Coil component

The coil component design addresses the issue of size by using parallel connections and insulating members to reduce overlap, achieving a smaller and cost-effective coil component.

JP2025187647APending Publication Date: 2025-12-25TAMURA KK
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Patent Information

Application Number
JP2024096631
Authority / Receiving Office
JP · JP
Patent Type
Applications
Current Assignee / Owner
Filing Date
2024-06-14
Publication Date
2025-12-25

AI Technical Summary

Technical Problem

Existing coil components are large in size due to the overlapping of conductive members in the stacking direction during joining, which increases the dimensions of the coil component.

Method used

A coil component design where adjacent conductive members are connected via parallel connection portions on a plane perpendicular to the stacking direction, with insulating members between turns, and connection portions are arranged in notches to reduce overlap, using a bobbin and core structure to contain the connections within the component's bounds.

Benefits of technology

The design allows for a smaller coil component size in the stacking direction, reduces mold costs, and ensures effective insulation without needing additional space for insulation distances, thus minimizing the overall size and cost.

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Abstract

To provide a coil component in which a dimension in a stacking direction can be reduced.SOLUTION: The coil component 100 includes a coil 2 formed by stacking a plurality of conductive members 21, 22, 23, and 24, and an insulating member 3 disposed between adjacent turns to insulate the adjacent conductive members 21, 22, 23, and 24. The conductive members 21, 22, 23, and 24 each have connection portions 213, 224a, 224b, 234a, 234b, and 242 for connection to other conductive members 21, 22, 23, and 24, and the respective connection portions 213, 224a, 224b, 234a, 234b, and 242 of the adjacent conductive members 21, 22, 23, and 24 are arranged in parallel on the same plane extending orthogonally to a stacking direction.SELECTED DRAWING: Figure 2
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Description

[Technical Field]

[0001] The present invention relates to a coil component including a coil formed of a plurality of conductive members. [Background technology]

[0002] Examples of coil components include transformers and reactors used in various electrical devices. For example, a coil component has a coil attached to a bobbin. A pin terminal is partially embedded in the bobbin, and the coil is electrically connected to the pin terminal. The tip of the pin terminal is inserted into a substrate and joined by soldering or the like. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2002-175922 Summary of the Invention [Problem to be solved by the invention]

[0004] A coil may be formed by stacking multiple conductive members. These multiple conductive members are joined by soldering, welding, or the like. When joining the conductive members, adjacent conductive members are joined by overlapping them in the stacking direction. This increases the dimensions of the coil in the stacking direction, resulting in an increase in the size of the coil component.

[0005] The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a coil component that can be made smaller in size in the stacking direction. [Means for solving the problem]

[0006] In order to achieve the above object, the coil component of the present invention comprises a coil formed by stacking a plurality of conductive members, and an insulating member disposed between each turn to insulate the adjacent conductive members, wherein the conductive members have connection portions that connect to other conductive members, and the connection portions of the adjacent conductive members are arranged in parallel on the same plane extending perpendicular to the stacking direction. [Effects of the Invention]

[0007] According to the present invention, it is possible to obtain a coil component whose size in the stacking direction can be reduced. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 2 is a perspective view showing the overall configuration of the assembly. [Figure 2] FIG. 2 is a perspective view showing the overall configuration of the coil. [Figure 3] FIG. [Figure 4] FIG. 10 is an enlarged side view of the bending portion. [Figure 5] FIG. 2 is a perspective view showing the overall configuration of the bobbin. [Figure 6] FIG. 2 is a view of the bobbin with the coil attached thereto, as seen from the rear side. [Figure 7] FIG. [Figure 8] FIG. 2 is an overall perspective view of the coil component. [Figure 9] FIG. 2 is a view of the coil component as seen from the yoke side. DETAILED DESCRIPTION OF THE INVENTION

[0009] (Embodiment) Coil components according to embodiments will be described with reference to the drawings. In the drawings, for ease of understanding, dimensions, positional relationships, ratios, shapes, etc. may be emphasized or components may be omitted, but the present invention is not limited to such emphasis.

[0010] The coil component 100 (see FIGS. 6 and 7) is mounted on the surface of a circuit board and constitutes part of a power supply circuit. The coil component 100 of this embodiment is a transformer that converts voltage levels using electromagnetic induction, and is installed in an automobile. Note that the coil component 100 is not limited to a transformer, and may also be a reactor or the like.

[0011] 1 is a perspective view showing the overall configuration of an assembly. As shown in FIG. 1, the coil device 100 has an assembly 1 formed by assembling a coil 2 to a bobbin 4. That is, the coil device 100 includes the coil 2 and the bobbin 4.

[0012] FIG. 2 is a perspective view showing the overall configuration of coil 2. FIG. 3 is an exploded perspective view of coil 2. Coil 2 is made up of multiple conductive members 21, 22, 23, and 24. Conductive members 21, 22, 23, and 24 are, for example, bus bars punched out of copper plate. Each conductive member 21, 22, 23, and 24 is stacked with its wide surface facing each other. Conductive members 21 and 24 are located at the top or bottom in the stacking direction. Conductive members 22 and 23 are sandwiched between conductive members 21 and 24. Each conductive member 21, 22, 23, and 24 is not covered with an insulating coating such as an enamel coating.

[0013] Conductive members 21, 22, 23, and 24 are connected to adjacent conductive members 21, 22, 23, and 24. A three-turn coil 2 is formed by stacking four conductive members 21, 22, 23, and 24. Conductive members 21, 22, 23, and 24 are fixed with insulating tape or the like. In this embodiment, conductive member 21 is the lowest end and conductive member 24 is the highest end, and the conductive member 21 side will be described as the first turn.

[0014] Conductive member 21 is disposed at the bottom end, which is one end in the stacking direction. Conductive member 21 is flat and forms the first turn of coil 2. Conductive member 21 has a pair of straight line portions 211a, 211b and a connecting portion 212 connecting the pair of straight line portions 211a, 211b, and is generally U-shaped.

[0015] The extension length of straight portion 211b is shorter than the length of straight portion 211a. Straight portion 211b has connecting portion 213 that connects to conductive member 22. Connecting portion 213 is bent 90 degrees from the tip of straight portion 211b to the outside of coil 2. The line width of connecting portion 213 is half the length of the other conductive members 21.

[0016] Conductive member 22 is adjacent to conductive member 21 and is disposed above conductive member 21. Conductive member 22 has a generally U-shape having a pair of straight line portions 221a, 221b and a connecting portion 222 connecting the pair of straight line portions 221a, 221b.

[0017] Straight portion 221a of conductive member 22 has bent portion 223a and flat portion 223b. Bent portion 223a is formed between flat portion 223b and connecting portion 222, and flat portion 223b is at the same height as conductive member 21. Bent portion 223a descends one turn and bends downward so that flat portion 223b is at the same height as conductive member 21. That is, of conductive member 22, flat portion 223b forms the first turn of coil 2 together with conductive member 21. Flat portion 223b is a flat surface.

[0018] A connecting portion 224a is formed at the tip of the straight portion 221a. The connecting portion 224a connects to the connecting portion 213 of the conductive member 21. The straight portion 221a has a notched portion 225a, which is a portion of the connecting portion 224a that has been cut away. The notched portion 225a cuts out half of the line width of the conductive member 22, and the remaining conductive member 22 forms the connecting portion 224a. Therefore, the line width of the connecting portion 224a is half the line width of the other conductive members 22.

[0019] The size of the notch 225a is the same as the size of the connection portion 213 of the conductive member 21. The connection portion 213 of the conductive member 21 is disposed in the space of this notch 225a. That is, the connection portion 224a of the conductive member 22 and the connection portion 213 of the conductive member 21 are disposed in parallel on the same plane extending perpendicular to the stacking direction. In other words, the connection portion 224a of the conductive member 22 and the connection portion 213 of the conductive member 21 do not overlap in the stacking direction. When the connection portion 213 and the connection portion 224a are connected in parallel, their width is the same as the line width of the conductive members 21, 22. The connection portion 224a of the conductive member 22 and the connection portion 213 of the conductive member 21 are connected and joined by soldering.

[0020] A connecting portion 224b is formed at the tip of the straight portion 221b. The connecting portion 224b connects to the connecting portion 234a of the conductive member 23. The straight portion 221b has a notch portion 225b, which is a portion of the connecting portion 224b cut away. The notch portion 225b cuts out half of the line width of the conductive member 22, and the remaining conductive member 22 forms the connecting portion 224b. Therefore, the line width of the connecting portion 224b is half the line width of the other conductive member 22. The size of the notch portion 225b is the same as the size of the connecting portion 234a of the conductive member 23. The connecting portion 234a of the conductive member 23 is arranged in the space of this notch portion 225b.

[0021] Conductive member 23 is adjacent to conductive member 22 and is disposed above conductive member 22. Conductive member 23 has a generally U-shape having a pair of straight line portions 231a, 231b and a connecting portion 232 connecting the pair of straight line portions 231a, 231b. Conductive member 23 is layered such that connecting portion 232 faces straight line portion 221a of conductive member 22.

[0022] The conductive member 23 has a bent portion 233. The bent portion 233 is located approximately in the center of the connecting portion 232. FIG. 4 is an enlarged side view of the bent portions 223a and 233. The bent portion 233 is located in close proximity to the bent portion 223a of the conductive member 22. "Close proximity" refers to a distance that allows the adjacent conductive members 22 and 23 to be insulated from each other by the space S formed by the bent portions 223a and 233, and refers to, for example, the same side of the turns that form the coil 2. However, the bent portion 233 does not face the bent portion 223a of the conductive member 22, but faces the flat portion 223b. Therefore, a space S is formed by the bent portion 223a and flat portion 232b of the conductive member 22, the bent portion 233 of the conductive member 23, and the connecting portion 232 (the shaded area surrounded by a dotted line in FIG. 4).

[0023] Bent portion 233 is bent downward so that part of connecting portion 232 and straight portion 231a are at the same height as connecting portion 224b of conductive member 22. That is, bent portion 233 is bent downward by one turn. Of conductive member 22, part of connecting portion 232 and straight portion 231a form the second turn of coil 2.

[0024] Returning to FIG. 3, a connecting portion 234a is formed at the tip portion of the straight portion 231a. The connecting portion 234a is disposed in the notch 225b of the conductive member 22. The connecting portion 234a of the conductive member 23 and the connecting portion 224b of the conductive member 22 are disposed in parallel on the same plane extending perpendicular to the stacking direction. In other words, the connecting portion 234a of the conductive member 23 and the connecting portion 224b of the conductive member 22 do not overlap in the stacking direction. When the connecting portion 234a and the connecting portion 224b are connected in parallel, the width is the same as the line width of the conductive members 22, 23. The connecting portion 234a of the conductive member 23 and the connecting portion 224b of the conductive member 22 are connected and joined by soldering.

[0025] A connecting portion 234b is formed at the tip of the straight portion 231b. The connecting portion 234b is connected to the connecting portion 242 of the conductive member 24. The line width of the connecting portions 234a and 234b is half the line width of the other conductive members 23.

[0026] Conductive member 24 is adjacent to conductive member 23 and is disposed above conductive member 23, forming the uppermost end, which is the other end of coil 2. Conductive member 24 is disposed at the same height as straight portion 231b of conductive member 23. That is, conductive member 24, together with conductive member 23, forms the third turn of coil 2. Conductive member 24 is made up of a pair of straight portions 241a, 241b. Straight portions 241a, 241b of conductive member 24 are connected at their respective ends so that they are perpendicular to each other, forming a roughly L-shape.

[0027] A connecting portion 242 is formed at the tip of the straight portion 241a. The connecting portion 242 connects to the connecting portion 234b of the conductive member 23. The straight portion 241a has a notch 243 formed by cutting out a portion of the connecting portion 242. The notch 243 cuts out half of the line width of the conductive member 24, and the remaining conductive member 24 forms the connecting portion 242. Therefore, the line width of the connecting portion 242 is half the line width of the other conductive members 24.

[0028] The size of the notch 243 is the same as the size of the connection portion 234b of the conductive member 23. The connection portion 234b of the conductive member 23 is disposed in the space of this notch 243. That is, the connection portion 242 of the conductive member 24 and the connection portion 234b of the conductive member 23 are disposed in parallel on the same plane extending perpendicular to the stacking direction. In other words, the connection portion 242 of the conductive member 24 and the connection portion 234b of the conductive member 23 do not overlap in the stacking direction. When the connection portion 242 and the connection portion 234b are connected in parallel, their width is the same as the line width of the conductive members 23, 24. The connection portion 242 of the conductive member 24 and the connection portion 234b of the conductive member 23 are connected and joined by soldering.

[0029] 3, the coil device 100 further includes an insulating member 3. The insulating member 3 is provided between the turns of the coil 2. That is, the insulating member 3 is provided between the first and second turns of the coil 2 and between the second and third turns of the coil 2. The insulating member 3 insulates the conductive members 21, 22, 23, and 24.

[0030] The insulating member 3 may be a thin plate-like material such as insulating paper or insulating film. The coil device 100 includes a plurality of insulating members 3. The insulating members 3 have the same shape and size. In this embodiment, the insulating member 3 is generally L-shaped.

[0031] Four insulating members 3 are provided. Two insulating members 3 are provided between each turn. Two insulating members 3 are provided between each turn so that their short sides are connected. The insulating members 3 are arranged on the sides of the turns of the coil 2 where the bent portions 223a, 233 are not formed. The turns of the coil 2 refer to each layer of the coil 2 in which a plurality of the conductive members are stacked.

[0032] FIG. 5 is a perspective view showing the overall configuration of the bobbin 4. The coil 2 is attached to the bobbin 4. The coil 2 is fixed to the bobbin 4 by attaching the coil 2 and the bobbin 4 with tape over one or more turns. The bobbin 4 is made of an insulating resin. Examples of resins that can be used to make the bobbin 4 include epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), and PBT (Polybutylene Terephthalate).

[0033] As shown in FIG. 5 , the bobbin 4 has a mounting surface 41, an inner wall 42, and an outer wall 43. The mounting surface 41 is a surface on which the coil 2 is mounted. The coil 2 is mounted on the mounting surface 41 so that the wide surface of the coil 2 abuts against the mounting surface 41. In this embodiment, the coil 2 is assembled to the bobbin 4 so that the conductive member 24 abuts against the mounting surface 41. The mounting surface 41 has an opening 411. The opening 411 is formed in the central portion of the mounting surface 41. The outer diameter of the opening 411 is approximately the same size as the middle leg 53 of the core 5, and is slightly smaller than the inner diameter of the coil 2. The opening 411 is approximately rectangular.

[0034] The inner wall 42 is provided on the edge portion of the opening 411. The inner wall 42 is made up of four inner walls 42a, 42b, 42c, and 42d. Each of the inner walls 42a, 42b, 42c, and 42d is provided along each side of the roughly rectangular opening 411, and adjacent inner walls 42a, 42b, 42c, and 42d are connected to each other. In other words, the inner wall 42 is provided around the entire circumference of the opening 411, following the edge of the opening 411. The outer diameter of the inner wall 42 is approximately the same as the inner diameter of the coil 2, and the outer peripheral surface of the inner wall 42 abuts against the inner peripheral surface of the coil 2.

[0035] The inner wall 42 rises from the mounting surface 41 in a direction perpendicular to the mounting surface 41. When the coil 2 is placed on the mounting surface 41, the inner wall 42 rises to a position higher than the height of the coil 2.

[0036] The inner wall 42 has a notch 421. The notch 421 cuts the inner wall 42 from the upper end of the inner wall 42 toward the mounting surface 41. The notch 421 is cut out until the height of the inner wall 42 at the portion where the notch 421 is formed becomes substantially the same as the height of the coil 2 when the coil 2 is placed on the mounting surface 41. In other words, the height of the inner wall 42 at the portion where the notch 421 is formed becomes substantially the same as the height of the coil 2.

[0037] Two notches 421 are provided. Notch 421a is provided in the center of inner wall 42b. Notch 421b is provided in the center of inner wall 42d. Notches 421a and 421b are provided opposite each other with opening 411 in between.

[0038] The outer wall 43 is provided on the outer edge of the mounting surface 41. The outer wall 43 rises from the mounting surface 41 in a direction perpendicular to the mounting surface 41. When the coil 2 is placed on the mounting surface 41, the outer wall 43 rises to a position higher than the height of the coil 2. Two outer walls 43 are provided. The outer wall 43a faces the inner wall 42b. The outer wall 43b faces the inner wall 42d.

[0039] Each of the outer walls 43a, 43b is provided with a notch 431. The notch 431 is cut out until the height of the outer walls 43a, 43b becomes substantially the same as the height of the coil 2 when the coil 2 is placed on the placement surface 41. In other words, the portions of the outer walls 43a, 43b where the notch 431 is formed become substantially the same as the height of the coil 2.

[0040] A pin terminal (not shown) is embedded in the bobbin 4. The lower end of the pin terminal is embedded in the bobbin 4, and the upper end protrudes from the bobbin 4. The pin terminal is made of a conductive material. The tip of the pin terminal is inserted into a board, and the pin terminal and the board are joined by soldering or the like.

[0041] FIG. 6 is a view of the bobbin 4 with the coil 2 attached thereto, as viewed from the back of the bobbin 4. The back of the bobbin 4 is the surface opposite the mounting surface 41. As shown in FIG. 6, the connection portions 213, 224a, 224b, 234a, 234b, and 242 extend toward the outside of the bobbin 4. However, the connection portions 213, 224a, 224b, 234a, 234b, and 242 are located within the uppermost or lowermost region of the bobbin 4. In other words, the connection portions 213, 224a, 224b, 234a, 234b, and 242 do not protrude beyond the uppermost or lowermost region of the bobbin 4. The vertical direction here refers to a direction parallel to the mounting surface 41 and perpendicular to the arrangement direction of the center leg 53 and the outer leg 54 of the core 5, which will be described later. Moreover, the uppermost end or the lowermost end of the bobbin 4 refers to the upper end or the lower end of the placement surface 41 .

[0042] FIG. 7 is an exploded perspective view of the coil device 100. FIG. 8 is an overall perspective view of the coil device 100. The coil device 100 further includes a core 5. The core 5 is made of a magnetic material. The core 5 forms a magnetic path through which the magnetic flux generated by the coil 2 flows. The core 5 may be a powder magnetic core, a ferrite magnetic core, a laminated steel plate, a metal composite core, or the like. A metal composite core is a magnetic material formed by kneading magnetic powder and resin and then hardening the resin.

[0043] The core 5 is made up of a pair of E-shaped members 51 and 52. The E-shaped members 51 and 52 have a center leg 53, a pair of outer legs 54, and a yoke portion 55 connecting the center leg 53 and the pair of outer legs 54. The coil 2 is attached to the center leg 53. The center leg 53 and the pair of outer legs 54 are arranged side by side so that their extension directions are parallel. The outer legs 54 are arranged on both sides of the center leg 53, with the center leg 53 in between. The E-shaped members 51 and 52 are joined at the tip end surfaces of the center leg 53 and the outer legs 54. This makes the core 5 a ring-shaped closed magnetic circuit having a roughly θ shape.

[0044] A tape (not shown) is wound around the outer periphery of the core 5. The tape secures the E-shaped members 51 and 52 so that they do not come apart.

[0045] 9 is a view of the coil device 100 as viewed from the yoke portion 55 side. When the assembly 1 is attached to the core 5, the connection portions 213, 224a, 224b, 234a, 234b, and 242 are arranged on the upper or lower surface of the outer leg 54 of the core 5. However, the connection portions 213, 224a, 224b, 234a, 234b, and 242 are arranged within an extension region of the upper or lower surface of the outer leg 54 of the core 5. In other words, they do not protrude outward beyond the outer peripheral surface of the outer leg 54 of the core 5.

[0046] (effect) As described above, coil device 100 of this embodiment includes coil 2 formed by stacking multiple conductive members 21, 22, 23, and 24, and insulating members 3 disposed between each turn to insulate adjacent conductive members 21, 22, 23, and 24. Conductive members 21, 22, 23, and 24 have connecting portions 213, 224a, 224b, 234a, 234b, and 242 that connect to other conductive members 21, 22, 23, and 24, and the connecting portions 213, 224a, 224b, 234a, 234b, and 242 of adjacent conductive members 21, 22, 23, and 24 are disposed in parallel on the same plane extending perpendicular to the stacking direction.

[0047] In this way, the connecting portions 213, 224a, 224b, 234a, 234b, and 242 are joined while being arranged side by side in the stacking direction, which allows the dimension of the coil device 100 in the stacking direction to be smaller than when the connecting portions are joined while overlapping each other in the stacking direction as in the conventional case.

[0048] The connection portions 224a, 224b, 242 have notches 225a, 225b, 243 cut out from the conductive members 22, 24, and the connection portions 213, 234a, 234b connected to the connection portions 224a, 224b, 242 are arranged in the notches 225a, 225b, 243 and are connected to the connection portions 224a, 224b, 242.

[0049] In this way, by providing the cutouts 225a, 225b, and 243 and arranging the connection portions 213, 234a, and 234b in the cutouts 225a, 225b, and 243, the connection portions can be made small.

[0050] In particular, in this embodiment, the line width of each of the connecting portions 213, 224a, 224b, 234a, 234b, and 242 is half the line width of the other conductive members 21, 22, 23, and 24. If the connecting portions were arranged side by side without shortening their line width, the connecting portions would require the line width of two conductive members, resulting in a large size. However, as in this embodiment, by halving the line width of each of the connecting portions 213, 224a, 224b, 234a, 234b, and 242 and arranging the connecting portions 213, 234a, and 234b in the cutout portions 225a, 225b, and 243, the connecting portions can be reduced to the line width of one conductive member, thereby enabling the coil device 100 to be made smaller.

[0051] Four conductive members 21, 22, 23, and 24 are provided, and conductive members 22 and 23 arranged between them in the stacking direction have bent portions 223a and 233 that bend downward by one turn. The bent portions 223a and 233 are arranged in close proximity to each other but do not face each other.

[0052] As a result, a space S is generated near the conductive members 22 and 23 where the bent portions 223a and 233 are formed. Therefore, the space S can ensure an insulating distance between the conductive members 22 and 23. Because the bent portions 223a and 233 are bent, it is difficult for the insulating member 3 to be sandwiched between them. Therefore, by arranging the bent portions 223a and 233 so that the space S is formed, the space S can ensure insulation between the conductive members 22 and 23.

[0053] Furthermore, if the bent portions 223a, 233 were arranged in opposing positions, there is a risk that the slopes of the bent portions 223a, 233 would interfere with each other. Therefore, it is necessary to secure a space between the bent portions 223a, 233 in advance, taking into account dimensional tolerances, etc., which would result in an increase in size in the stacking direction. Therefore, the bent portions 223a, 233 are arranged in positions close to each other but not opposing each other, thereby forming the space S. This eliminates the risk of interference between the bent portions 223a, 233 and eliminates the need to secure a space, allowing the coil device 100 to be made smaller in size in the stacking direction.

[0054] A plurality of insulating members 3 are provided, and the plurality of insulating members 3 have the same shape and size. This allows the insulating members 3 to be manufactured using the same mold. This reduces mold costs, leading to cost savings.

[0055] The coil device 100 further includes a bobbin 4 to which the coil 2 is attached, and the connection portions 213, 224a, 224b, 234a, 234b, and 242 do not protrude from the uppermost or lowermost end of the bobbin 4, but are contained within an extension region between the uppermost and lowermost ends of the bobbin 4. This prevents the coil device 100 from becoming larger in size in the vertical direction of the bobbin 4.

[0056] The coil device 100 further includes a core 5 on which the coil 2 is mounted, and the core 5 has a plurality of outer legs 54 and a yoke portion 55 connecting the outer legs 54. The connecting portions 213, 224a, 224b, 234a, 234b, and 242 do not protrude from the outer peripheral surfaces of the outer legs 54, but are provided on the upper or lower surfaces of the outer legs 54. This prevents the coil device 100 from becoming larger in size in the direction in which the outer legs 54 are arranged.

[0057] (Other embodiments) Although the present specification describes an embodiment of the present invention, this embodiment is presented as an example and is not intended to limit the scope of the invention. The above-described embodiment can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the scope of the invention. The embodiments and their modifications are included within the scope and spirit of the invention, as well as within the scope of the invention and its equivalents as set forth in the claims.

[0058] In the above embodiment, the connection portions 213, 224a, 224b, 234a, 234b, and 242 are connected by soldering, but they may also be connected by welding. However, in the case of welding, the connection portions 213, 224a, 224b, 234a, 234b, and 242 are joined by melting them, which may result in the welded portions protruding. To insulate the welded portions from other components, an insulation distance must be secured in advance to account for any protrusions, which increases the size of the coil component 100. On the other hand, soldering can be stretched thinly, so there is no need to secure an insulation distance in advance to account for any protrusions, as is the case with welding. Therefore, soldering is preferable because it allows the coil component 100 to be made smaller.

[0059] Furthermore, in the above embodiment, the coil 2 is formed from four conductive members 21, 22, 23, and 24, but the number of conductive members may be five or more. The connection portions are arranged at 90-degree intervals from one end to the other end in the stacking direction. Therefore, for example, if there are five conductive members and four connection portions, the connection portions may be arranged so that connection portions are formed at all corners of the bobbin 4.

[0060] In the above embodiment, the connecting portions 213, 234a, and 234b are the same size as the notched portions 225a, 225b, and 243, but the connecting portions 213, 234a, and 234b may be larger than the notched portions 225a, 225b, and 243. Even in this case, the connecting portions 213, 234a, and 234b are disposed in the spaces of the notched portions 225a, 225b, and 243, thereby enabling the coil device 100 to be miniaturized. [Explanation of symbols]

[0061] 100 Coil parts 1 assembly 2 coils 21 Conductive materials 211a, 211b Straight section 212 Connecting part 213 Connection 22 Conductive materials 221a, 221b Straight section 222 Connecting part 223a Refraction 223b Flat area 224a, 224b connection parts 225a, 225b Notch 23 Conductive materials 231a, 231b Straight section 232 Connecting part 233 Refraction 234a, 234b connection parts 24 Conductive materials 241a, 241b Straight section 242 Connection 3. Insulating materials 4 bobbins 41 Placement surface 411 Aperture 42 Inner wall 421 Notch 43, 43a, 43b exterior walls 431 Notch 5 cores 51, 52 E-shaped members 53 Middle leg 54 Outer leg 54 York

Claims

1. a coil formed by laminating a plurality of conductive members; an insulating member disposed between each turn to insulate the adjacent conductive members; Equipped with the conductive member has a connection portion for connection to another conductive member, the connection portions of the adjacent conductive members are arranged in parallel on the same plane extending perpendicular to the stacking direction; A coil component characterized by:

2. the connecting portion has a notch formed by cutting out the conductive member, a connecting portion adjacent to the connecting portion having the notch portion is disposed in the notch portion and is disposed in parallel with the connecting portion having the notch portion; The coil component according to claim 1 ,

3. the connecting portion has the same size as the notch portion; The coil component according to claim 2 ,

4. Four or more of the conductive members are provided, Among the conductive members, each of the conductive members arranged between the conductive members in the stacking direction has a bent portion that bends downward by one turn, The bending portions are arranged in positions close to each other and not facing each other.

4. The coil component according to claim 1, wherein:

5. The insulating member is provided in plurality, The insulating members are of the same shape and size; 4. The coil component according to claim 1, wherein:

6. Further provided is a bobbin to which the coil is attached, the connecting portion does not protrude from the uppermost or lowermost end of the bobbin, but is contained within an extension area between the uppermost and lowermost ends of the bobbin; 4. The coil component according to claim 1, wherein:

7. Further, a core is provided to mount the coil, The core has a center leg and a pair of outer legs disposed with the center leg therebetween, The coil is attached to the middle leg; The connecting portion does not protrude from the outer peripheral surface of the outer leg, and is provided on the upper surface or the lower surface of the outer leg.

4. The coil component according to claim 1, wherein:

Citation Information

Patent Citations

  • High-frequency large current transformer

    JP2002175922A