COIL COMPONENT

Abstract

A coil component (5, 5A) has a first coil section (51) formed by flat winding a first flat wire (50) around an axial line (AX) extending in a first direction; a first end section (52) having one end (50a) extending from an inner circumference of the first coil section (51); and a second end section (53) having the other end (50b) extending from an outer circumference of the first coil section (51). The first end section (52) has a first bend section (52a) formed by angular bending of the first flat wire (50) from the inner circumference and extending beyond the first coil section (51) in the first direction; and a first extension section (52b) formed by flat bending of the first flat wire (50) from the first bend section (52a) and extending in a second direction intersecting with the first direction.

Description

Background of the invention: Technical field

[0001] The present invention relates to a coil component. State of the art

[0002] A coil component comprising a pair of coil elements and a coupling section is described in Japanese patent application publication JP 2016-039322. Here, the coil elements are each formed in multiple layers by flat winding a wire made from a conductor with a rectangular cross-section. In each coil element, one end of the wire is located at the innermost circumference of the element, and the other end of the wire extends from the outermost circumference. The ends of the wires are coupled together by the coupling section.

[0003] The coil component described in the publication has a multi-layered structure to pull out the section of winding wire with its coil end. This allows the coil component to increase in size.

[0004] The present invention describes a coil component that can be miniaturized. Summary of the invention

[0005] According to one aspect of the present invention, a coil component is provided comprising a first coil section formed by flat winding a first flat wire around an axial line extending in a first direction, such that the first coil section has a single layer in the first direction; a first end section having one end of the first flat wire and extending from (or starting from) an inner circumference of the first coil section; and a second end section having the other end of the first flat wire and extending from (or starting from) an outer circumference of the first coil section.The first end section has a first bending section formed by angular bending of the first flat wire from / to the inner circumference of the first coil section and extending beyond the first coil section in the first direction; and a first extension section formed by flat bending of the first flat wire from / to the first bending section and extending in a second direction intersecting with the first direction.

[0006] Further aspects and advantages of the invention will become apparent from the following description in conjunction with the accompanying drawings, which illustrate the principles of the invention by way of example. Brief description of the characters

[0007] The invention, together with its tasks and advantages, is best understood by reference to the following description of the embodiments in conjunction with the accompanying drawings, in which: Fig. 1 a perspective view illustrating a schematic configuration of a transformer to which a coil component is attached according to an embodiment; Fig. 2 a cross-sectional view along a line II-II in Fig. 1 is; Fig. 3 a perspective view of the in Fig. The coil component shown in section 1 is; Fig. 4 a perspective view illustrating a schematic configuration of a transformer to which a coil component according to another embodiment is attached; Fig. 5 a perspective exploded view of the in Fig. The coil component shown in section 4 is; Fig. 6A a side view of the in Fig. The coil component shown in section 4 is; and Fig. 6B a top view of the in Fig. The coil component shown is 4. Detailed description of the embodiments

[0008] The following describes coil components according to several embodiments with reference to the accompanying drawings. In the description of the drawings, identical or substantially identical components have the same reference numerals and are not repeated. An XYZ coordinate system may be shown in each drawing. A Y-axis direction (second direction) is a direction that intersects an X-axis direction (third direction) and a Z-axis direction (first direction) (for example, perpendicular to them). The Z-axis direction is a direction that intersects the X-axis direction and the Y-axis direction (for example, perpendicular to them). In the following description, the X-axis direction is defined, for example, as a left-right direction (latitude direction), the Y-axis direction as a front-back direction (depth direction), and the Z-direction as an up-down direction (height direction).The X-axis direction, the Y-axis direction, and the Z-axis direction are not limited to the directions described above.

[0009] The following describes a schematic configuration of a transformer, in which a coil component according to one embodiment is attached with reference to Fig. 1 and Fig. 2 is applied / set up. Fig. Figure 1 is a perspective view illustrating the schematic configuration of the transformer to which the coil component is applied / attached according to the embodiment. Fig. 2 is a cross-sectional view along a line II-II in Fig. 1. One in Fig. 1 and Fig. Transformer 1, illustrated in Figure 2, is a device that converts a primary voltage into a secondary voltage and comprises a core 2, a primary winding 3, a secondary winding 4, and a coil former 6. Note that representations of the coil former 6 in Figure 2 are not shown. Fig. 2 are omitted.

[0010] The core 2 is a magnetic body that forms magnetic tracks. The core 2 has a central leg section 21, a pair of side leg sections 22, and a pair of coupling sections 23. The central leg section 21 and the pair of side leg sections 22 each extend in the upward-downward direction. The central leg section 21 and the pair of side leg sections 22 are arranged substantially parallel to each other. The pair of side leg sections 22 are located away from the central leg section 21 on opposite sides of it in the left-right direction. That is, the central leg section 21 is positioned between the pair of side leg sections 22. The pair of coupling sections 23 are sections that connect the pair of side leg sections 22 to the central leg section 21. The coupling sections 23 each have a flat, plate-like shape.One of the coupling sections 23 connects one end of the middle leg section 21 to one end of each of the side leg sections 22. The other of the coupling sections 23 connects the other end of the middle leg section 21 to the other end of each of the side leg sections 22.

[0011] In the present embodiment, the core 2 is an EI core formed from a core element 2a with an E-shape and a core element 2b with an I-shape. The core 2 is not limited to an EI core, but can be an EE core or a PQ core.

[0012] Primary winding 3 and secondary winding 4 are coil components, each formed by winding a strip of flat wire into a spiral. Primary winding 3 and secondary winding 4 are flat coils formed by winding the flat wire while bending it in a direction consistent with the wire's thickness. The thickness direction of the flat wire is a direction along a short side of a cross-section of the flat wire that intersects (for example, perpendicular to) the direction in which the flat wire extends. Primary winding 3 and secondary winding 4 are wound around the center leg section 21. Secondary winding 4 is positioned away from primary winding 3 in an upward-downward direction. Primary winding 3 and secondary winding 4 have identical structures. Primary winding 3 and secondary winding 4 will be described in detail later.

[0013] The coil formers 6 are elements that hold the primary winding 3 and the secondary winding 4. Each coil former 6 is made of an insulating material. Examples of insulating materials for the coil formers 6 include resin and plastic. The coil formers 6 electrically insulate the primary winding 3 from the secondary winding 4 and both the primary winding 3 and the secondary winding 4 from the core 2. The transformer 1 also has path cores that are provided between the primary winding 3 and the secondary winding 4 in the upward-downward direction. The path cores are magnetic bodies that, together with the core 2, form magnetic tracks through which magnetic leakage flux passes. In this case, the path cores can each be accommodated within the corresponding coil former 6.

[0014] In the following, one of the coil components 5 belonging to the primary winding 3 and the secondary winding 4 is described with reference to Fig. 3 described. Fig. 3 is a perspective view of the in Fig. 1 shown coil component. As in Fig. As shown in Figure 3, the coil component 5 is formed from a (single) flat wire 50 (first flat wire) and has a coil section 51 (first coil section), an end section 52 (first end section), and an end section 53 (second end section). The flat wire 50 is formed from a conductive element (for example, copper) with a rectangular cross-section that intersects a direction (for example, perpendicular to it) in which the flat wire 50 extends, and an insulating film covering a surface of the conductive element.

[0015] The coil section 51 is formed by flat winding the flat wire 50 around an axial line AX extending in the upward-downward direction. In flat winding, the flat wire is wound while being bent in the thickness direction of the flat wire. The flat wire 50 is wound in the coil section 51, so that the coil section 51 has a single layer in the upward-downward direction. In other words, in the coil section 51, the flat wire 50 is wound in a spiral shape on the same plane. In the present embodiment, the coil section 51 has a rectangular outline in plan view.

[0016] The end section 52 has an end 50a of the flat wire 50 and is a section drawn out from an inner circumference of the coil section 51. The end section 52 further comprises a bending section 52a (first bending section) and an extension section 52b (first extension section). The bending section 52a is formed by angular bending of the flat wire 50 from the inner circumference of the coil section 51 and extends upwards beyond the coil section 51 (an upper end of the coil section 51) in the upward-downward direction. In angular bending, a flat wire is bent in a lateral direction. The lateral direction of the flat wire is a direction along a long side of a cross-section of the flat wire that intersects the direction in which the flat wire extends (for example, perpendicular to it). The extension section 52b is continuous with an upper end of the bending section 52a.The extension section 52b is formed by shallow bending of the flat wire 50 from the bending section 52a and extends forwards. In shallow bending, the flat wire is bent in the thickness direction of the flat wire. The extension section 52b extends forwards from the inner circumference of the coil section 51 beyond an outer circumference of the coil section 51.

[0017] The end section 53 has the other end 50b of the flat wire 50 and is a section drawn out from the outer circumference of the coil section 51. The end section 53 further comprises a bent section 53a (second bent section) and an extended section 53b (second extended section). The bent section 53a is formed by bending the flat wire 50 at an angle from the outer circumference of the coil section 51 and extends upwards beyond the coil section 51 (the upper end of the coil section 51) in the upward-downward direction. In the present embodiment, an upper end of the bent section 53a and the upper end of the bent section 53a are located at essentially the same height in the upward-downward direction. The extended section 53b is continuous with the upper end of the bent section 53a.Extension section 53b is formed by the shallow bending of the flat wire 50 from / to the bending section 53a and extends forwards. Extension section 53b and extension section 52b are arranged in the left-right direction and are essentially at the same height in the upward-downward direction. Extension section 52b and extension section 53b extend essentially parallel to each other.

[0018] The position (orientation) of the flat wire 50 in extension section 52b is essentially the same as that of the flat wire 50 in extension section 53b. That is, both the width direction of the flat wire 50 in extension section 52b and the width direction of the flat wire 50 in extension section 53b are the left-right direction, and both the thickness direction of the flat wire 50 in extension section 52b and the thickness direction of the flat wire 50 in extension section 53b are the upward-downward direction.

[0019] As described above, in coil component 5, the coil section 51 is formed by flat-winding the flat wire 50 around the axial line AX extending in the upward-downward direction, such that the coil section 51 has a single layer in the upward-downward direction. The end section 52, with one end 50a of the flat wire 50, extends from the inner circumference of the coil section 51, and the end section 53, with the other end 50b of the flat wire 50, extends from the outer circumference of the coil section 51. In the end section 52, the bending section 52a is formed by bending the flat wire 50 at an angle from / to the inner circumference of the coil section 51 and extends beyond the coil section 51 in the upward-downward direction. and the extension section 52b is formed by the flat bending of the flat wire 50 from / off the bending section 52a and extends forwards.Thus, the end section 52 is extended from the inner circumference of the coil section 51 without obstructing the coil section 51. In this configuration, the coil section 51 does not need to have multiple layers in the upward-downward direction, making it possible to reduce the size of the coil component 5 (lower profile).

[0020] As in Fig. As shown in Figure 2, when coil component 5 is used as the primary winding 3 and the secondary winding 4, the primary winding 3 and the secondary winding 4 each have a single layer in the up-down direction. This shortens the length of the magnetic track and reduces the size of the transformer 1 in the up-down direction (lower profile).

[0021] In the end section 53, the bending section 53a is formed by the angular bending of the flat wire 50 from the outer circumference of the coil section 51; and the extension section 53b is formed by the flat bending of the flat wire 50 from / to the bending section 53a and extends forward. This configuration aligns the position (orientation) of the flat wire 50 in the extension section 53b with the position of the flat wire 50 in the extension section 52b. Accordingly, the coil component 5 is easily mounted on a circuit board or the like.

[0022] In the following, a coil component according to another embodiment is described with reference to Fig. 4, Fig. 5, Fig. 6A and Fig. 6B described. Fig. Figure 4 is a perspective view illustrating a schematic configuration of a transformer to which the coil component is / will be applied according to another embodiment. Fig. 5 is a perspective exploded view of the in Fig. 4 coil components shown. Fig. 6A is a side view of the in Fig. 4 coil components shown. Fig. 6B is a top view of the in Fig. 4 coil components shown.

[0023] A in Fig. The transformer 1A shown in Figure 4 differs from transformer 1 primarily in that transformer 1A has a secondary winding 4A instead of secondary winding 4. Secondary winding 4A differs from secondary winding 4 primarily in that coil component 5A corresponds to secondary winding 4A instead of coil component 5.

[0024] As in Fig. As shown in Figure 5, coil component 5A differs from coil component 5 primarily in that coil component 5A has an inner coil C1 and an outer coil C2. That is, the secondary winding 4A has a structure in which the inner coil C1 and the outer coil C2 are connected in parallel. The outer coil C2 is formed from a single flat wire 60 (second flat wire) and has a coil section 61 (second coil section), an end section 62 (third end section), and an end section 63 (fourth end section). Similar to flat wire 50, the flat wire 60 consists of a conductive element (for example, copper) with a rectangular cross-section that intersects a direction (for example, perpendicular to it) in which the flat wire 60 extends, and an insulating film covering one surface of the conductive element.

[0025] The coil section 61 is formed by flat-winding the flat wire 60 around the axial line AX. The coil section 51 is surrounded by the coil section 61. In particular, an inner circumference of the coil section 61 lies along the outer circumference of the coil section 51. The flat wire 60 is wound in the coil section 61, such that the coil section 61 has a single layer in the upward-downward direction. In other words, in the coil section 61, the flat wire 60 is wound in a spiral shape on the same plane as the plane on which the coil section 51 is wound. In the present embodiment, the coil section 61 has a rectangular outline in plan view.

[0026] The end section 62 has an end 60a of the flat wire 60 and is a section drawn out from the inner circumference of the coil section 61. The end section 62 further comprises a bent section 62a (third bent section) and an extension section 62b (third extension section). The bent section 62a is formed by bending the flat wire 60 at an angle from the inner circumference of the coil section 61 and extends upwards in the upward-downward direction beyond the coil section 61 (an upper end of the coil section 61). The extension section 62b is continuous with an upper end of the bent section 62a. The extension section 62b is formed by bending the flat wire 60 flat from the bent section 62a and extends forwards. The extension section 62b extends forward from / to the inner circumference of the coil section 61 beyond an outer circumference of the coil section 61.

[0027] The end section 63 has the other end 60b of the flat wire 60 and is a section drawn out from the outer circumference of the coil section 61. The end section 63 has a bent section 63a and an extension section 63b. The bent section 63a is formed by bending the flat wire 60 at an angle from the outer circumference of the coil section 61 and extends upwards beyond the coil section 61 (the upper end of the coil section 61) in the upward-downward direction. In the present embodiment, an upper end of the bent section 63a and the upper end of the bent section 62a are located at essentially the same height in the upward-downward direction. The extension section 63b is continuous with the upper end of the bent section 63a. The extension section 63b is formed by the flat bending of the flat wire 60 from / to the bending section 63a and extends forwards.Extension section 63b and extension section 62b are arranged in a left-right direction and are essentially at the same level in the upward-downward direction. Extension section 62b and extension section 63b extend essentially parallel to each other.

[0028] The position (orientation) of the flat wire 60 in extension section 62b is essentially the same as that of the flat wire 60 in extension section 63b. That is, both the width direction of the flat wire 60 in extension section 62b and the width direction of the flat wire 60 in extension section 63b are the left-right direction, and both the thickness direction of the flat wire 60 in extension section 62b and the thickness direction of the flat wire 60 in extension section 63b are the upward-downward direction.

[0029] As in Fig. As shown in Figure 6A, bending section 52a extends upwards beyond bending section 62a; and extension section 52b is located above extension section 62b. As shown in Fig. As shown in Figure 6B, extension section 52b overlaps with extension section 62b when viewed in the upward-downward direction (top view). In other words, extension section 52b and extension section 62b are arranged in the upward-downward direction and extend forward parallel to each other.

[0030] In a similar way to how in Fig. As shown in Figure 6A, bending section 53a extends upwards beyond bending section 63a; and extension section 53b is located above extension section 63b. As shown in Fig. As shown in Figure 6B, extension section 53b overlaps with extension section 63b when viewed in the upward-downward direction (top view). In other words, extension section 53b and extension section 63b are arranged in the upward-downward direction and extend forward parallel to each other.

[0031] As in Fig. As shown in Figure 6A, the bending section 53a and the bending section 62a are located in the same position in the front-back direction and are arranged in the left-right direction.

[0032] As described above, the same configuration for coil component 5A as for coil component 5 produces the same advantageous effects. Coil component 5A has the inner coil C1 and the outer coil C2. In the outer coil C2, the coil section 61 is also formed by flat-winding the flat wire 60 around the axial line AX extending in the upward-downward direction, so that the coil section 61 has a single layer in the upward-downward direction. The end section 62 with one end 60a of the flat wire 60 extends from the inner circumference of the coil section 61; and the end section 63 with the other end 60b of the flat wire 60 extends from the outer circumference of the coil section 61.In the end section 62, the bending section 62a is formed by the angular bending of the flat wire 60 from / to the inner circumference of the coil section 61 and extends beyond the coil section 61 in the upward-downward direction; and the extension section 62b is formed by the shallow bending of the flat wire 60 from / to the bending section 62a and extends forward. Thus, the end section 62 is extended from the inner circumference of the coil section 61 without obstructing the coil section 61. In this configuration, the coil section 61 does not need to have multiple layers in the upward-downward direction, so it is possible to reduce the size of the coil component 5A (lower profile).

[0033] In the end section 63, the bending section 63a is formed by the angular bending of the flat wire 60 from the outer circumference of the coil section 61; and the extension section 63b is formed by the flat bending of the flat wire 60 from / to the bending section 63a and extends forward. This configuration aligns the position (orientation) of the flat wire 60 in the extension section 63b with the position of the flat wire 60 in the extension section 62b. Accordingly, the coil component 5A is easily mounted on a circuit board or the like.

[0034] Furthermore, in coil component 5A, the bending section 53a of the inner coil C1 and the bending section 62a of the outer coil C2 are arranged in the left-right direction. This arrangement reduces the space between coil section 51 (inner coil C1) and coil section 61 (outer coil C2). Consequently, it is possible to further reduce the size of coil component 5A.

[0035] Extension section 52b overlaps with extension section 62b when viewed in the upward-downward direction (top view). In this configuration, extension sections 52b and 62b are close together, so they are simply joined. Similarly, extension section 53b overlaps with extension section 63b in the upward-downward direction (top view). In this configuration, extension sections 53b and 63b are close together, so they are simply joined. Consequently, the inner coil C1 and the outer coil C2 are simply connected in parallel.

[0036] Since the inner coil C1 and the outer coil C2 are connected in parallel, the current flowing through the secondary winding (4A) is reduced by half. This reduces losses and the heat generated in the secondary winding (4A).

[0037] The embodiments of the present invention are described in detail above; however, the coil components according to the present invention are not limited to the embodiments described above.

[0038] For example, the end section 52 and the end section 53 of the coil component 5 are pulled out forward; however, the direction in which the end section 52 is pulled out and the direction in which the end section 53 is pulled out are not limited to forward. The direction in which the end section 52 is pulled out and the direction in which the end section 53 is pulled out can be the same or different from each other.

[0039] The extension section 52b may be located in a different position than the extension section 53b in the upward-downward direction. For coil component 5, the bending section 53a need not extend upward beyond the upper end of coil section 51. Likewise, the extension section 62b may be located in a different position than the extension section 63b in the upward-downward direction. The bending section 63a need not extend upward beyond the upper end of coil section 61.

[0040] The position (orientation) of the flat wire 50 in extension section 52b can differ from the position of the flat wire 50 in extension section 53b. For example, in the case of coil component 5, the end section 53 need not have the bending section 53a and can extend directly forward from the outer circumference of coil section 51. In this case, an edge bending process for the end section 53 is not required, thus simplifying the manufacture of the coil component 5.

[0041] The position of the flat wire 60 in extension section 62b can differ from the position of the flat wire 60 in extension section 63b. For example, in coil component 5A, the end section 63 need not have the bending section 63a and can extend directly forward from the outer circumference of coil section 61. In this case, the edge bending process for the end section 63 is not required, thus simplifying the manufacture of coil component 5A.

[0042] Core 2 can protrude forward to cover coil section 51 of primary winding 3. In this case, core 2 has a shape that does not interfere with end sections 52 and 53. Coil component 5A, instead of coil component 5, can correspond to primary winding 3. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] JP 2016-039322

[0002]

Claims

[1] Coil component (5, 5A) with: a first coil section (51) formed by flat winding a first flat wire (50) around an axial line (AX) extending in a first direction, such that the first coil section (51) has a single layer in the first direction; a first end section (52) which has an end (50a) of the first flat wire (50) and is drawn out from an inner circumference of the first coil section (51); and a second end section (53) which has the other end (50b) of the first flat wire (50) and is drawn out from an outer circumference of the first coil section (51), characterized by , that the first terminal section (52) exhibits: - a first bending section (52a) formed by angular bending of the first flat wire (50) from the inner circumference of the first coil section (51) and extending beyond the first coil section (51) in the first direction; and - a first extension section (52b) formed by flat bending of the first flat wire (50) from the first bending section (52a) and extending in a second direction intersecting with the first direction. [2] Coil component (5, 5A) according to claim 1, characterized by , that the second terminal section (53) exhibits: - a second bending section (53a) formed by the angular bending of the first flat wire (50) from the outer circumference of the first coil section (51); and - a second extension section (53b) formed by the flat bending of the first flat wire (50) from the second bending section (53a) and extending in the second direction. [3] Coil component (5A) according to claim 2, further comprising: a second coil section (61) formed by flat winding a second flat wire (60) around the axial line (AX), such that the second coil section (61) has a single layer in the first direction, wherein the second coil section (61) surrounds the first coil section (51); a third end section (62) which has an end (60a) of the second flat wire (60) and is drawn out from an inner circumference of the second coil section (61); and a fourth end section (63) which has the other end (60b) of the second flat wire (60) and is drawn out from an outer circumference of the second coil section (61), characterized by, that the third terminal section (62) exhibits: - a third bending section (62a) formed by the angular bending of the second flat wire (60) from the inner circumference of the second coil section (61) and extending beyond the second coil section (61) in the first direction; and - a third extension section (62b) formed by the flat bending of the second flat wire (60) from the third bending section (63a) and extending in the second direction; and the second bending section (53a) and the third bending section (62a) are arranged in a third direction which intersects with the first direction and the second direction. [4] Coil component (5A) according to claim 3, characterized by , that the first extension section (52b) overlaps with the third extension section (62b), as seen in the first direction.

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