Coil components

Abstract

To provide a coil component that can be miniaturized. [Solution] The coil component 5 comprises a coil section 51 in which a flat wire 50 is flatwise wound in a single layer around an axis AX extending in the vertical direction, an end section 52 which includes one end 50a of the flat wire 50 and is drawn out from the inner circumference of the coil section 51, and an end section 53 which includes the other end 50b of the flat wire 50 and is drawn out from the outer circumference of the coil section 51. The end section 52 is edgewise bent from the inner circumference of the coil section 51 and has a bent section 52a which protrudes more than the coil section 51 in the vertical direction, and an extended section 52b which is flatwise bent from the bent section 52a and extends in the front-rear direction.

Description

Technical Field

[0001] The present disclosure relates to a coil component.

Background Art

[0002] Patent Document 1 describes a coil component including a pair of coil elements in which windings having a rectangular cross-section of a conductor are flat-wound in multiple layers, one end of the winding is disposed on the innermost circumference, and the other end of the winding is drawn out to the outermost circumference, and a connecting portion that connects one ends of the windings.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The coil component described in Patent Document 1 has a multilayer structure in order to draw out the coil ends. Therefore, there is a possibility that the coil component may be enlarged.

[0005] The present disclosure describes a coil component that can be miniaturized.

Means for Solving the Problems

[0006] A coil component according to one aspect of the present disclosure includes a first coil portion flat-wound in a single layer around an axis along which a first straight angle line extends in a first direction, a first end portion including one end of the first straight angle line and drawn out from the inner circumference of the first coil portion, and a second end portion including the other end of the first straight angle line and drawn out from the outer circumference of the first coil portion. The first end portion has a first bent portion that is edgewise bent from the inner circumference of the first coil portion and protrudes from the first coil portion in the first direction, and a first extending portion that is flatwise bent from the first bent portion and extends in a second direction intersecting the first direction.

[0007] In this coil component, a first flat wire is flatwound in a single layer around an axis extending in a first direction to form a first coil section. A first end, including one end of the first flat wire, is drawn out from the inner circumference of the first coil, and a second end, including the other end of the first flat wire, is drawn out from the outer circumference of the first coil. At the first end, a first bend is edge-bent from the inner circumference of the first coil section, protruding beyond the first coil section in the first direction, and a first extension is flat-bent from the first bend, extending in a second direction intersecting the first direction. Therefore, the first end is drawn out from the inner circumference of the first coil section without interfering with the first coil section. With this configuration, it is not necessary to make the first coil section multilayered in the first direction, making it possible to miniaturize the coil component.

[0008] The second end may have a second bent portion that is edgewise bent from the outer circumference of the first coil portion, and a second extended portion that is flatwise bent from the second bent portion and extends in the second direction. In this case, the orientation (direction) of the first rectangular wire in the second extended portion can be matched with the orientation of the first rectangular wire in the first extended portion. Therefore, it becomes easier to mount the coil component on a substrate or the like.

[0009] The above coil component is a second coil section in which a second rectangular wire is flatwise wound in a single layer around an axis, and may further comprise a second coil section surrounding a first coil section, a third end section including one end of the second rectangular wire and drawn out from the inner circumference of the second coil section, and a fourth end section including the other end of the second rectangular wire and drawn out from the outer circumference of the second coil section. The third end section may have a third bent section that is edgewise bent from the inner circumference of the second coil section and protrudes more than the second coil section in a first direction, and a third extended section that is flatwise bent from the third bent section and extends in a second direction. The second bent section and the third bent section may be arranged side by side in the first direction and in a third direction intersecting the second direction. In this case, the space between the first coil section and the second coil section can be reduced. Therefore, it becomes possible to miniaturize the coil component.

[0010] The first extension may overlap with the third extension when viewed from the first direction. In this case, since the first extension and the third extension are close together, they can be easily joined together. [Effects of the Invention]

[0011] According to this disclosure, coil components can be miniaturized. [Brief explanation of the drawing]

[0012] [Figure 1] Figure 1 is a perspective view showing a schematic configuration of a transformer to which a coil component according to one embodiment is applied. [Figure 2] Figure 2 is a cross-sectional view along the line II-II in Figure 1. [Figure 3] Figure 3 is a perspective view of the coil component shown in Figure 1. [Figure 4] Figure 4 is a perspective view showing a schematic configuration of a transformer to which a coil component according to another embodiment is applied. [Figure 5] Figure 5 is an exploded perspective view of the coil component shown in Figure 4. [Figure 6] Figure 6(a) is a side view of the coil component shown in Figure 4. Figure 6(b) is a top view of the coil component shown in Figure 4. [Modes for carrying out the invention]

[0013] The following describes coil components according to several embodiments with reference to the attached drawings. In the description of the drawings, the same reference numerals are used for identical or equivalent elements, and redundant descriptions are omitted. Each figure may show an XYZ coordinate system. The Y-axis direction (second direction) is the direction that intersects (e.g., is perpendicular to) the X-axis direction (third direction) and the Z-axis direction (first direction). The Z-axis direction is the direction that intersects (e.g., is perpendicular to) the X-axis direction and the Y-axis direction. In the following, as an example, the X-axis direction will be described as the left-right direction (width direction), the Y-axis direction as the front-back direction (depth direction), and the Z-axis direction as the up-down direction (height direction). The X-axis direction, Y-axis direction, and Z-axis direction are not limited to the directions described above.

[0014] The schematic configuration of a transformer to which a coil component according to one embodiment is applied will be described with reference to Figures 1 and 2. Figure 1 is a perspective view showing the schematic configuration of a transformer to which a coil component according to one embodiment is applied. Figure 2 is a cross-sectional view along the line II-II in Figure 1. The transformer 1 shown in Figures 1 and 2 is a device that converts a primary voltage to a secondary voltage and includes a core 2, a primary winding 3, a secondary winding 4, and a bobbin 6. Note that the bobbin 6 is not shown in Figure 2.

[0015] Core 2 is a magnetic material that forms a magnetic path. Core 2 includes a central leg 21, a pair of side legs 22, and a pair of connecting parts 23. Each of the central leg 21 and the pair of side legs 22 extends in the vertical direction. The central leg 21 and the pair of side legs 22 are arranged substantially parallel to each other. The pair of side legs 22 are provided apart from the central leg 21 in the left-right direction. In the left-right direction, the central leg 21 is positioned between the pair of side legs 22. The pair of connecting parts 23 are the parts that connect the pair of side legs 22 to the central leg 21. Each connecting part 23 has a flat plate shape. One connecting part 23 connects one end of the central leg 21 to one end of each side leg 22. The other connecting part 23 connects the other end of the central leg 21 to the other end of each side leg 22.

[0016] In this embodiment, the core 2 is an EI core composed of an E-shaped core member 2a and an I-shaped core member 2b. The shape of the core 2 is not limited to the EI core, and it may be an EE core or a PQ core.

[0017] The primary winding 3 and the secondary winding 4 are coil components formed by winding a strip-shaped rectangular wire in a spiral shape. The primary winding 3 and the secondary winding 4 are flatwise coils formed by winding the rectangular wire in the thickness direction of the rectangular wire. The thickness direction of the rectangular wire is the direction along the short side of the cross section that intersects (for example, is orthogonal to) the extending direction of the rectangular wire. The primary winding 3 and the secondary winding 4 are wound around the central leg 21. The secondary winding 4 is provided apart from the primary winding 3 in the vertical direction. The primary winding 3 and the secondary winding 4 have the same structure. Details of the primary winding 3 and the secondary winding 4 will be described later.

[0018] The bobbin 6 is a member that holds the primary winding 3 and the secondary winding 4. The bobbin 6 is made of an insulating material. Examples of the insulating material constituting the bobbin 6 include resins such as plastics. The bobbin 6 electrically separates the primary winding 3 and the secondary winding 4 and also electrically separates the primary winding 3 and the secondary winding 4 from the core 2. The transformer 1 may further include a pass core provided between the primary winding 3 and the secondary winding 4 in the vertical direction. The pass core is a magnetic body that forms a magnetic path for leakage magnetic flux together with the core 2. In this case, the bobbin 6 may accommodate the pass core.

[0019] Next, while referring to FIG. 3, the coil component 5 constituting the primary winding 3 and the secondary winding 4 will be described. FIG. 3 is a perspective view of the coil component shown in FIG. 1. As shown in FIG. 3, the coil component 5 is composed of one rectangular wire 50 (first rectangular wire) and includes a coil portion 51 (first coil portion), an end portion 52 (first end portion), and an end portion 53 (second end portion). The rectangular wire 50 is composed of a conductive member (for example, copper) having a rectangular cross section that intersects (for example, is orthogonal to) its extending direction and an insulating film covering the surface of the conductive member.

[0020] The coil portion 51 is formed by flatwise winding a flat rectangular wire 50 around an axis AX along which the flat rectangular wire 50 extends in the vertical direction. Flatwise winding means bending and winding the flat rectangular wire in the thickness direction of the flat rectangular wire. In the coil portion 51, the flat rectangular wire 50 is wound in a single layer in the vertical direction. In other words, in the coil portion 51, the flat rectangular wire 50 is wound in a spiral shape on the same plane. In the present embodiment, the coil portion 51 has a rectangular outer shape in plan view.

[0021] The end portion 52 includes one end 50a of the flat rectangular wire 50 and is a portion drawn out from the inner circumference of the coil portion 51. The end portion 52 includes a bent portion 52a (first bent portion) and an extending portion 52b (first extending portion). The bent portion 52a is edgewise bent from the inner circumference of the coil portion 51 and protrudes upward from the coil portion 51 (the upper end of the coil portion 51) in the vertical direction. Edgewise bending means bending the flat rectangular wire in the width direction of the flat rectangular wire. The width direction of the flat rectangular wire is the direction along the long side of the cross section that intersects (for example, is orthogonal to) the extending direction of the flat rectangular wire. The extending portion 52b is continuous with the upper end of the bent portion 52a and is flatwise bent from the bent portion 52a and extends forward. Flatwise bending means bending the flat rectangular wire in the thickness direction of the flat rectangular wire. The extending portion 52b extends forward from the inner circumference of the coil portion 51 beyond the outer circumference of the coil portion 51.

[0022] The end portion 53 includes the other end 50b of the flat rectangular wire 50 and is a portion drawn out from the outer circumference of the coil portion 51. The end portion 53 includes a bent portion 53a (second bent portion) and an extending portion 53b (second extending portion). The bent portion 53a is edgewise bent from the outer circumference of the coil portion 51 and protrudes upward from the coil portion 51 (the upper end of the coil portion 51) in the vertical direction. In the present embodiment, in the vertical direction, the upper end of the bent portion 53a is located at substantially the same height as the upper end of the bent portion 52a. The extending portion 53b is continuous with the upper end of the bent portion 53a and is flatwise bent from the bent portion 53a and extends forward. The extending portion 53b is arranged side by side with the extending portion 52b in the left - right direction and is located at substantially the same height in the vertical direction. The extending portion 52b and the extending portion 53b extend substantially parallel to each other.

[0023] The orientation (direction) of the rectangular wire 50 in the extended portion 52b is substantially the same as the orientation of the rectangular wire 50 in the extended portion 53b. In other words, the width direction of the rectangular wire 50 in the extended portion 52b and the width direction of the rectangular wire 50 in the extended portion 53b are both left-right directions, and the thickness direction of the rectangular wire 50 in the extended portion 52b and the thickness direction of the rectangular wire 50 in the extended portion 53b are both up-down directions.

[0024] As described above, in the coil component 5, a flat wire 50 is flatwise wound in a single layer around an axis AX extending in the vertical direction to form a coil section 51. One end 52 of the flat wire 50, including one end 50a, is drawn out from the inner circumference of the coil section 51, and the other end 53, including the other end 50b of the flat wire 50, is drawn out from the outer circumference of the coil section 51. At the end 52, the bent portion 52a is edgewise bent from the inner circumference of the coil section 51 and protrudes beyond the coil section 51 in the vertical direction, while the extended portion 52b is flatwise bent from the bent portion 52a and extends forward. Therefore, the end 52 is drawn out from the inner circumference of the coil section 51 without interfering with the coil section 51. With this configuration, there is no need to make the coil section 51 multilayered in the vertical direction, so it is possible to miniaturize (reduce the height of) the coil component 5.

[0025] As shown in Figure 2, by using coil components 5 for the primary winding 3 and secondary winding 4, each of the primary winding 3 and secondary winding 4 can be made into a single layer in the vertical direction. Therefore, the magnetic path length can be shortened, and the transformer 1 can be made smaller (lower profile) in the vertical direction.

[0026] At end 53, the bent portion 53a is edgewise bent from the outer circumference of the coil portion 51, and the extended portion 53b is flatwise bent from the bent portion 53a and extends forward. With this configuration, the orientation (direction) of the flat wire 50 in the extended portion 53b can be matched with the orientation of the flat wire 50 in the extended portion 52b. Therefore, the coil component 5 becomes easier to mount on a substrate or the like.

[0027] Next, a coil component according to another embodiment will be described with reference to Figures 4, 5, 6(a), and 6(b). Figure 4 is a perspective view showing a schematic configuration of a transformer to which the coil component according to the other embodiment is applied. Figure 5 is an exploded perspective view of the coil component shown in Figure 4. Figure 6(a) is a side view of the coil component shown in Figure 4. Figure 6(b) is a top view of the coil component shown in Figure 4.

[0028] Transformer 1A, shown in Figure 4, differs from transformer 1 mainly in that it includes a secondary winding 4A instead of secondary winding 4. Secondary winding 4A differs from secondary winding 4 mainly in that it is composed of coil component 5A instead of coil component 5.

[0029] As shown in Figure 5, coil component 5A differs from coil component 5 mainly in that it includes coil component 5 as an inner coil C1 and further includes an outer coil C2. In other words, 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 composed of a single flat rectangular wire 60 (second flat rectangular wire) and includes a coil portion 61 (second coil portion), an end portion 62 (third end portion), and an end portion 63 (fourth end portion). The flat rectangular wire 60, like the flat rectangular wire 50, is composed of a conductive member (e.g., copper) with a rectangular cross-section intersecting (e.g., perpendicular to) its extending direction and an insulating film covering the surface of the conductive member.

[0030] The coil section 61 is formed by flatwise winding of a rectangular wire 60 around an axis AX. The coil section 61 surrounds the coil section 51. Specifically, the inner circumference of the coil section 61 is provided along the outer circumference of the coil section 51. In the coil section 61, the rectangular wire 60 is wound in a single layer in the vertical direction. In other words, in the coil section 61, the rectangular wire 60 is wound in a spiral shape on the same plane as the coil section 51. In this embodiment, the coil section 61 has a rectangular outer shape in plan view.

[0031] The end portion 62 includes one end 60a of the rectangular wire 60 and is the portion drawn out from the inner circumference of the coil portion 61. The end portion 62 includes a bent portion 62a (third bent portion) and an extended portion 62b (third extended portion). The bent portion 62a is edgewise bent from the inner circumference of the coil portion 61 and protrudes above the coil portion 61 (upper end of the coil portion 61) in the vertical direction. The extended portion 62b is connected to the upper end of the bent portion 62a and extends forward from the bent portion 62a by flatwise bending. The extended portion 62b extends forward from the inner circumference of the coil portion 61 beyond the outer circumference of the coil portion 61.

[0032] End portion 63 includes the other end 60b of the flat wire 60 and is the portion drawn out from the outer circumference of the coil portion 61. End portion 63 includes a bent portion 63a and an extended portion 63b. The bent portion 63a is edgewise bent from the outer circumference of the coil portion 61 and protrudes above the coil portion 61 (upper end of the coil portion 61) in the vertical direction. In this embodiment, in the vertical direction, the upper end of the bent portion 63a is at substantially the same height as the upper end of the bent portion 62a. The extended portion 63b is connected to the upper end of the bent portion 63a and extends forward from the bent portion 63a by flatwise bending. The extended portion 63b is aligned with the extended portion 62b in the left-right direction and is at substantially the same height in the vertical direction. The extended portion 62b and the extended portion 63b extend substantially parallel to each other.

[0033] The orientation (direction) of the rectangular wire 60 in the extended portion 62b is substantially the same as that of the rectangular wire 60 in the extended portion 63b. In other words, the width direction of the rectangular wire 60 in the extended portion 62b and the width direction of the rectangular wire 60 in the extended portion 63b are both left-right directions, and the thickness direction of the rectangular wire 60 in the extended portion 62b and the thickness direction of the rectangular wire 60 in the extended portion 63b are both up-down directions.

[0034] As shown in Figure 6(a), the bent portion 52a protrudes above the bent portion 62a, and the extended portion 52b is located above the extended portion 62b. As shown in Figure 6(b), the extended portion 52b overlaps with the extended portion 62b when viewed from above (in a plan view). In other words, the extended portions 52b and 62b are arranged side by side in the vertical direction and extend forward parallel to each other.

[0035] Similarly, as shown in Figure 6(a), the bent portion 53a protrudes above the bent portion 63a, and the extended portion 53b is located above the extended portion 63b. As shown in Figure 6(b), the extended portion 53b overlaps with the extended portion 63b when viewed from above (in a plan view). In other words, the extended portions 53b and 63b are arranged side by side in the vertical direction and extend forward parallel to each other.

[0036] As shown in Figure 6(a), the bent portion 53a and the bent portion 62a are located at the same position in the front-rear direction and are arranged side by side in the left-right direction.

[0037] As explained above, the same effects as those of coil component 5 are achieved in coil component 5A with the same configuration as coil component 5. Coil component 5A includes an inner coil C1 and an outer coil C2. In the outer coil C2, a flat wire 60 is flatwise wound in a single layer around an axis AX extending in the vertical direction to form a coil portion 61. One end 62 of the flat wire 60, including one end 60a, is drawn out from the inner circumference of the coil portion 61, and the other end 63, including the other end 60b of the flat wire 60, is drawn out from the outer circumference of the coil portion 61. At the end 62, the bent portion 62a is edgewise bent from the inner circumference of the coil portion 61 and protrudes beyond the coil portion 61 in the vertical direction, and the extended portion 62b is flatwise bent from the bent portion 62a and extends forward. Therefore, the end 62 is drawn out from the inner circumference of the coil portion 61 without interfering with the coil portion 61. With this configuration, there is no need to make the coil section 61 multilayered in the vertical direction, which makes it possible to miniaturize (reduce the height of) the coil component 5A.

[0038] At end portion 63, the bent portion 63a is edgewise bent from the outer circumference of the coil portion 61, and the extended portion 63b is flatwise bent from the bent portion 63a and extends forward. With this configuration, the orientation (direction) of the flat wire 60 in the extended portion 63b can be matched with the orientation of the flat wire 60 in the extended portion 62b. Therefore, the coil component 5A can be easily mounted on a substrate or the like.

[0039] Furthermore, in the coil component 5A, the bent portion 53a of the inner coil C1 and the bent portion 62a of the outer coil C2 are arranged side by side in the left-right direction. This configuration reduces the space between the coil portion 51 (inner coil C1) and the coil portion 61 (outer coil C2). Therefore, it becomes possible to further miniaturize the coil component 5A.

[0040] The extended portion 52b overlaps with the extended portion 62b when viewed from above (in a plan view). Therefore, since the extended portions 52b and 62b are close together, they can be easily joined together. Similarly, the extended portion 53b overlaps with the extended portion 63b when viewed from above (in a plan view). Therefore, since the extended portions 53b and 63b are close together, they can be easily joined together. From the above, it becomes possible to easily connect the inner coil C1 and the outer coil C2 in parallel.

[0041] Since the inner coil C1 and the outer coil C2 are connected in parallel, the current flowing through the secondary winding 4A is halved. This makes it possible to reduce losses and heat generation in the secondary winding 4A.

[0042] Although embodiments of the present disclosure have been described in detail above, the coil components relating to the present disclosure are not limited to the embodiments described above.

[0043] For example, although the ends 52 and 53 of the coil component 5 are pulled forward, the direction in which the ends 52 and 53 are pulled out is not limited to forward. The direction in which the ends 52 and 53 are pulled out may be the same or different.

[0044] The extended portion 52b may be located at a different height from the extended portion 53b in the vertical direction. In the coil component 5, the bent portion 53a does not have to protrude above the upper end of the coil portion 51. Similarly, the extended portion 62b may be located at a different height from the extended portion 63b in the vertical direction. The bent portion 63a does not have to protrude above the upper end of the coil portion 61.

[0045] The orientation (direction) of the rectangular wire 50 in the extended portion 52b and the orientation of the rectangular wire 50 in the extended portion 53b may be different from each other. For example, in the coil component 5, the end portion 53 may not include the bent portion 53a and may extend directly forward from the outer circumference of the coil portion 51. In this case, since there is no need to perform edgewise bending at the end portion 53, the manufacturing of the coil component 5 can be simplified.

[0046] The orientation of the rectangular wire 60 in the extended portion 62b and the orientation of the rectangular wire 60 in the extended portion 63b may be different from each other. For example, in the coil component 5A, the end portion 63 may not include the bent portion 63a and may extend directly forward from the outer circumference of the coil portion 61. In this case, since there is no need to perform edgewise bending at the end portion 63, the manufacturing of the coil component 5A can be simplified.

[0047] The core 2 may protrude forward so as to cover the coil portion 51 of the primary winding 3. In this case, the core 2 is configured in a shape that does not interfere with the ends 52 and 53. The primary winding 3 may be composed of a coil component 5A instead of the coil component 5. [Explanation of Symbols]

[0048] 5,5A…coil part, 50…horizontal line (first horizontal line), 50a…one end, 50b…other end, 51…coil part (first coil part), 52…end (first end), 52a…bending part (first bending part), 52b…extension part (first extension part), 53…end (second end), 53a…bending part (second bending part), 53b…extension part (second extension part), 60…horizontal line (second horizontal line), 60a…one end, 60b…other end, 61…coil part (second coil part), 62…end (third end), 62a…bending part (third bending part), 62b…extension part (third extension part), 63…end (fourth end), 63a…bending part, 63b…extension part, AX…axis.

Claims

1. A first coil section in which a first rectangular wire is flatwise wound in a single layer around an axis extending in a first direction, The first end includes one end of the first rectangular wire and is drawn out from the inner circumference of the first coil portion, The second end, which includes the other end of the first rectangular wire and is drawn out from the outer circumference of the first coil portion, Equipped with, The first end is, A first bent portion is edgewise bent from the inner circumference of the first coil portion and protrudes more than the first coil portion in the first direction, A first extending portion is flatwise bent from the first bending portion and extends in a second direction intersecting the first direction, A coil component having the following characteristics.

2. The second end is, A second bent portion is edgewise bent from the outer circumference of the first coil portion, A second extending portion is flat-bent from the second bending portion and extends in the second direction, A coil component according to claim 1, having the following characteristics.

3. A second coil section in which a second rectangular wire is flatwise wound in a single layer around the axis, the second coil section surrounding the first coil section, A third end, which includes one end of the second rectangular wire and is drawn out from the inner circumference of the second coil portion, The fourth end, which includes the other end of the second rectangular wire and is drawn out from the outer circumference of the second coil portion, Furthermore, The third end is, A third bent portion is formed by edgewise bending from the inner circumference of the second coil portion, and protrudes more than the second coil portion in the first direction. A third extending portion is flatwise bent from the third bending portion and extends in the second direction, It has, The coil component according to claim 2, wherein the second bent portion and the third bent portion are arranged side by side in a third direction intersecting the first direction and the second direction.

4. The coil component according to claim 3, wherein the first extending portion overlaps with the third extending portion when viewed from the first direction.

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