins, it is necessary to avoid interference between the wire feeder and the coil bobbins and to use a special winding method to wind the winding, which reduces the efficiency of the winding process.

[0011] The present invention has been made in view of the above-mentioned problems and provides a method for manufacturing a coil bobbin and a coil bobbin capable of such manufacturing, which reduces interference between a winding device and a coil bobbin in a winding process and improves the efficiency of the winding process.

[0012] Solutions for solving problems

[0013] According to the present invention, a coil frame is provided, characterized in that the coil frame has: a winding; and a first frame and a second frame, which are arranged horizontally in a manner of axially following each other, the winding is continuously wound across the first frame and the second frame, and transitions from the first frame to the second frame through an inner space sandwiched by the horizontally arranged first frame and the second frame, and the winding has a slack portion in the inner space.

[0014] A coil component is provided, characterized in that the coil component comprises: the above-mentioned coil skeleton; and a core, which has magnetic legs respectively penetrating the first skeleton and the second skeleton in the winding axis direction of the winding, and the core is composed of a combination of multiple magnetic components. In the coil component, the first skeleton and the second skeleton have: a winding axis portion, which is for winding the winding; and a flange portion, which is respectively formed at one end and the other end of the first skeleton and one end and the other end of the second skeleton, and the flange portion protrudes relative to the winding axis portion in a direction intersecting the axial direction, and the flange portion of one end of each of the first skeleton and the second skeleton or the flange portion of the other end has a protrusion on the outer side surface on the opposite side to the winding axis portion, and at least one of the magnetic components is arranged across the flange portion of the first skeleton and the flange portion of the second skeleton, and the protrusion is arranged around the magnetic component.

[0015] According to the present invention, a method for manufacturing a coil bobbin is provided, wherein the coil bobbin has: a winding; and a first bobbin and a second bobbin, which are arranged horizontally with each other and respectively have a reel portion for winding the winding, wherein the method for manufacturing the coil bobbin includes: a winding process, in which the winding is continuously wound across the reel portion of the first bobbin and the reel portion of the second bobbin while the first bobbin and the second bobbin are arranged vertically with the reel portions arranged in a roughly straight line with each other; and a folding process, in which the first bobbin and the second bobbin are folded with the length region of the winding spanning the first bobbin and the second bobbin, i.e., the transition portion, being located inward, so that the first bobbin and the second bobbin are arranged horizontally.

[0016] The coil bobbin of the above invention can be manufactured as follows: during the winding process, the winding is continuously wound with the two bobbins arranged longitudinally so as to be arranged in a substantially straight line in the axial direction, and then the two bobbins are folded so as to be arranged transversely so as to follow each other in the axial direction. When the winding is wound with the two bobbins arranged longitudinally, the other bobbin does not exist in the radial direction of one bobbin around which the winding is wound, thereby preventing interference between the winding device and the coil bobbin.

[0017] Effects of the Invention

[0018] According to the coil bobbin, coil component, and coil bobbin manufacturing method of the present invention, the interference between the winding device and the coil bobbin in the winding process can be reduced, thereby improving the efficiency of the winding process. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The above-mentioned objects and other objects, features, and advantages will become more apparent from the preferred embodiments described below and the following drawings attached to the preferred embodiments.

[0020] Figure 1 It is a perspective view of the coil bobbin according to the first embodiment of the present invention (however, illustration of the winding is omitted).

[0021] Figure 2 It is a perspective view of the coil bobbin according to the first embodiment (however, illustration of the second bobbin and the winding wound around the second bobbin is omitted).

[0022] Figure 3 It is a top view of the coil bobbin of the first embodiment.

[0023] Figure 4 This is a front view of the coil bobbin according to the first embodiment.

[0024] Figure 5 The coil bobbin of the first embodiment is Figure 3 The cross section indicated by the one-dot chain line is a longitudinal sectional view as viewed from the direction of the arrow line VV.

[0025] Figure 6 The coil bobbin of the first embodiment is Figure 4 The cross section indicated by the single-dot chain line is a cross-sectional view as viewed from the direction of the arrow line VI-VI.

[0026] Figure 7 This is a perspective view of the bobbin in the expanded state according to the first embodiment.

[0027] Figure 8 This is a side view of the coil bobbin in the expanded state according to the first embodiment, as viewed from the side where the recess is formed.

[0028] Figure 9 This is a perspective view of the coil component according to the first embodiment.

[0029] Figure 10 It is a perspective view of the coil component according to the first embodiment (however, illustration of the terminal portion is omitted).

[0030] Figure 11 It is a longitudinal sectional view of the coil component according to the first embodiment (however, illustration of the winding and the terminal portion is omitted). DETAILED DESCRIPTION

[0031] The various components of the coil frame and coil parts of the present invention do not need to exist separately and independently. It is allowed that multiple components form one component, one component is formed by multiple components, a certain component is part of other components, a part of a certain component overlaps with a part of other components, etc.

[0032] In addition, there are cases where the coil bobbin manufacturing method of the present invention is described using multiple steps described in sequence, but the order of the description does not limit the order or timing of executing the multiple steps. Therefore, when implementing the coil bobbin manufacturing method of the present invention, the order of the multiple steps can be changed within a range that does not hinder the content, and some or all of the execution times of the multiple steps can also overlap with each other.

[0033] Hereinafter, embodiments of the present invention will be described based on the accompanying drawings. In the drawings, corresponding components are denoted by the same reference numerals, and duplicate descriptions are omitted as appropriate.

[0034] In this embodiment, there is a case where the axial direction of the first skeleton and the second skeleton is called the longitudinal direction, and the direction perpendicular to the longitudinal direction is called the transverse direction. In addition, there is a case where, when the first skeleton and the second skeleton are arranged in a horizontal row, the direction perpendicular to the longitudinal direction and the arrangement direction of the first skeleton 111 and the second skeleton 112 is called the front-to-back direction of the coil skeleton 10 and the skeleton 110. For example, Figure 5 In the direction between the back and front of the paper, Figure 6 The vertical direction of the paper is the front-back direction. In addition, the side of the coil frame 10 and the frame 110 in the folded state having the protruding area and the recessed portion is called the "upper side", and the opposite side of the "upper side" is called the "lower side". For example, Figure 5 and Figure 11 In Chinese, the upper side of the paper is the “upper side” and the lower side of the paper is the “lower side”.

[0035] <First embodiment>

[0036] (Coil skeleton)

[0037] Figure 1 It is a perspective view showing an example of the bobbin according to the first embodiment of the present invention.

[0038] First, the outline of the bobbin 10 according to the present embodiment will be described.

[0039] Coil bobbin 10 includes winding 120, first bobbin 111, and second bobbin 112. First bobbin 111 and second bobbin 112 are arranged in a horizontal row, following each other axially. Winding 120 is wound continuously across first bobbin 111 and second bobbin 112, and transitions from first bobbin 111 to second bobbin 112 through inner space 130 between the horizontally arranged first bobbin 111 and second bobbin 112. Winding 120 also has slack 121 within inner space 130.

[0040] Next, the bobbin 10 of this embodiment will be described in detail.

[0041] Among them, the coil bobbin 10 refers to a component having one or more skeletons 110 and wound with a winding 120. In this embodiment, the component in which the winding 120 is wound around two skeletons 110 is sometimes referred to as the coil bobbin 10. The skeleton 110 refers to a component that serves as a reel for winding the winding 120. The skeleton 110 is a long strip that is longer in the direction of the reel. In this embodiment, the coil bobbin 10 has a first skeleton 111 and a second skeleton 112 as the skeletons 110. The axial direction of the first skeleton 111, the second skeleton 112, and the reel portion 113 discussed later refers to the extension direction of the first skeleton 111 or the second skeleton 112.

[0042] In the present embodiment, the cross-section of the skeleton 110 is set to be rectangular, but it can also be circular, square, or polygonal. In addition, the skeleton 110 in the present embodiment is a straight axis skeleton with the center line of the reel being a straight line, and the skeleton 110 can also be in a non-linear shape such as an arc. It is also possible that, for example, the two skeletons each have a semicircular shape, and when the two skeletons 110 are arranged horizontally, the two skeletons 110 become a ring as a whole. The winding 120 is a wire wound around the first skeleton 111 and the second skeleton 112. The winding 120 is composed of a conductor made of metal such as copper and aluminum.

[0043] Among them, the first skeleton 111 and the second skeleton 112 are arranged horizontally in a manner of axially following each other, which means that the scroll direction of one of the two skeletons (for example, the first skeleton 111) has the scroll direction component of the other skeleton (the second skeleton 112). Preferably, the scroll direction of one of the first skeleton 111 and the second skeleton 112 has an axial direction component that is larger than the orthogonal component orthogonal to the scroll direction of the other skeleton. More preferably, the first skeleton 111 is parallel or substantially parallel to the second skeleton 112. The axial direction of the first skeleton 111 and the axial direction of the second skeleton 112 may not be completely parallel, and may be in a crossed state or a twisted state. In the following, sometimes Figure 1 The state in which the first frame 111 and the second frame 112 are arranged in a horizontal row in a manner that follows each other in the axial direction is called a folded state. Figure 7 and Figure 8 In this manner, the first frame and the second frame are arranged substantially linearly in the axial direction, and this arrangement state is sometimes referred to as a deployed state.

[0044] As in Figure 6Indicated by the double-dashed line, the inner space 130 refers to the space sandwiched between the first and second frames 111, 112 when the first and second frames 111, 112 are arranged side by side. In this embodiment, flange portions 116 (upper flange portion 116 and lower flange portion 114), discussed later, are formed at both protruding ends of the first and second frames 111, 112. The upper flange portions 116 and the lower flange portions 114 abut against each other, respectively. In this embodiment, the inner space 130 is the space sandwiched between the upper flange portion 116 and the lower flange portion 114, and is sandwiched between the scroll portions 113 of the first and second frames 111, 112.

[0045] like Figure 6 As shown, the inner space 130 has at least two opening surfaces 131 in the transverse direction. The opening surface 131 refers to an imaginary surface that connects the portion of the first frame 111 that protrudes most in one direction in the front and rear directions with the portion of the second frame 112 that protrudes most in the same direction when the two frames 110 are in the folded state. Figure 6 As shown, one opening surface 131 (131a) is an imaginary surface that connects the circumferential surface of the scroll portion 113 located on the front side (lower side of the paper) of the first skeleton 111 with the circumferential surface of the scroll portion 113 located on the front side of the second skeleton 112, and the other opening surface 131 (131b) is an imaginary surface that connects the circumferential surface of the scroll portion 113 located on the rear side (upper side of the paper) of the first skeleton 111 with the circumferential surface of the scroll portion 113 located on the rear side of the second skeleton 112.

[0046] The inner space 130 of this embodiment is defined by the opposing side surfaces of the first and second frames 111 and 112 , the upper and lower flange portions 116 and 114 of the first and second frames 111 and 112 , and the opening surfaces 131 ( 131 a and 131 b ).

[0047] When the frame 110 does not have the flange portion 116, the axial expansion of the inner space 130 extends to both axial ends of the first frame 111 and the second frame 112. When the flange portion is not provided at the end of the frame 110 but is provided in the axial middle portion so that the winding is wound on both sides, the axial expansion of the inner space 130 also extends to both axial ends of the first frame 111 and the second frame 112.

[0048] Here, continuously winding the winding 120 across the first bobbin 111 and the second bobbin 112 means winding the same winding 120 around the first bobbin 111 and the second bobbin 112. Specifically, one end of the winding 120 wound around the first reel portion 113a (the reel portion 113 of the first bobbin 111) located at the upper end of the first reel portion 113a is connected to one end of the winding 120 wound around the second reel portion 113b (the reel portion 113 of the second bobbin 112) located at the upper end of the second reel portion 113b.

[0049] Among them, the winding 120 spanning between the first skeleton 111 and the second skeleton 112 in the folded state of the first skeleton 111 and the second skeleton 112 is called the boundary portion 123. Specifically, the length area of ​​the winding 120 connecting the point where the winding 120 wound on the first reel portion 113a is separated from the first reel portion 113a on the upper end side and the point where the winding 120 wound on the second reel portion 113b is in contact with the second reel portion 113b on the upper end side is the boundary portion 123. The boundary portion 123 in this embodiment is the position X (refer to the position X) in the winding 120 where the winding to the first skeleton 111 ends and the winding 120 leaves the first skeleton 111. Figure 6 ) to the position Y (refer to the position Y) where the winding 120 contacts the second frame 112 and begins to be wound around the second frame 112 Figure 6 ) of the winding 120 in the length region. The boundary portion 123 includes a transition portion 122 (see Figure 8 ).

[0050] The winding 120 passes through the inner space 130 and transitions from the first frame 111 to the second frame 112, which means that at least a portion of the boundary portion 123 exists in the inner space 130. Specifically, Figure 6 As shown, one end of the boundary portion 123 existing in the inner space 130 passes through an opening surface 131a on one side of the inner space 130 and opens to the outside of the inner space 130, while the other end of the boundary portion 123 existing in the inner space 130 passes through an opening surface 131b on the other side of the inner space 130 and opens to the outside of the inner space 130. A portion of the boundary portion 123 may exist outside the inner space 130.

[0051] A portion of the boundary portion 123 is as follows Figure 2 The figure shows a bent portion. Figure 6 In the figure, the cross section of the winding 120 is shown in the middle of the boundary portion 123 because the bending portion is relatively Figure 4 The cross section shown in FIG is protruding outward. In the figure, the cross section of the winding 120 is schematically shown as a circle, but in reality it is sometimes elliptical.

[0052] In this embodiment, the winding 120 is continuously wound around the two bobbins 110 as follows. The winding 120 is wound around the first reel portion 113a from the lower end to the upper end in the axial direction of the first bobbin 111 in a clockwise direction when the first bobbin 111 is viewed from above. Then, the winding 120 is passed through the inner space 130 sandwiched between the first bobbin 111 and the second bobbin (at Figure 4 The winding 120 is then wound around the second bobbin 112 from the upper end toward the lower end of the second bobbin 113b in a counterclockwise direction when viewing the second bobbin 112 from above.

[0053] For example, the winding 120 may be wound counterclockwise around the first reel 113a when viewing the first bobbin 111 from above, and the winding 120 may be wound clockwise around the second reel when viewing the second bobbin 112 from above.

[0054] When core 140 (U-core 142 and I-core 143), discussed later, is attached to coil bobbin 10, coil component 100 is formed with a closed magnetic circuit structure. In coil component 100, the magnetic lines of force generated by the coil pass through the core, forming a loop. By winding 120 so that the winding directions of winding 120 at first reel portion 113a and second reel portion 113b are opposite to each other when viewing coil bobbin 10 from the same side (e.g., top), coil component 100 is formed so that winding 120 is wound in the same direction relative to the direction of the magnetic lines of force.

[0055] Here, slack portion 121 refers to a portion of the length of winding 120 at or near boundary portion 123, and is a region that is slack compared to other length regions of winding 120 wound around or near the middle portion of reel portion 113. Specifically, slack portion 121 is a region of winding 120 at or near boundary portion 123 that corresponds to any of the following: a portion of winding 120 subjected to lower tension than winding 120 wound around the lower end of reel portion 113; a portion of winding 120 that is not linear at boundary portion 123; and a portion of winding 120 with a larger winding diameter than winding 120 wound around the lower end of reel portion 113. The winding 120 wound around the lower end of the reel portion 113 refers to the winding 120 wound around the middle portion or the vicinity of the middle portion of, for example, the first reel portion 113 a or the second reel portion 113 b .

[0056] In this embodiment, if Figure 2As shown, boundary portion 123 is not linear but rather has a bend. Specifically, boundary portion 123 has an excess length corresponding to the length of transition portion 122, discussed later, and the excess length of winding 120 is bent midway along boundary portion 123. In this embodiment, boundary portion 123 serves as slack portion 121.

[0057] In this embodiment, the boundary portion 123 spanning only the first skeleton 111 and the second skeleton 112 is shown as a slack portion 121, but it is not limited to this. The winding 120 wound on, for example, the first skeleton 111 or the second skeleton 112 sometimes also becomes a slack portion 121. For example, since the boundary portion 123 has an extra length, the winding 120 sometimes loosens in the radial direction on the upper end side of the first reel portion 113a or the second reel portion 113b. The radial direction refers to the direction radially from the axis of the skeleton 110 toward the periphery. Hereinafter, when the cross-section of the reel portion 113 or the flange portion 116 is not circular but polygonal, the above-mentioned direction will also be referred to as the radial direction.

[0058] In the case where the winding 120 wound on the upper end of the reel portion 113 is wound with a lower tension than the winding 120 wound on the middle portion of the reel portion 113 due to slack, a portion of the length of the winding 120 is also included as the slack portion 121. In this case, the winding 120 wound on the reel portion 113, which becomes the slack portion 121, may or may not be in contact with the reel portion 113. In addition, in the case where the winding 120 wound on the upper end of the reel portion 113 has a larger diameter than the winding 120 wound on the middle portion of the reel portion 113 due to slack, the winding 120 wound on the reel portion 113 with a larger diameter than the winding 120 wound on the middle portion of the reel portion 113 is also included as the slack portion 121.

[0059] In this embodiment, the slack portion 121 is twisted relative to the direction in which the winding 120 extends. Specifically, the slack portion 121 is twisted by an amount corresponding to the angle at which the first and second frames 111, 112 are rotated during the folding process described later. For example, when the unfolded first and second frames 111, 112 are folded 180 degrees during the folding process so that the first and second frames 111, 112 are arranged side by side, a 180-degree twist is generated in the slack portion 121.

[0060] If the first frame 111 and the second frame 112 are folded from the unfolded state, the transition portion 122 discussed later is also folded. Figure 2 As shown in this embodiment, in the folded state, the transition portion 122 (refer to Figure 8) also has a bent shape. This is because the direction of rotation of the winding 120 when the slack portion 121 is to eliminate the twist is opposite to the direction of rotation of the winding 120 when the bent transition portion 122 is to become straight. Therefore, the bent transition portion 122 is prevented from becoming straight. Thus, by twisting the slack portion 121, it becomes easier to maintain the bent shape of the transition portion 122, which will be discussed later. This prevents the winding 120 wound on the reel portion 113 from unwinding due to the excess length of the winding 120 corresponding to the transition portion 122.

[0061] Due to the twist in winding 120, boundary portion 123 may become substantially linear, and the tension of winding 120 wound around the upper end of reel portion 113 may be equal to the tension of winding 120 wound around the middle portion of reel portion 113, or the winding diameter of winding 120 may not be increased compared to winding 120 wound around the middle portion of reel portion 113. In this case, a portion of the length of winding 120 having the twist is defined as slack portion 121.

[0062] Preferably, regardless of whether there is twisting, the following portions in the winding 120 on the upper end side of the reel portion 113 are slack portions 121, and the portions are as described above: a portion to which lower tension is applied than the winding 120 wound to the lower end side of the reel portion 113; a boundary portion 123 where the winding 120 is not linear; or a portion having a larger winding diameter than the winding diameter of the winding 120 wound to the lower end side of the reel portion 113.

[0063] Because the winding 120 has a slack portion 121 and the portion transitioning from the first frame 111 to the second frame 112 has excess length, the winding 120 can be manufactured using the following manufacturing method as discussed later: the first frame 111 and the second frame 112 are set in an unfolded state and the winding 120 is continuously wound.

[0064] Alternatively, the present invention can be manufactured using the manufacturing method discussed below: the winding 120 is passed through the inner space 130 across the first frame 111 and the second frame 112 , and the winding 120 is continuously wound in the same direction from the first frame 111 to the second frame 112 in the unfolded state.

[0065] By disposing a portion of slack portion 121 in inner space 130 of first bobbin 111 and second bobbin 112, slack portion 121 is prevented from being exposed outside coil bobbin 10. This prevents slack portion 121 from being cut or worn, thereby reducing performance degradation of coil component 100 and unexpected shortening of insulation distance.

[0066] The first and second bobbins 111 and 112 include a reel portion 113 around which the winding 120 is wound. The first and second bobbins 111 and 112 include a protruding region extending in the circumferential direction of the reel portion 113 at one end portion thereof.

[0067] The reel portion 113 refers to the area of ​​the first bobbin 111 or the second bobbin 112 around which the winding 120 is wound. If the first bobbin 111 or the second bobbin 112 has a protruding area such as the flange portion 116 discussed later, the reel portion 113 is the area axially closer to the center of the protruding area such as the flange portion 116. If the first bobbin 111 or the second bobbin 112 has flange portions 116 at both ends (upper flange portion 116 and lower flange portion 114), the reel portion 113 is the area sandwiched between the upper flange portion 116 and the lower flange portion 114.

[0068] The protruding area refers to the following area: a protrusion protruding relative to the scroll part 113 in a direction intersecting the axial direction, including the protrusion, which goes around the circumference of the scroll part 113. In this embodiment, the protruding area is formed at the protruding ends of the first skeleton 111 and the second skeleton 112, but it can also be set in the middle of the axial length of the first skeleton 111 and the second skeleton 112. In this embodiment, as Figure 1 While the entire protruding region is shown as a protrusion, that is, the protruding region is in the form of the flange portion 116 discussed later, this is not limiting. For example, only a portion of the protruding region may have a protrusion, and the portion of the protruding region other than the protrusion may be continuous with the circumferential surface of the reel portion 113. Furthermore, the protruding region may have multiple protrusions.

[0069] The protruding region (upper flange portion 116) has a recessed portion 115 formed into a concave shape from the outer periphery of the protruding region toward the winding shaft portion 113. Recessed portion 115 is provided in the protruding portion of the protruding region and is the portion of upper flange portion 116 that forms the concave shape. During the winding process of winding 120, which will be discussed later, winding 120 passes through recessed portion 115.

[0070] The radial height of the recess 115 based on the circumferential surface of the scroll portion 113 only needs to be lower than the height of the protrusion in the protruding area. It may be higher than the height of the circumferential surface of the scroll portion 113, or it may be the same height as the circumferential surface of the scroll portion 113. The first skeleton 111 and the second skeleton 112 are arranged in such a way that at least a portion of their respective recesses 115 exists on the inner side sandwiched by the first skeleton 111 and the second skeleton 112. The presence of at least a portion of the recess 115 on the inner side sandwiched by the first skeleton 111 and the second skeleton 112 means that at least a portion of the opening of the recess 115 exists on the inner side sandwiched by the first skeleton 111 and the second skeleton 112. The opening of the recess 115 refers to the imaginary peripheral edge of the protrusion when the protrusion does not form the recess 115.

[0071] In this embodiment, the recess 115 of the first bobbin 111 is opposite to the recess 115 of the second bobbin 112. That is, the recess 115 of the first bobbin 111 and the recess 115 of the second bobbin 112 are arranged at the same height in the axial direction of the first bobbin 111 and the second bobbin 112. In addition, the recess 115 of the first bobbin 111 and the recess 115 of the second bobbin 112 are opposite to each other in the circumferential direction of the first bobbin 111 and the second bobbin 112, and are connected to each other when viewed from the upper surface of the coil bobbin 10. However, this is not limiting, and the recess 115 of the first bobbin 111 and the recess 115 of the second bobbin 112 may not be opposite to each other. That is, the recess 115 of the first bobbin 111 and the recess 115 of the second bobbin 112 may also be arranged to be offset in the circumferential or axial direction of the first bobbin 111 and the second bobbin 112.

[0072] By providing a protruding region and providing a recessed portion 115 in the protruding region, a structure is formed that enables the winding process of the coil bobbin 10 manufacturing method, which will be discussed later. In other words, by passing the winding 120 through the recessed portions 115 of the first bobbin 111 and the second bobbin 112 during the winding process, the position of the winding 120 (transition portion 122, discussed later) that transitions from the first bobbin 111 to the second bobbin 112 can be determined in the unfolded state. This prevents the winding 120 from shifting laterally during the folding process of folding the first bobbin 111 and the second bobbin 112 into a horizontal arrangement, and enables the structure to be configured to implement the folding process in which the winding 120 is folded with the transition portion 122 positioned inward.

[0073] The width (circumferential dimension) of the recess 115 can be either narrow, approximately the same as the outer diameter of the winding 120, or longer than the outer diameter of the winding. To prevent lateral displacement of the winding 120 during the folding process, the width of the recess 115 can be set to a length that is less than one-quarter of the entire circumference of the protruding region. Furthermore, to further effectively prevent lateral displacement of the winding 120, the width of the recess 115 can be set to less than twice the outer diameter of the winding 120. To prevent lateral displacement of the winding 120, the depth of the recess 115 in the radial direction of the reel portion 113 can be set to a length that is greater than the diameter of the cross section of the winding 120.

[0074] Furthermore, by providing the protruding region, the winding 120 can be locked by the protruding portion, thereby preventing the winding 120 from unwinding from the protruding region to the side opposite to the winding shaft portion 113. If multiple protruding portions are provided in the protruding region, unwinding of the winding 120 can also be effectively prevented at multiple locations.

[0075] The slack portion 121 has the following length: Figure 7 and Figure 8 As shown in the figure, when first bobbin 111 and second bobbin 112 are arranged in a straight line so that one end portion provided with the protruding region (upper flange portion 116) abuts against each other, winding 120 can pass through recess 115 and span first bobbin 111 and second bobbin 112. Passing through recess 115 means that winding 120 is arranged so as to intersect the direction in which the protruding region extends, and a portion of winding 120 is surrounded by recess 115 on the surface where the protruding region extends.

[0076] More specifically, the length of the slack portion 121 is greater than the total length obtained by adding the height of the bottom of the recessed portion 115 of the first frame 111 from the circumference of the reel portion 113, the height of the bottom of the recessed portion 115 of the second frame 112, and the distance L1 from the recessed portion 115 of the first frame 111 to the recessed portion 115 of the second frame 112 when the first frame 111 and the second frame 112 are arranged in a straight line so that one end portion having the protruding area abuts against each other (see FIG. Figure 8 ) in total. The height of the bottom of the recess 115 from the circumferential surface of the scroll portion 113 refers to the height of the deepest part of the recess 115 with the circumferential surface of the scroll portion 113 as a reference in the radial direction. In addition, when the first skeleton 111 and the second skeleton 112 are arranged in a straight line so that one end portion having a protruding area abuts against each other, the distance from the recess 115 of the first skeleton 111 to the recess 115 of the second skeleton 112 refers to the distance between a point on the scroll portion 113 side of the respective recesses 115 of the first skeleton 111 and the second skeleton 112.

[0077] In this embodiment, the height of the recess 115 is the same as the height of the circumference of the reel portion 113 . Therefore, the height of the recess 115 of the first skeleton 111 from the circumference of the reel portion 113 and the height of the recess 115 of the second skeleton 112 are substantially zero.

[0078] In such a Figure 7 When the first skeleton 111 and the second skeleton 112 are arranged in a vertical row as shown in , their respective recesses 115 are connected. In this case, the distance from the recess 115 of the first skeleton 111 to the recess 115 of the second skeleton 112 is the distance from the inner surface of the upper flange portion 116a of the first skeleton 111 (the surface of the flange portion 116 on the side of the reel portion 113) to the inner surface of the upper flange portion 116b of the second skeleton 112. In other words, the distance from the recess 115 of the first skeleton 111 to the recess 115 of the second skeleton 112 includes the thickness of the upper flange portions 116 (116a, 116b) of the first skeleton 111 and the second skeleton 112 and the length between the upper flange portion 116a of the first skeleton 111 and the upper flange portion 116b of the second skeleton 112.

[0079] In the winding process discussed later, the first skeleton 111 and the second skeleton 112 are in an unfolded state. For example, after being wound onto the first skeleton 111, the winding 120 transitions from the first skeleton 111 to the second skeleton 112 through the recess 115 of the first skeleton 111 and the recess 115 of the second skeleton 112, and is wound onto the second skeleton 112.

[0080] When first bobbin 111 and second bobbin 112 are folded, winding 120, or transition portion 122, disposed between recess 115 of first bobbin 111 and recess 115 of second bobbin 112 in the unfolded state becomes part of slack portion 121. Specifically, slack portion 121 has at least a length sufficient to pass through recess 115 and span first bobbin 111 and second bobbin 112 in the unfolded state, enabling coil bobbin 10 to be manufactured using the method for manufacturing coil bobbin 10, which will be discussed later.

[0081] More specifically, when wound around the first reel portion 113a in the unwound state, the winding 120 radially extends from the circumference of the first reel portion 113a onto the recess 115, then crosses from the recess 115 of the first bobbin 111 to the recess 115 of the second bobbin 112. From the recess 115 of the second bobbin 112, it descends toward the circumference of the second reel portion 113b, where it is wound around the second reel portion 113b. In this embodiment, the bottom height of the recess 115 is zero. Therefore, the winding 120 wound around the first reel portion 113a does not radially extend onto the upper flange portion 116a, but instead transitions from the recess 115 of the first bobbin 111 to the recess 115 of the second bobbin 112 and is directly wound around the second reel portion 113b.

[0082] The slack portion 121 has a length that is greater than the sum of the height of the bottom of the recessed portion 115 from the circumference of the first reel portion 113a, the height of the bottom of the recessed portion 115 from the circumference of the second reel portion 113b, and the distance between the recessed portion 115 of the first bobbin 111 and the recessed portion 115 of the second bobbin 112. Thus, during the winding process, the winding 120 can be placed from the circumference of the first reel portion 113a onto the recessed portion 115 of the first bobbin 111, spanning between the recessed portions 115 of the first bobbin 115 and the recessed portions 115 of the second bobbin 112, and then descending from the recessed portion 115 of the second bobbin 112 toward the circumference of the second reel portion 113b.

[0083] like Figure 4 and Figure 5 As shown, the protruding area in this embodiment is a flange portion 116 that protrudes relative to the scroll portion 113 of the first skeleton 111 or the second skeleton 112 in a direction intersecting the axial direction. The flange portion 116 refers to a portion that protrudes relative to the circumferential surface of the scroll portion 113 over approximately the entire circumference of the protruding area. In this embodiment, the flange portion 116 is shown in a form in which the protruding area protrudes over the entire circumference except for the recessed portion 115, but is not limited to this. It is also possible that a part of the flange portion 116 does not protrude, but is continuous with the circumferential surface of the scroll portion 113. That is, the flange portion 116 may also have one or more recessed portions 115.

[0084] In the present embodiment, the flange portion 116 protrudes at a right angle to the axial direction, but the present invention is not limited thereto.

[0085] The winding 120 transitions from the first bobbin 111 to the second bobbin 112 at a position closer to the reel 113 than the outer side 116c of the upper flange 116. In this embodiment, the entire length of the boundary portion 123 exists at a position closer to the reel 113 than the outer side 116c of the upper flange 116a. That is, the winding 120 separates from the first reel 113a at a position closer to the reel 113 than the outer side 116c of the upper flange 116a, passes through the inner space 130 located closer to the reel 113 than the outer side 116c of the upper flange 116, and begins winding when it contacts the second reel 113b at a position closer to the reel 113 than the outer side 116c of the upper flange 116b. Alternatively, a portion of the slack portion 121 may exist on the side of the flange 116 opposite the reel 113. For example, when the slack portion 121 is long, a portion of the slack portion 121 may protrude above the upper flange portion 116 .

[0086] By providing upper flange portion 116 so that the protruding region extends substantially over its entire circumference, winding 120, which is to be unwound axially outward from reel portion 113, can be appropriately secured substantially over its entire circumference. The radial height of flange portion 116 is sufficient to secure winding 120. Specifically, the height of flange portion 116 is preferably greater than the cross-sectional diameter of winding 120.

[0087] Furthermore, the recessed portion 115 in this embodiment is a notch in the flange portion 116, formed by partially cutting away the flange portion 116. Providing the notch in the flange portion 116 reduces the slack 121 in the winding 120 compared to a case where the notch is not provided in the flange portion 116 and the entire circumference of the protruding region protrudes relative to the circumference of the reel portion 113. For example, in a case where the flange portion 116 does not have a notch, the winding 120 wound around the circumference of the first reel portion 113a rides on the upper flange portion 116a of the first bobbin 111, transitions to the upper flange portion 116b of the second bobbin 112, and descends from the upper flange portion 116b of the second bobbin 112 toward the circumference of the second reel portion 113b. Therefore, the slack 121 needs to have a length corresponding to the height of the upper flange portion 116 (116a and 116b). Therefore, if the notch is provided in the upper flange 116 , the height of the upper flange 116 on which the winding 120 rests becomes smaller or even zero, thereby shortening the length of the slack portion 121 required for transition from the first frame 111 to the second frame 112 .

[0088] In addition, the entire length of the boundary portion 123 transitions from the first skeleton 111 to the second skeleton 112 at a position closer to the reel portion 113 than the outer side surface 116c of the flange portion 116, thereby preventing the slack portion 121 from protruding unexpectedly to the outside of the coil component and causing damage to the winding of the slack portion 121 or being cut off.

[0089] like Figure 1 and Figure 3 As shown, the first frame 111 and the second frame 112 have concave and convex engaging portions 118 that engage with each other in a state in which they are arranged in a horizontal row in a manner of following each other in the axial direction. The concave and convex engaging portion 118 refers to at least a pair of engaging recesses 118a (see Figure 2 ) and the engaging protrusion 118b (see Figure 2 ). The engaging recess 118a and the engaging protrusion 118b are provided on the side of the first frame 111 and the second frame 112 that are opposite to each other when the first frame 111 and the second frame 112 are in the folded state. The engaging protrusion 118b is provided to protrude in the radial direction. The engaging recess 118a has a concave shape corresponding to the engaging protrusion 118b, and is recessed from the periphery of the first frame 111 or the second frame 112 toward the axial direction. As a result, the engaging recess 118a and the engaging protrusion 118b are engaged with each other in the folded state.

[0090] In this embodiment, the shape of the engaging convex portion 118b is a shape that narrows monotonically toward the protruding direction. Examples of the shapes of the engaging convex portion 118b and the engaging concave portion 118a include a semicircle and a triangle.

[0091] Each of the first frame 111 and the second frame 112 has one of the engaging recessed portion 118a and the engaging convex portion 118b. That is, the first frame 111 and the second frame 112 together have one or more pairs of the concave-convex engaging portions 118.

[0092] In this embodiment, as will be discussed later, flange portions 116 (upper flange portion 116 and lower flange portion 114) are provided at both ends of the first frame 111 and the second frame 112. In addition, when the first frame 111 and the second frame 112 are in a folded state, the upper flange portions 116 of the first frame 111 and the second frame 112 and the lower flange portions 114 abut against each other. The engaging recess 118a or the engaging protrusion 118b is provided on the mutually abutting edges of the upper flange portion 116 and the lower flange portion 114 of the first frame 111 and the second frame 112, but is not limited thereto. A concave-convex engaging portion 118 may also be provided on the scroll portion 113 of the first frame 111 and the second frame 112. In the case where a protrusion such as a flange is provided midway along the scroll portion 113, as in the modified example discussed later, a concave-convex engaging portion 118 may also be provided on the flanges of the first frame 111 and the second frame 112. In addition, when there is a portion protruding from the peripheral surface of the winding shaft portion 113 on the axially outer side of the flange portion 116 , the concave-convex engagement portion 118 may be provided at the protruding portion.

[0093] In this embodiment, the first and second frames 111, 112 are provided with recessed engagement portions 118a or protruding engagement portions 118b on the upper flange portion 116 and the lower flange portion 114, respectively. Specifically, the upper flange portion 116 is provided with two pairs of recessed and protruding engagement portions 118 between the first and second frames 111, 112, and the lower flange portion 114 is also provided with two pairs of recessed and protruding engagement portions 118. More specifically, each flange portion 116 has one recessed engagement portion 118a and one protruding engagement portion 118b.

[0094] The concave-convex engaging portion 118 may be provided only on the upper flange portion 116 or the lower flange portion 114, or may be provided on both the upper flange portion 116 and the lower flange portion 114. In addition, between the flange portions (116a and 114a) of the first frame 111 and the flange portions (116b and 114b) of the second frame 112 that abut, only one pair of concave-convex engaging portions 118 may be provided, or a plurality of pairs of concave-convex engaging portions 118 may be provided.

[0095] The engagement of first frame 111 and second frame 112 by concave-convex engagement portion 118 prevents displacement of first frame 111 and second frame 112 in the lateral direction relative to the engagement direction of concave-convex engagement portion 118. This facilitates stable assembly of coil component 100.

[0096] In addition, since the engaging protrusion 118b has a shape that narrows monotonically toward the protruding direction, when the first frame 111 and the second frame 112 are folded from the unfolded state to the folded state, the engaging concave portion 118a and the engaging protrusion 118b do not interfere with each other, and the concave and convex engaging portions 118 can engage with each other.

[0097] In this embodiment, the first and second frames 111 and 112 also include the concave-convex engaging portion 118 and the protrusion 117, which will be discussed later, and have the same shape. Specifically, the position where the concave-convex engaging portion 118 is formed is set to be equidistant from the center of the side of the flange 116 where the concave-convex engaging portion 118 is formed. In addition, the engaging concave portion 118a, the engaging convex portion 118b, and the protrusion 117 in the first and second frames 111 and 112 are formed so as to be rotationally symmetrical in position and shape when the coil bobbin 10 is viewed longitudinally in the folded state.

[0098] Thus, the first bobbin 111 and the second bobbin 112 can be manufactured using the same manufacturing equipment, and the productivity of the coil bobbin 10 can be improved.

[0099] (Coil parts)

[0100] Next, the coil component 100 including the bobbin 10 will be described.

[0101] Figure 9 This is a perspective view of the coil component 100. Figure 10 This is a perspective view of coil component 100 as seen from another viewpoint. Figure 11 It is a longitudinal sectional view of coil component 100 .

[0102] The coil component 100 includes the coil bobbin 10 and a core 140 formed by combining a plurality of magnetic members. Figure 11 As shown in the figure, the core 140 has magnetic legs 141 that pass through the first skeleton 111 and the second skeleton 112 in the winding direction of the winding 120, respectively. Among them, the coil component 100 in this embodiment refers to a component used with a coil skeleton 10. However, the use is not limited. The core 140 is composed of at least two magnetic components, and the magnetic components are integrally formed from a magnetic material such as ferrite. In this embodiment, the core 140 is composed of a U-core 142 having a U shape and an I-core 143 having an I shape, but it is not limited to this. For example, the core can also be composed of two U-shaped cores.

[0103] Through holes are provided in the first frame 111 and the second frame 112 in the axial direction, and one end of the U core 142 is inserted into the through hole 119 of each of the first frame 111 and the second frame 112 .

[0104] As described above, first and second bobbins 111 and 112 include a reel portion 113 around which winding 120 is wound, and flange portions (116, 114) formed at one and other ends of the first and second bobbins, projecting in a direction intersecting the axial direction relative to reel portion 113. Upper flange portion 116 includes a recess 115.

[0105] The flange portion 116 at one end or the flange portion 116 at the other end of each of the first and second frames 111, 112 has a protrusion 117 on the outer side surface 116c on the side opposite the reel portion 113. Specifically, the upper flange portion 116a of the first frame 111 and the upper flange portion 116b of the second frame 112 each have a protrusion 117, or the lower flange portion 114a of the first frame 111 and the lower flange portion 114b of the second frame 112 each have a protrusion 117. In this embodiment, the protrusion 117 is provided on the upper flange portion 116 of the first frame 111 and the second frame 112.

[0106] The protrusion 117 is a portion that protrudes from the outer side surface 116 c of the flange portion 116 toward the side opposite to the reel portion 113 .

[0107] At least one of the magnetic components is configured to span the flange portion 116 of the first frame 111 and the flange portion 116 of the second frame 112, and a protrusion 117 is configured around the magnetic component. The magnetic component being configured to span the flange portion 116 of the first frame 111 and the flange portion 116 of the second frame 112 means that a portion of the magnetic component contacts the flange portion of the first frame 111, and another portion contacts the flange portion 116 of the second frame 112. In this embodiment, the I-core 143 contacts the outer side surface 116c of the upper flange portion 116 of each of the first frame 111 and the second frame 112.

[0108] In this embodiment, as in Figure 9As shown in the figure, the surface of the I-core 143 that contacts the upper flange portion 116a of the first skeleton 111 and the upper flange portion 116b of the second skeleton 112 is a rectangle. The protrusion 117 is in the shape of an L formed by the intersection of two straight lines, and the two straight lines are arranged along the edge of the magnetic component, but it is not limited to this. The protrusion 117 can be arranged near each side of the I-core 143 that contacts the flange portion 116 in a rectangular shape. For example, one protrusion 117 can be arranged for each of the four sides, or a plurality of protrusions 117 can be arranged on a straight line along the edge. In addition, the protrusion 117 and the magnetic component (I-core 143) may be in contact with each other or may not be in contact with each other, but may be adjacent.

[0109] In this embodiment, the protrusion 117 is provided on the upper flange 116, but it can also be provided on the lower flange 114. When the upper flange 116 is provided with the protrusion 117, in the expanded state, the protrusions 117 of the first and second bobbins 111 and 112 are sandwiched between the outer side surfaces 116c of the upper flanges 116 of the first and second bobbins 111 and 112. Furthermore, in the folded state, the I-core 143 is positioned on the outer side surfaces 116c of the upper flange 116, and the U-core 142 is inserted from the lower end of the coil bobbin 10. On the other hand, when the lower flange 114 is provided with the protrusion 117, in the expanded state, the outer side surfaces 116c of the upper flanges 116 of the first and second bobbins 111 and 112 are in contact with each other. Furthermore, in the folded state, the I-core 143 is positioned on the outer side surfaces 116c of the lower flange 114, and the U-core 142 is inserted from the upper end of the coil bobbin 10.

[0110] By providing protrusions 117 on lower flanges 114 of first and second frames 111, 112, the distance between upper flanges 116 of first and second frames 111, 112 in the unfolded state is reduced, thereby shortening the length of transition portion 122 extending from recess 115 of first frame 111 to recess 115 of second frame 112. This shortens slack 121, preventing winding 120 from unexpectedly protruding from coil component 100 when folded.

[0111] When protrusions 117 are provided on upper flanges 116 of first and second bobbins 111, 112, it is possible to easily prevent first and second bobbins 111, 112 from returning from a folded state to an unfolded state by inserting U-core 142 from the lower end of coil bobbin 10. This is because U-core 142 can be used to prevent the first and second bobbins 111, 112 from rotating at the lower end, farther from the center of the fold between first and second bobbins 111, 112, that is, from the upper end where transition portion 122 is located.

[0112] Furthermore, when protrusion 117 is provided on upper flange 116, the depth of recess 115 can be set to at least half the height of protrusion 117. The height of protrusion 117 refers to the axially outward height of protrusion 117 relative to the surface of flange 116. If protrusion 117 is provided on upper flange 116, transition portion 122 of winding 120, discussed later, becomes longer by an amount corresponding to the height of protrusion 117. By setting the depth of recess 115 to at least half the height of protrusion 117, the lengthening of transition portion 122 due to the height of protrusion 117 can be reduced.

[0113] By placing the magnetic member on the flange portion 116 of the first frame 111 and the flange portion 116 of the second frame 112, and placing the protrusion 117 around the magnetic member, the magnetic member is positioned to prevent lateral displacement of the magnetic member on the flange portion 116 (116a, 114a) of the first frame 111 and the flange portion 116 (116b, 114b) of the second frame 112. This makes it easier to stably assemble the coil component 100.

[0114] (Terminal part)

[0115] like Figure 9 As shown, coil component 100 has terminal portions 150. Both ends of winding 120 are electrically connected to an electronic substrate (not shown) via terminal portions 150 and mounted. As a method of mounting on an electronic substrate, a method of directly mounting winding 120 on the electronic substrate using soldering or the like can be exemplified.

[0116] Specifically, the terminal portion 150 is constructed as follows. The terminal portion 150 has a mounting base 151, which is arranged on the lower side of the coil component and parallel to the flange portion 116. The two ends of the winding 120 are led out from the reel portion 113 of the first frame 111 or the second frame 112 to the lower side of the flange portion 116, and pass through the mounting base 151 and are led out to the lower side of the mounting base 151. The mounting base 151 and the coil component 100 are fixed using a sealing material such as resin to be discussed later. The two ends of the winding 120 are arranged in a manner parallel to each other and are mounted on the electronic substrate as rod-shaped terminals 152 using soldering or the like. Alternatively, the top end of the led-out winding 120 can be extended and widened to form a surface parallel to the mounting base 151, and the extended and widened surface can be mounted on the electronic substrate as a surface-mounted terminal 152 using soldering or the like.

[0117] The method of mounting the coil on the electronic substrate is not limited to connecting the winding 120 to the electronic substrate as the terminal 152. For example, it is also possible to provide a connection terminal electrically connected to the mounting terminal on the coil component 100, and to wrap the ends of the winding 120 around the corresponding connection terminal to electrically connect the connection terminal to the winding 120. The mounting terminal is joined to the electronic substrate by soldering or the like.

[0118] The coil bobbin 10 of the present embodiment may also include no winding 120 and core 140, but may be provided in the form of two bobbins 110 (a first bobbin 111 and a second bobbin 112). As described above, the coil bobbin 10 of the present embodiment includes two bobbins 110 (a first bobbin 111 and a second bobbin 112). The bobbin 110 has a protruding area extending in the circumferential direction of the reel portion 113 on which the winding 120 is wound at one end of the bobbin 110. A recess 115 is provided in the protruding area, which is formed into a concave shape that is recessed from the outer periphery toward the reel portion 113 of the bobbin. The bobbin 110 has a concave-convex engaging portion 118. When the two bobbins 110 (the first bobbin 111 and the second bobbin 112) are arranged in a horizontal row in a manner that follows each other axially and the recess 115 faces inwardly toward the space sandwiched by the two bobbins 110, the concave-convex engaging portions 118 engage with each other.

[0119] This coil bobbin 10 can be easily wound with the winding 120 and manufactured using the coil bobbin 10 manufacturing method discussed later. Specifically, by passing the winding 120 through the recess 115 during the winding process, the position of the winding 120 transitioning from the first bobbin 111 to the second bobbin 112 can be determined within a certain range. This prevents the winding 120 from shifting laterally during the folding process of folding the first bobbin 111 and the second bobbin 112 into a horizontal arrangement.

[0120] Furthermore, by providing the protruding region, it is possible to prevent the winding 120 from being unwound from the protruding region to the side opposite to the winding shaft portion 113 .

[0121] Furthermore, the presence of the concave-convex engagement portion 118 can prevent the first frame 111 and the second frame 112 from shifting laterally in the folded state, thereby facilitating assembly of the coil component 100 .

[0122] (Method for manufacturing coil bobbin)

[0123] Next, a summary of a method for manufacturing the above-mentioned bobbin 10 will be described.

[0124] The coil bobbin 10 includes: a winding 120; and a first bobbin 111 and a second bobbin 112, each of which has a reel portion 113 for winding the winding 120, and is arranged horizontally with respect to each other. The manufacturing method of the coil bobbin 10 includes a winding process and a folding process. In the winding process, the winding 120 is continuously wound across the reel portion 113 of the first bobbin 111 and the reel portion 113 of the second bobbin 112, while the first bobbin 111 and the second bobbin 112 are arranged vertically in a manner such that the reel portions 113 are arranged in a substantially straight line. In the folding process, the first bobbin 111 and the second bobbin 112 are folded so that the transition portion 122, which is a length region of the winding 120 spanning the first bobbin 111 and the second bobbin 112, is located inside, so that the first bobbin 111 and the second bobbin 112 are arranged horizontally.

[0125] Next, a method for manufacturing the bobbin 10 will be described in detail.

[0126] As described above, the first frame 111 and the second frame 112 have a protruding region extending in the circumferential direction of the scroll portion 113 at least at one end portion, and the protruding region has a recessed portion 115 formed in a concave shape that is recessed from the outer peripheral edge of the protruding region toward the scroll portion 113. The protruding region is provided at one end portion on the side where the first frame 111 and the second frame 112 abut.

[0127] In the winding process, such as Figure 7 and Figure 8 As shown, the first skeleton 111 and the second skeleton 112 are arranged in a straight line in such a manner that one end portion of the first skeleton 111 and the second skeleton 112 abut against each other and the recessed portions 115 of the first skeleton 111 and the second skeleton 112 are located on the same side of the circumference of the scroll portion 113. The recessed portions 115 of the first skeleton 111 and the second skeleton 112 are located on the same side of the circumference of the scroll portion 113, which means that the opening directions of the recessed portions 115 of the first skeleton 111 and the second skeleton 112 are substantially the same. Specifically, it means that when the first skeleton 111 and the second skeleton 112 are in the unfolded state, when the first skeleton 111 and the second skeleton 112 are observed from any lateral direction orthogonal to the scroll direction, the openings of the recessed portions 115 of the first skeleton 111 and the second skeleton 112 can be visually identified at the same time. Preferably, the recessed portion 115 of the first skeleton 111 and the recessed portion 115 of the second skeleton 112 are connected to each other. That is, when viewed axially from the first and second frames 111, the recessed portion 115 of the first frame 111 overlaps at least partially with the recessed portion 115 of the second frame 112. When the recessed portion of the first frame 111 and the recessed portion of the second frame 112 are connected, the distance between the recessed portion 115 of the first frame 111 and the recessed portion 115 of the second frame 112 can be shortened, thereby shortening the length of the slack portion 121, compared to a case where the recessed portion 115 of the first frame 111 and the recessed portion 115 of the second frame 112 are not connected.

[0128] When the winding 120 is thinner than the height of the protruding portion 117 , the recessed portions 115 of the first and second bobbins 111 and 112 may not be connected in the folded state, or may be offset in the circumferential direction or radial direction.

[0129] like Figure 8 As shown in the figure, in the winding process of the winding 120, the winding 120 is continuously wound across the reel portion 113 of the first bobbin 111 and the reel portion 113 of the second bobbin 112 in such a manner that the transition portion 122 passes through the recessed portion 115 of the first bobbin 111 and the second bobbin 112. Specifically, the winding 120 is wound from one end ( Figure 8 The left end of the coil) is wound around to the other end ( Figure 8 The winding 120 further passes through the recess 115 of the second frame 112 and passes from one end of the second frame 112 ( Figure 8 The left end of the Figure 8 on the right side of the image).

[0130] The transition portion 122 of the winding 120 is the length of the winding 120 sandwiched between the winding 120 wound on the first reel portion 113a and the winding 120 wound on the second reel portion 113b. In this embodiment, the transition portion 122 is the length from the recess 115 of the first bobbin 111 to the recess 115 of the second bobbin 112.

[0131] During the folding process, the first frame 111 and the second frame 112 are folded so that the transition portion 122 is located inside, that is, so that the recessed portions 115 of the first frame 111 and the second frame 112 are located inside each other. At this time, the first frame 111 and the second frame 112, which are arranged in a substantially straight line, are rotated approximately 180 degrees without twisting until they are arranged side by side so as to follow each other axially.

[0132] When the coil frame 10 is folded, the plurality of magnetic members are inserted or arranged, and the terminal portion 150 is provided. The winding 120 is sometimes as Figure 2 As shown in the figure, the recess 115 (see Figure 1 ) and protrudes outward relative to the outer side surface 116c of the flange portion 116. In this case, due to the winding 120 protruding from the outer side surface 116c of the flange portion 116, the I core 143 and the outer side surface 116c of the flange portion 116 cannot be stably contacted, which may cause poor adhesion between the I core 143 and the flange portion 116. In order to avoid this, the winding 120 protruding outward relative to the outer side surface 116c of the flange portion 116 is pressed toward the winding shaft portion 113. Figure 4The figure in the figure shows that it is preferable to arrange the I-core 143 in a state where the winding 120 does not protrude upward from the outer side surface 116 c of the flange portion 116 .

[0133] The I-core 143 as a magnetic member can be fixed to the flange portion 116 with an adhesive. In addition, the mounting base 151 and the U-core 142 can also be fixed to the coil bobbin 10 with an adhesive. The portion other than the terminal 152 can also be covered with a sealing material such as epoxy resin or polyester resin.

[0134] Both ends of the winding 120 are electrically connected to the electronic substrate as described above.

[0135] When the winding 120 is wound around the first bobbin 111 with the first bobbin 111 and the second bobbin 112 arranged in a horizontal row, the wire supply portion of the winding device is likely to interfere with the second bobbin 112, which is located close to the first bobbin 111 in the radial direction of the first bobbin 111. Therefore, in order to wind the winding 120 with the first bobbin 111 and the second bobbin 112 close to each other, it is necessary to avoid interference between the second bobbin 112 and the wire supply portion while winding, which reduces the efficiency of the winding process of the winding 120.

[0136] When winding 120 is wound around first bobbin 111 with reel portions 113 of first bobbin 111 and second bobbin 112 arranged in a straight line, second bobbin 112 does not exist in the radial direction of first bobbin 111, thereby preventing interference between second bobbin 112 and the wire supply portion. This allows winding 120 to be wound continuously from first bobbin 111 to second bobbin 112, improving the efficiency of the winding process for winding 120.

[0137] Furthermore, after winding the winding 120, the first bobbin 111 and the second bobbin 112 are folded and brought into close proximity, thereby freely adjusting the gap between the first bobbin 111 and the second bobbin 112. In other words, the gap between the first bobbin 111 and the second bobbin 112 can be reduced, miniaturizing the coil bobbin 10.

[0138] In addition, when the winding 120 is to be wound around the first skeleton 111 and the second skeleton 112 in sequence in a state where the first skeleton 111 and the second skeleton 112 are arranged in a horizontal row, it is necessary to switch the direction of winding the winding on the first skeleton 111 and the second skeleton 112. That is, it is necessary to wind the winding 120 in opposite directions on the first reel portion 113a and the second reel portion 113b. This is to wind the winding 120 in the same direction relative to the direction of the magnetic lines of force of the closed magnetic circuit formed by the magnetic member. On the other hand, when the first skeleton 111 and the second skeleton 112 are set to the unfolded state and the winding 120 is wound, the winding 120 is wound in the same direction when winding it around the first skeleton 111 and when winding it around the second skeleton 112, and there is no need to switch the winding direction. Furthermore, by folding the first and second frames 111 and 112, the winding directions of the winding 120 on the first and second reels 113a and 113b are naturally opposite to each other. This eliminates the need to switch the winding direction of the winding 120, thereby improving the efficiency of the winding process.

[0139] By providing the recess 115 at the end portion of the first and second bobbins 111, 112 that abut against each other in the unfolded state, the position of the winding 120 across the first and second bobbins 111, 112 can be determined within a certain range. This prevents the winding 120 from shifting laterally during the folding process, and the folded position of the winding 120 in the manufactured coil bobbin 10 can be maintained constant.

[0140] In addition, the present invention is not limited to the above-described embodiment, and includes various modifications, improvements, and other aspects within the scope that can achieve the object of the present invention.

[0141] In the first embodiment, the first and second bobbins 111 and 112 may not have protruding regions such as the flanges 116. In this case, the winding 120 spans between the first and second bobbins 111 and 112 from any location therebetween.

[0142] The coil bobbin 10 may also include three or more bobbins 110. That is, in the winding process, the three or more bobbins 110 may be arranged in a straight line and the winding 120 may be wound continuously, and in the folding process, two or more locations may be folded so that the transition portion 122 is on the inner side. When the winding 120 is wound around, for example, three bobbins 110, the three bobbins 110 are folded so as to be arranged in a triangle, and when the winding 120 is wound around four bobbins 110, the four bobbins are folded so as to be arranged in a quadrilateral. In this way, the winding 120 can be wound around all sides of a polygonal closed magnetic circuit.

[0143] The winding 120 may also be wound in multiple layers relative to the bobbin 110. By winding the winding 120 into an odd number of layers, such as three or five layers, the two ends of the winding 120 can be arranged at the lower end of the coil bobbin 10 to form the terminal portion 150, and the winding 120 can be transitioned from the first bobbin 111 to the second bobbin 112 at the upper end of the coil bobbin 10.

[0144] In addition, multiple windings 120 can also be wound relative to the skeleton 110. In this case, the multiple windings 120 can be wound in an overlapping manner, or the multiple windings 120 can be wound separately at different positions in the winding direction of the reel portion 113. That is, the winding positions of the reel portion 113 can also be separated according to the windings 120. In this case, in order to separate the winding positions of the windings 120, a flange can be provided in the middle of the length direction of the reel portion 113, one winding 120 can be wound at a position closer to one side than the flange, and the other windings 120 can be wound at a position closer to the other side than the flange. In addition, a concave-convex engaging portion 118 can also be formed on the flange.

[0145] The above-mentioned embodiment includes the following technical ideas.

[0146] (1) A coil frame, characterized in that the coil frame comprises: a winding; and a first frame and a second frame, which are arranged horizontally in a manner of axially following each other, the winding is continuously wound across the first frame and the second frame, and transitions from the first frame to the second frame through an inner space sandwiched by the horizontally arranged first frame and the second frame, and the winding has a slack portion in the inner space.

[0147] (2) The coil skeleton according to (1) is characterized in that the first skeleton and the second skeleton have: a winding shaft portion on which the winding is wound; and a protruding area which extends circumferentially along the winding shaft portion at one end portion of the first skeleton and one end portion of the second skeleton, the protruding area having a concave portion which is recessed from the outer peripheral edge of the protruding area toward the winding shaft portion, and the first skeleton and the second skeleton are arranged in such a manner that at least a part of the respective concave portions is present on the inner side sandwiched by the first skeleton and the second skeleton.

[0148] (3) A coil frame according to (2), wherein the slack portion has a length such that when the first frame and the second frame are arranged in a straight line so that one end portion provided with the protruding area abuts against each other, the winding can cross the first frame and the second frame through the recess.

[0149] (4) The coil skeleton according to (3) is characterized in that the length of the slack portion is greater than a total length, which is a length obtained by adding together the height of the bottom of the recessed portion of the first skeleton from the circumference of the winding shaft portion, the height of the bottom of the recessed portion of the second skeleton, and the distance from the recessed portion of the first skeleton to the recessed portion of the second skeleton when the first skeleton and the second skeleton are arranged in a straight line so that one end portion having the protruding area abuts against each other.

[0150] (5) A coil frame according to any one of (2) to (4), characterized in that the protruding area is a flange portion protruding relative to the winding portion of the first frame or the winding portion of the second frame in a direction intersecting the axial direction, and the winding transitions from the first frame to the second frame at a position closer to the winding portion than the outer side surface of the flange portion.

[0151] (6) The coil bobbin according to any one of (1) to (5), wherein the first bobbin and the second bobbin have concave and convex engaging portions that engage with each other while being arranged side by side so as to follow each other in the axial direction.

[0152] (7) A coil component, characterized in that the coil component comprises: a coil frame described in any one of (1) to (6); and a core having magnetic legs respectively penetrating the first frame and the second frame in the winding axis direction of the winding, the core being composed of a combination of multiple magnetic components, and in the coil component, the first frame and the second frame having: a winding axis portion on which the winding is wound; and a flange portion respectively formed at one end and the other end of the first frame and one end and the other end of the second frame, the flange portion protruding relative to the winding axis portion in a direction intersecting the axial direction, the flange portion of the one end portion or the flange portion of the other end portion of each of the first frame and the second frame having a protrusion on the outer side surface on the side opposite to the winding axis portion, at least one of the magnetic components is arranged across the flange portion of the first frame and the flange portion of the second frame, and the protrusion is arranged around the magnetic component.

[0153] (8) A coil bobbin comprising two bobbins, characterized in that:

[0154] The frame has a protruding area at one end portion thereof extending in the circumferential direction of a winding shaft portion around which the winding is wound.

[0155] The protruding region is provided with a recessed portion formed in a concave shape that is recessed from the outer peripheral edge toward the scroll portion of the frame.

[0156] The frames have concave and convex engagement portions that engage with each other when the two frames are arranged side by side so as to follow each other in the axial direction and the concave portions face inwardly toward a space sandwiched between the two frames.

[0157] (9) A method for manufacturing a coil bobbin, the coil bobbin comprising: a winding; and a first bobbin and a second bobbin, which are arranged horizontally to each other and each have a reel portion for winding the winding, wherein the method for manufacturing the coil bobbin comprises: a winding process, in which the winding is continuously wound across the reel portion of the first bobbin and the reel portion of the second bobbin while the first bobbin and the second bobbin are arranged vertically with the reel portions arranged in a substantially straight line relative to each other; and a folding process, in which the first bobbin and the second bobbin are folded so that the length region of the winding spanning the first bobbin and the second bobbin, i.e., the transition portion, is located inside, so that the first bobbin and the second bobbin are arranged horizontally.

[0158] (10) A method for manufacturing a coil bobbin according to (9), wherein the first bobbin and the second bobbin have a protruding area extending in the circumferential direction of the winding shaft portion at least at one end portion, and the protruding area has a concave portion formed to be recessed from the outer peripheral edge of the protruding area toward the winding shaft portion, and in the winding process, the first bobbin and the second bobbin are arranged in a straight line in such a manner that the one end portions abut each other and the concave portions are located on the same side of the circumference of the winding shaft portion, and the winding is continuously wound across the winding shaft portion of the first bobbin and the winding shaft portion of the second bobbin in such a manner that the transition portion passes through the concave portion of the first bobbin and the concave portion of the second bobbin.

Claims

1. A coil skeleton, characterized in that: The coil frame has: a winding; and a first frame and a second frame, which are arranged in a horizontal row in a manner of following each other in the axial direction. The winding is wound continuously across the first frame and the second frame, and transitions from the first frame to the second frame through an inner space sandwiched by the first frame and the second frame in a horizontal row. The winding has a slack portion in the inner space.

2. The coil frame according to claim 1, characterized in that: The first skeleton and the second skeleton have: a reel portion on which the winding is wound; and a protrusion area extending along the circumference of the scroll portion at one end of the first skeleton and one end of the second skeleton, The protrusion region has a recessed portion formed in a concave shape recessed from the outer peripheral edge of the protrusion region toward the scroll portion, The first frame and the second frame are arranged so that at least a part of the respective recessed portions is present on the inner side sandwiched by the first frame and the second frame.

3. The coil skeleton according to claim 2, wherein: The slack portion has a length such that the winding can pass through the recess and span the first and second bobbins when the first and second bobbins are arranged in a straight line so that one ends provided with the protruding regions abut against each other.

4. The coil frame according to claim 3, characterized in that: The length of the relaxed portion is greater than a total length obtained by adding together the height of the bottom of the recessed portion of the first skeleton from the circumferential surface of the reel portion, the height of the bottom of the recessed portion of the second skeleton, and the distance from the recessed portion of the first skeleton to the recessed portion of the second skeleton when the first skeleton and the second skeleton are arranged in a straight line so that one end portion having the protruding area abuts against each other.

5. The coil frame according to any one of claims 2 to 4, characterized in that: The protruding region is a flange portion protruding relative to the scroll portion of the first frame or the scroll portion of the second frame in a direction intersecting the axial direction. The winding is transferred from the first bobbin to the second bobbin at a position closer to the winding shaft portion than the outer side surface of the flange portion.

6. The coil bobbin according to any one of claims 1 to 5, wherein: The first frame and the second frame have concave-convex engaging portions that engage with each other in a state where they are arranged side by side so as to follow each other in the axial direction.

7. A coil component, characterized in that: The coil component comprises: The coil bobbin according to any one of claims 1 to 6; and The core has magnetic legs respectively penetrating the first frame and the second frame in the winding axis direction of the winding, and the core is composed of a plurality of magnetic components. In the coil component, The first skeleton and the second skeleton have: a reel portion on which the winding is wound; and flange portions, which are respectively formed at one end and the other end of the first frame and at one end and the other end of the second frame, and the flange portions protrude relative to the reel portion in a direction intersecting the axial direction, The flange portion at the one end portion or the flange portion at the other end portion of each of the first frame and the second frame has a protruding portion on the outer side surface on the side opposite to the reel portion. At least one of the magnetic members is arranged across the flange portion of the first frame and the flange portion of the second frame, and the protrusion is arranged around the magnetic member.

8. A coil frame, which is a coil frame comprising two frames, characterized in that: The frame has a protrusion area extending in the circumferential direction of a winding shaft portion around which the winding is wound at one end of the frame. The protruding region is provided with a recessed portion formed in a concave shape that is recessed from the outer peripheral edge toward the scroll portion of the frame, The frames include concave-convex engaging portions that engage with each other when the two frames are arranged side by side so as to follow each other in the axial direction and the concave portions face inwardly toward a space sandwiched between the two frames.

9. A method for manufacturing a coil frame, the coil frame comprising: a winding; and a first frame and a second frame, which are arranged side by side with each other and each having a winding shaft portion for winding the winding, wherein: The manufacturing method of the coil skeleton comprises: a winding step in which the winding is continuously wound across the winding portion of the first bobbin and the winding portion of the second bobbin in a state in which the first bobbin and the second bobbin are arranged longitudinally in a manner such that the winding portions are arranged substantially linearly with each other; and A folding step, in which the first frame and the second frame are folded with the transition portion, which is a length region spanning the first frame and the second frame in the winding, located inside, so that the first frame and the second frame are arranged in a horizontal row.

10. The method for manufacturing a coil skeleton according to claim 9, wherein: The first frame and the second frame have a protruding area extending in the circumferential direction of the reel portion at least at one end. The protruding region has a recessed portion formed in a concave shape recessed from the outer peripheral edge of the protruding region toward the scroll portion, In the winding process, the first skeleton and the second skeleton are arranged in a straight line in such a manner that the one end portions abut against each other and the recesses are located on the same side of the circumference of the winding shaft portion, and the winding is continuously wound across the winding shaft portion of the first skeleton and the winding shaft portion of the second skeleton in such a manner that the transition portion passes through the recess of the first skeleton and the recess of the second skeleton.

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