Coil device

Abstract

To provide a coil device which has two coil elements disposed in the same device, while having improved occupancy of a winding wire.SOLUTION: A coil device comprises: a core having a wound core part; and a winding part in which a first wire and a second wire are wound around the wound core part in multiple layers. The winding part has: a first portion in which the first wire and the second wire in the same turn are wound adjacent to each other in the same one of the layers; and a second portion in which the first wire and the second wire in the same turn are wound not adjacent to each other in the different ones of the layers.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a coil device, and more particularly to a coil device in which two coil elements are arranged within the same device. [Background technology]

[0002] Coil devices that place two coil elements within the same device are used in various fields, for example as power inductors, noise filters, transformers, etc. Furthermore, in circuits that need to handle high current values, coil devices that have a wire wound around a core are more suitable for use than stacked chip coils.

[0003] Patent Document 1 proposes a coil device in which two windings are wound around a core to magnetically combine the two windings within the device. However, such a conventional coil device has a problem in that the gaps where no windings are arranged are large within the coil device, particularly near both ends of the winding core, and therefore the occupancy rate of the windings within the coil device is low. If the occupancy rate of the windings is low, the inductance of the coil device may decrease, and this may hinder the miniaturization of the coil device. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2003-324018 A Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention has been made in consideration of the above circumstances, and has an object to provide a coil device in which two coil elements are arranged within the same device, thereby improving the occupancy rate of the windings. [Means for solving the problem]

[0006] In order to achieve the above object, a coil device according to the present invention comprises: A coil device including a core having a winding core portion, and a winding portion in which a first wire and a second wire are wound in multiple layers around the winding core portion, The winding portion is a first portion in which the first wire and the second wire of the same turn are wound adjacent to each other in the same layer; The first wire and the second wire of the same turn have a second portion in which they are not adjacent to each other and are wound in different layers.

[0007] The coil device according to the present invention has a first portion in which the first and second wires of the same turn are wound adjacent to each other in the same layer, and a second portion in which the first and second wires of the same turn are wound not adjacent to each other but in different layers, thereby making it possible to reduce gaps where no wire is arranged, which tend to form particularly near both ends of the winding core. Therefore, such a coil device can improve the occupancy rate of the windings, improve inductance, and is advantageous in terms of miniaturization.

[0008] Also, for example, the innermost layer of the wound portion that contacts the winding core portion may be made up of only the first portion.

[0009] Since the innermost layer can be wound around the core without being affected by unevenness in the winding, by comprising only the first portion, the occupancy rate of the winding can be improved.

[0010] Also, for example, the winding portion may have a third portion in which the first wire and the second wire of the same turn are wound in the same layer but not adjacent to each other. Also, for example, the winding portion may have a fourth portion in which the first wire and the second wire of the same turn are wound adjacent to each other in different layers.

[0011] By having the third and fourth parts in addition to the first and second parts, the coil device can reduce the gaps between the windings and between the windings and the core, thereby improving the occupancy rate of the windings.

[0012] Also, for example, in the second portion, one of the first wire and the second wire in the same turn that is wound in an outer layer may be located closer to the center in the winding axis direction of the winding core portion than the other of the first wire and the second wire in the same turn that is wound in an inner layer that is closer to the winding core portion than the outer layer.

[0013] By positioning the other wire wound in the inner layer in the second portion near the end of the winding core away from the center of the winding axis, it is possible to improve the occupancy rate of the wire near the end of the winding core, where gaps are relatively likely to form.

[0014] Also, for example, the final turn of the first wire and the final turn of the second wire in the winding section may both be at one end of the winding core section in the winding axis direction, and may be positioned closer to a winding core second end, which is the other end in the winding axis direction, than a winding core first end, which is the side from which the ends of the first wire and the second wire away from the winding section are pulled out.

[0015] By positioning the final turn of the first wire and the second wire near the second end of the winding core, the portions of the first wire and the second wire pulled out from the winding section can be brought into contact with the corners of the core at a gentle angle, thereby preventing the problem of damage to the surface of the wire.

[0016] Also, for example, the final turn of the first wire and the final turn of the second wire may be included in the first portion.

[0017] Since the first wire in the final turn and the second wire in the final turn are wound adjacent to each other in the same layer, the first wire and the second wire can be easily pulled out from the winding portion in any direction.

[0018] Also, for example, the winding portion may have a second turn of the first wire wound behind a first turn of the first wire included in the first portion and wound in a second layer closer to the winding core portion than a first layer including the first turn of the first wire, The winding portion may have a second turn of the second wire wound after a first turn of the second wire, which is the same turn as the first turn of the first wire, and the second turn of the second wire wound in the second layer, which is the same turn as the second turn of the first wire.

[0019] The winding section, which has a second turn wound after the first turn and arranged in an inner layer, winds the first wire and the second wire by utilizing the slopes and unevenness formed by the first wire and the second wire during winding, thereby reducing the gaps between the wires and between the wire and the core and improving the occupancy rate of the wire.

[0020] Also, for example, at least one of the third turn of the first wire that is the farthest from the winding core portion and the fourth turn of the second wire that is the farthest from the winding core portion may intersect with a line that passes through a center position of the winding axis direction of the winding core portion and is perpendicular to the winding axis direction.

[0021] In such a coil device, the part of the winding section farthest from the winding core section is positioned near the center of the winding core section in the winding axis direction, thereby preventing the first wire and the second wire from being positioned biased to one side in the winding axis direction and improving the occupancy rate of the wires.

[0022] For example, the core portion may have a central outer peripheral surface that is located toward the center of the core portion in the winding axis direction and extends along the winding axis direction, and an end curved surface that extends from the central outer peripheral surface to a core first end that is one end of the core portion in the winding axis direction, and from the central outer peripheral surface to a core second end that is the other end of the core portion in the winding axis direction, The end curved surface may have a curvature smaller than a curvature of a cross section perpendicular to a wire extension direction of the first wire and the second wire.

[0023] By providing the winding core with such curved end surfaces, the gaps formed between the first wire and the second wire and the winding core can be reduced, thereby improving the occupancy rate of the wires.

[0024] Also, for example, the core may have a first flange portion connected to a winding core first end portion, which is one end portion of the winding core portion in the winding axis direction, and a second flange portion connected to a winding core second end portion, which is the other end portion of the winding core portion in the winding axis direction.

[0025] When a core having a first flange and a second flange is used, gaps are likely to occur near the first flange and the second flange, but a coil device whose winding portion has a first portion and a second portion can improve the occupancy rate of the wire even when the first flange and the second flange are present.

[0026] Also, for example, in the second portion, one of the first wire and the second wire of the same turn that is wound in an outer layer may be separated from the first flange portion and the second flange portion, and the other of the first wire and the second wire of the same turn that is wound in an inner layer closer to the winding core portion than the outer layer may contact the first flange portion or the second flange portion.

[0027] There is a tendency for gaps where no wire is placed to form near the first and second flanges, but when the other wire in the second portion comes into contact with the first or second flange, gaps are less likely to form, thereby improving the occupancy rate of the wire.

[0028] Also, for example, the first flange may be provided with a first electrode portion, a second electrode portion, a third electrode portion, and a fourth electrode portion that are insulated from one another, The first electrode portion and the third electrode portion to which the first wire is connected may be disposed on one diagonal line of the first flange portion, The second electrode portion and the fourth electrode portion to which the second wire is connected may be disposed on another diagonal line of the first flange portion.

[0029] In such a coil device, one end of each of the first wire and the second wire is connected to an electrode portion that is rotated 180 degrees relative to the other end, so that the coil device can be efficiently manufactured using an automatic winding machine. [Brief description of the drawings]

[0030] [Figure 1] FIG. 1 is a perspective view of a coil device according to an embodiment of the present invention, as viewed obliquely from above. [Diagram 2] FIG. 2 is a perspective view of the coil device shown in FIG. 1 as viewed obliquely from below. [Diagram 3] FIG. 3 is a conceptual diagram showing a winding portion of the first wire and the second wire included in the coil device shown in FIG. [Figure 4] FIG. 4 is a conceptual diagram in which the first portion of the winding portion shown in FIG. 3 is highlighted. [Diagram 5] FIG. 5 is a conceptual diagram in which the second portion of the winding portion shown in FIG. 3 is highlighted. [Figure 6] FIG. 6 is a conceptual diagram in which the third portion of the winding portion shown in FIG. 3 is highlighted. [Figure 7] FIG. 7 is a conceptual diagram in which the fourth portion of the winding portion shown in FIG. 3 is highlighted. [Figure 8] FIG. 8 is a conceptual diagram in which a part of the winding portion shown in FIG. 3 is highlighted. [Figure 9] FIG. 9 is a conceptual diagram showing a wound state of a first wire and a second wire included in a coil device according to a reference example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] Hereinafter, the present invention will be described based on the embodiments shown in the drawings. Fig. 1 is a perspective view of a coil device 10 according to an embodiment of the present invention, seen from diagonally above. The coil device 10 according to an embodiment of the present invention shown in Figs. 1 to 8 is used, for example, as a choke coil, a noise filter, etc., and is particularly preferably an inductor device for use in a vehicle, in which two coil elements are arranged within the same coil device 10.

[0032] As shown in Fig. 1, the coil device 10 has a core 20, an exterior resin 15, and a winding portion 30 (see Fig. 3) covered with the exterior resin 15. Also, Fig. 2 is a perspective view of the coil device 10 seen obliquely from below. As shown in Fig. 2, the coil device 10 has a first electrode portion 61, a second electrode portion 62, a third electrode portion 63, and a fourth electrode portion 64.

[0033] 3, which is a cross-sectional view of the coil device 10, the core 20 is a drum core 20 having a winding core portion 22, a first flange portion 24, and a second flange portion 26. The winding core portion 22 has a first wire 30a and a second wire 30b wound in multiple layers. The cross section (cross section on the XY axis plane) of the winding core portion 22 is not particularly limited and may be a square cross section, a rectangular cross section, a circular cross section, or any other cross-sectional shape, but in this embodiment, it is substantially circular (not shown).

[0034] As shown in FIG. 3, the winding core 22 has a central outer peripheral surface 22c that is located at the center with respect to the winding axis direction of the winding core 22 and extends along the winding axis direction (Z-axis direction), and an end curved surface 22d that extends from the central outer peripheral surface 22c to a winding core first end 22a, which is one end of the winding core 22 in the winding axis direction, and from the central outer peripheral surface 22c to a winding core second end 22b, which is the other end of the winding core 22 in the winding axis direction. In a cross section passing through the winding axis as shown in FIG. 3, the central outer peripheral surface 22c extends linearly, whereas the end curved surface 22d is curved. The end curved surface 22d has a curvature smaller than the curvature of a cross section perpendicular to the wire extension direction of the first wire 30a and the second wire 30b. By having the end curved surface 22d have a curvature smaller than the curvature of the wire cross section shown in FIG. 3, it is possible to reduce the gap formed between the first wire 30a and the second wire 30b and the winding core 22.

[0035] The first flange 24 is connected to a core first end 22a, which is one end in the winding axis direction of the core portion 22 (the end in the negative direction of the Z axis). The second flange 26 is connected to a core second end 22b, which is the other end in the winding axis direction of the core portion 22 (the end in the positive direction of the Z axis). Note that exterior resin 15 and electrode portions 61-64 are not shown in Figs. 3-9.

[0036] From the viewpoint of mountability of the coil device 10, it is preferable that the core 20 of the coil device 10 has the first flange portion 24 and the second flange portion 26 shown in Fig. 1 to Fig. 3. However, the core 20 may have another shape having a winding core portion 22. Note that the X-axis, Y-axis, and Z-axis used in the description of the coil device 10 are mutually perpendicular, and the Z-axis coincides with the winding axis direction.

[0037] The exterior resin 15 shown in Fig. 1 and Fig. 2 covers the winding section 30 shown in Fig. 3. By covering the winding section 30 with the exterior resin 15, the first wire 30a and the second wire 30b of the winding section 30 can be effectively protected, and short circuit defects can also be suppressed. In addition, the exterior resin 15 is preferably made of a resin containing a magnetic material. By configuring it in this way, the exterior resin 15 containing a magnetic material becomes a path for the magnetic field, improving the magnetic characteristics of the coil device 10. The magnetic material contained in the exterior resin 15 is not particularly limited, but examples thereof include magnetic powder similar to the magnetic powder constituting the core 20, or other magnetic powder.

[0038] 2, a first electrode portion 61, a second electrode portion 62, a third electrode portion 63, and a fourth electrode portion 64, which are insulated from one another, are provided on the underside of the first flange portion 24. Both ends of the first wire 30a are connected to the first electrode portion 61 and the third electrode portion 63, and both ends of the second wire 30b are connected to the second electrode portion 62 and the fourth electrode portion 64.

[0039] The first electrode portion 61 and the third electrode portion 63 to which the first wire 30a is connected are disposed on one diagonal line 24a of the first flange portion 24, and the second electrode portion 62 and the fourth electrode portion 64 to which the second wire 30b is connected are disposed on the other diagonal line 24b of the first flange portion 24. In such a coil device 10, one end of the first wire 30a and the second wire 30b are both connected to electrode portions at positions rotated 180 degrees with respect to the other end, and therefore the coil device 10 can be efficiently manufactured by an automatic winding machine.

[0040] The first to fourth electrode portions 61 to 64 are formed using conductive metal plates, and examples of the material include, but are not limited to, tough pitch steel, phosphor bronze, brass, iron, nickel, etc. For example, the first to fourth electrode portions 61 to 64 may be made of a material other than conductive metal plates, such as a plating layer of silver or tin, a paste layer, or a thin film.

[0041] Both ends of the first wire 30a and the second wire 30b are connected to the first to fourth electrode portions 61 to 64 by laser welding. However, the method of connecting the first wire 30a and the second wire 30b to the first to fourth electrode portions 61 to 64 is not limited to laser welding, and they may be connected by other methods such as thermocompression bonding, fusing, and soldering.

[0042] The first wire 30a and the second wire 30b forming the winding portion 30 shown in FIG. 3 are not particularly limited, and may be, for example, a conductive core wire such as a rectangular wire, a round wire, a twisted wire, a Litz wire, or a braided wire made of copper or the like, or a wire having such a conductive core wire coated with an insulating coating. Specifically, known winding wires such as AIW (polyimide wire), UEW (polyurethane wire), UEW, and USTC may be used. The wire diameters of the first wire 30a and the second wire 30b are not particularly limited, and may be, for example, 0.1 to 0.5 mm. The wire diameters and materials of the two wires 30a and 30b may be the same or different.

[0043] FIG. 3 is a conceptual diagram showing the winding state of the first wire 30a and the second wire 30b in the winding section 30, and shows a cross section of the core 20 and the winding section 30. The open circles in the winding section 30 represent the first wire 30a, and the shaded circles in the winding section 30 represent the second wire 30b. The numbers in the circles indicate which turn each part of the first wire 30a and the second wire 30b is. For example, the number "1" is written on the first turn at the beginning of the winding of the first wire 30a and the second wire 30b (the first turn 38a of the first wire 30a and the first turn 38b of the second wire 30b), and the number "22" is written on the 22nd turn at the end of the winding of the first wire 30a and the second wire 30b (the 22nd turn 36a of the first wire 30a and the 22nd turn 36b of the second wire 30b).

[0044] 3 is formed by simultaneously winding a first wire 30a and a second wire 30b around the winding core 22, as will be described later in the method of forming the winding portion 30 in the coil device 10. The first wire 30a and the second wire 30b are magnetically combined inside the coil device 10.

[0045] 3, the winding section 30 is formed by winding the first wire 30a and the second wire 30b in six layers around the winding core section 22, and the number of turns of each of the first wire 30a and the second wire 30b is 22. The number of layers and the number of turns of the winding section 30 of the coil device 10 are not limited as long as the first wire 30a and the second wire 30b are wound in multiple layers. In addition, the number of turns of the first wire 30a and the second wire 30b is preferably the same, but may be different.

[0046] The wound portion 30 shown in Fig. 3 has a first portion 31 shown in Fig. 4, a second portion 32 shown in Fig. 5, a third portion 33 shown in Fig. 6, and a fourth portion 34 shown in Fig. 7. Fig. 4 shows the first portion 31 in the wound portion 30 shown in Fig. 3 in a darker color (highlighted), and shows the other portions 32 to 34 in the wound portion 30 in a lighter color.

[0047] As shown in Fig. 4, the first portion 31 includes the first wire 30a and the second wire 30b of the same turn wound side by side in the same layer. As shown in Fig. 4, the first turn to the seventh turn, the ninth turn to the eleventh turn, the fourteenth turn, the eighteenth turn to the twentieth turn, and the twenty-second turn constitute the first portion 31. Examples of the first portion 31 include the first turn 38a of the first wire 30a and the first turn 38b of the second wire 30b, and the twenty-second turn 36a of the first wire 30a and the twenty-second turn 36b of the second wire 30b shown in Fig. 3.

[0048] The first portion 31 accounts for the largest proportion of the four portions included in the winding section 30, and the proportion of the first portion 31 is particularly high in the portion close to the winding core 22 and in the portion close to the center line 27 that passes through the center position of the winding axis direction of the winding core 22 and is perpendicular to the winding axis direction. In particular, the first layer 41, which is the innermost layer of the winding section 30 and contacts the winding core 22, is made only of the first portion 31. Since the first layer 41, which is the innermost layer, is not affected by the unevenness of the inner layers when winding, it is preferable to configure it only with the first portion 31 and the fourth portion 34 (see FIG. 7) from the viewpoint of increasing the occupancy rate of the wire, and it is even more preferable to configure it only with the first portion 31. However, the first layer 41, which is the innermost layer, may include a part of the second portion 32 (see FIG. 5), etc.

[0049] 5 shows the second portion 32 of the winding portion 30 shown in FIG. 3 in a darker color (highlighted), and shows other portions 31, 33, 34 of the winding portion 30 in a lighter color. As shown in FIG. 5, in the second portion 32, the first wire 30a and the second wire 30b of the same turn are wound in different layers without being adjacent to each other.

[0050] 5, the 12th turn, the 15th turn, and the 16th turn constitute the second portion 32. Examples of the second portion 32 include the 12th turn 32a of the first wire 30a and the 12th turn 32b of the second wire 30b, as well as the 16th turn 32c of the first wire 30a and the 16th turn 32d of the second wire 30b, as shown in FIG.

[0051] For example, the 16th turn 32c of the first wire 30a is located in the third layer 43, and the 16th turn 32d of the second wire 30b is located in the fourth layer 44, so that the two are wound in different layers. Also, as shown in Fig. 3 or 5, the 15th and 17th turns of the first wire 30a are sandwiched between the 16th turn 32c of the first wire 30a and the 16th turn 32d of the second wire 30b, so that the two are not adjacent to each other and are not in contact with each other.

[0052] Furthermore, in the second portion 32, of the first wire 30a and the second wire 30b of the same turn, one of the wires wound in the outer layer is located closer to the center in the winding axis direction of the winding core 22 than the other of the first wire 30a and the second wire 30b of the same turn, which is wound in an inner layer closer to the winding core 22 than the outer layer. For example, in the second portion 32, the 12th turn 32a of the first wire 30a wound in the fourth layer 44, which is the outer layer, is located closer to the center line 27 in the winding axis direction of the winding core 22 than the 12th turn 32b of the second wire 30b wound in the third layer 43, which is the inner layer.

[0053] In the second portion 32, one wire wound in the inner layer is located farther from the center line 27 in the winding axis direction than the other wire wound in the outer layer, which makes it possible to suitably prevent the problem of gaps being formed near the first flange 24 and the second flange 26 where no wire is located. The 15th and 16th turns 32c, 32d of the second portion 32 also satisfy this relationship. However, it is not necessary for all parts included in the second portion 32 to satisfy this relationship, and only a part of the second portion 32 may satisfy this relationship.

[0054] 5, one of the first wire 30a and the second wire 30b of the same turn that is wound in the outer layer may be spaced apart from the first flange 24 and the second flange 26, and the other of the first wire 30a and the second wire 30b of the same turn that is wound in the inner layer that is closer to the winding core than the outer layer may be in contact with the first flange 24 or the second flange 26. For example, in the second portion 32, the 12th turn 32a of the first wire 30a wound in the fourth layer 44 that is the outer layer is spaced apart from the first flange 24 and the second flange 26, and the 12th turn 32b of the second wire 30b wound in the third layer 43 that is the inner layer is in contact with the second flange 26. As a result, the gap between the second flange 26 and the wires 30a, 30b is filled by the 12th turn 12b of the second wire 30b, and further the gap between the 12th turn 32a of the first wire 30a and the 12th turn 32b of the second wire 30b is filled by other wires such as the 9th turn and 13th turn of the second wire 30b, thereby effectively preventing the problem of gaps forming near the second flange 26.

[0055] 6 shows the third portion 33 in the winding portion 30 shown in FIG. 3 in a darker color (highlighted), and shows the other portions 31, 32, 34 in the winding portion 30 in a lighter color. As shown in FIG. 6, in the third portion 33, the first wire 30a and the second wire 30b of the same turn are wound in the same layer without being adjacent to each other.

[0056] 6, the 8th turn, the 13th turn, and the 21st turn constitute the third portion 33. Examples of the third portion 33 include the 13th turn 33a of the first wire 30a and the 13th turn 33b of the second wire 30b shown in FIG.

[0057] For example, the 13th turn 33a of the first wire 30a is located in the fourth layer 44, and the 13th turn 33b of the second wire 30b is located in the fourth layer 44, so that both are wound in the same layer. In addition, the 12th turn and the 20th turn of the first wire 30a and the 20th turn of the second wire 30b are sandwiched between the 13th turn 33a of the first wire 30a and the 13th turn 33b of the second wire 30b, so that they are not adjacent to each other and do not contact each other.

[0058] 7 shows the fourth portion 34 of the winding portion 30 shown in Fig. 3 in a darker color (highlighted), and shows the other portions 31-33 of the winding portion 30 in a lighter color. As shown in Fig. 7, in the fourth portion 34, the first wire 30a and the second wire 30b of the same turn are wound adjacent to each other in different layers.

[0059] 7, the fourth portion 34 includes the 17th turn 34a of the first wire 30a and the 17th turn 34b of the second wire 30b. The 17th turn 34a of the first wire 30a is located in the fourth layer 44, and the 17th turn 34b of the second wire 30b is located in the fifth layer 45, so that the two are wound in different layers. In addition, the 17th turn 34a of the first wire 30a and the 17th turn 34b of the second wire 30b are adjacent to each other and in contact with each other.

[0060] 9 is a cross-sectional view showing a wound state of a coil device 110 according to a reference example. The coil device 110 has a winding portion 130 formed by simultaneously winding a first wire 130a and a second wire 130b around the same core 20 as the coil device 10.

[0061] In the winding section 130 shown in FIG. 9, the first wire 130a and the second wire 130b are wound in a state where the same turns are always in contact with each other, and the winding section 130 has only two parts: a first part where the first wire 130a and the second wire 130b of the same turn are wound adjacent to each other in the same layer, and a fourth part where the first wire 130a and the second wire 130b of the same turn are wound adjacent to each other in different layers. Such a winding section 130 has a problem that a relatively large gap (void) 190 where the first wire 130a and the second wire 130b are not arranged is formed, for example, in a part between the second layer and the second flange 26. In addition, the winding section 130 tends to have many gaps 192 around the 17th and 18th turns close to the first flange 24.

[0062] In contrast, the winding portion 30 shown in FIG. 3 has the third portion 33 shown in FIG. 6 and the second portion 32 shown in FIG. 5, thereby reducing the gaps between the first wire 30a and the second wire 30b and between the wires 30a, 30b and the core 20, thereby improving the occupancy rate of the wires.

[0063] In other words, by forming the second portion 32 and the third portion 33 in which the first wire 30a and the second wire 30b of the same turn do not come into contact, the winding portion 30 shown in FIG. 3 can reduce the gap that would occur if the winding portion 130 were formed with the first wire 130a and the second wire 130b always in contact as shown in FIG. 9, thereby improving the occupancy rate of the wire.

[0064] 5, the second portion 32 of the winding section 30 has a structure in which only one of the wires in the same turn drops inward (toward the inner layer) at both ends in the winding axis direction of a predetermined layer (third layer 43), such as the 12th turn 32b of the second wire 30b and the 16th turn 32c of the first wire 30a. The coil device 10 having such a structure can prevent the problem of the first wire 30a and the second wire 30b being pressed against the first flange 24 or the second flange 26 during winding and being damaged, while also preventing the problem of gaps being formed between the flanges 24, 26 and the wires 30a, 30b.

[0065] This is because, in the coil device 10, when the winding portion 30 is formed, only one of the first wire 30a and the second wire 30b naturally follows the unevenness of the underlying wire and enters into the gap between the flanges 24, 26 and the other wire 30a, 30b. Therefore, when the winding portion 30 in the coil device 10 is formed, the force pulling the wires 30a, 30b in the winding axis direction can be reduced, and the wires 30a, 30b can be prevented from contacting the first flange 24 or the second flange 26 or rubbing against the first flange 24 or the second flange 26, which would damage the wires 30a, 30b.

[0066] Below, the structure of the coil device 10 will be explained in more detail, while giving an example of a manufacturing method for the coil device 10 and a method for forming the winding portion 30. However, the manufacturing method for the coil device 10 and the method for forming the winding portion 30 are not limited to the examples shown below.

[0067] In the first stage of forming the winding section 30 in the coil device 10 shown in Fig. 1, the core 20 to which the first to fourth electrode units 61 to 64 are attached is first set in an automatic winding machine. The core 20 is manufactured by molding, for example, compression molding, CIM (ceramic injection molding) molding, MIM (metal injection molding) molding, or the like, and sintering as necessary. The first to fourth electrode units 61 to 64 are fixed to the core 20, for example, by adhesion. However, the method of forming the core 20 and the method of fixing the first to fourth electrode units 61 to 64 are not limited to these.

[0068] Next, a nozzle for guiding the first wire 30a and the second wire 30b shown in FIG. 3 is operated to the core 20 set in the automatic winding machine, and the first wire 30a and the second wire 30b are brought into contact with the winding start position on the winding core portion 22 (the position of the first turn 38a of the first wire 30a and the first turn 38b of the second wire 30b).

[0069] Next, while the nozzle pulls the first wire 30a and the second wire 30b, the automatic winding machine rotates the core 20, thereby winding the first wire 30a and the second wire 30b in order from the 1st turn to the 22nd turn shown in Fig. 3 to form the wound portion 30. As shown in Fig. 4, the 1st to 11th turns are included in the first portion 31 except for the 8th turn (third portion 33 see Fig. 6).

[0070] In this case, unlike the winding section 130 shown in Fig. 9, the winding section 30 shown in Fig. 3 is not formed in order from the inner first layer 41 to the outer sixth layer 46, but a part of the outer layer is formed before the inner layer. Fig. 8 is a conceptual diagram in which a part of the winding section 30 shown in Fig. 3 is highlighted.

[0071] 8, the winding portion 30 has a tenth turn 37a which is the second turn of the first wire 30a wound behind the seventh turn 31b which is the first turn of the first wire 30a included in the first portion 31, and wound in the second layer 42 which is the second layer closer to the winding core portion 22 than the third layer 43 which is the first layer including the seventh turn 31b of the first wire 30a. The winding portion 30 also has a tenth turn 37b of the second wire 30b which is wound behind the seventh turn 31b of the second wire 30b which is the same turn as the seventh turn 31b of the first wire 30a, and wound in the second layer 42 which is the same turn as the tenth turn 37a of the first wire 30a.

[0072] 8, the seventh turn 31a, 31b which is the first turn of the first wire 30a and the second wire 30b is located closer to the center (closer to the center line 27) in the winding axis direction of the winding core 22 than the tenth turn 37a, 37b which is the second turn of the first wire 30a and the second wire 30b. The relationship between the seventh turn 31a, 31b of the first wire 30a and the second wire 30b and the eighth turn of the first wire 30a and the second wire 30b is similar.

[0073] 8, when forming the winding portion 30, the center side in the winding axis direction of the winding core portion 22 is first formed into a pyramid shape, and then both end sides in the winding axis direction of the winding core portion 22 are formed. As a result, the wires 30a, 30b constituting the turns (the 10th turn and the 8th turn) formed later on the both end sides are guided to enter the gaps between the turns already formed into pyramid shapes and the flange portions 24, 26. For this reason, in this coil device 10, the gaps between the flange portions 24, 26 and the wires 30a, 30b can be made small.

[0074] Furthermore, second portions 32 are formed at both ends of the third layer 43 as shown in FIG. 4, which reduces the gaps between the flange portions 24, 26 and the wires 30a, 30b and the gaps between the wires 30a, 30b, thereby increasing the occupancy rate of the wires 30a, 30b (the 12th to 17th turns).

[0075] Also, as shown in FIG. 3, the 22nd turn 36a, which is the final turn of the first wire 30a in the winding section 30, and the 22nd turn 36b, which is the final turn of the second wire 30b, are both located at one end in the winding axis direction of the winding core section 22, and are positioned closer to the winding core second end 22b, which is the other end in the winding axis direction, than the winding core first end 22a, which is the side from which the ends of the first wire 30a and the second wire 30b away from the winding section 30 are pulled out.

[0076] As a result, the 22nd turns 36a, 36b which are the final turns of the first wire 30a and the second wire 30b are disposed away from the flange first end 22a which connects to the first flange 24 on which the electrode portions 61-64 and the like are disposed. This makes it possible to reduce the angle at which the first wire 30a and the second wire 30b drawn out toward the electrode portions 61-64 bend upon contact with the first flange 24, thereby preventing damage to the first wire 30a and the second wire 30b due to contact with the first flange 24.

[0077] 3 and 4, the 22nd turn 36a which is the final turn of the first wire 30a and the 22nd turn 36b which is the final turn of the second wire 30b are included in the first portion 31. Since the 22nd turn 36a of the first wire 30a and the 22nd turn 36b of the second wire 30b are in contact with each other, the 22nd turns 36a, 36b of both the first wire 30a and the second wire 30b can be largely separated from the first flange portion 24.

[0078] As shown in FIG. 3 , at least one of the 22-turn 36a, which is the third turn of the first wire 30a and which is the farthest from the winding core portion 22, and the 22-turn 36b, which is the third turn of the second wire 30b and which is the farthest from the winding core portion 22, intersects with a center line 27 that passes through the center position of the winding core portion 22 in the winding axis direction and is perpendicular to the winding axis direction.

[0079] In such a coil device 10, the part where the winding section 30 has the most multiple layers is formed in the central part in the winding axis direction, i.e., in a position away from the first flange 24 and the second flange 26. Therefore, in such a coil device 10, the number of layers formed on the outer periphery of the winding core first end 22a and the winding core second end 22b close to the first flange 24 and the second flange 26 is suppressed, and the gaps between the wires 30a, 30b and between the wires 30a, 30b and the core 20 are reduced, thereby improving the occupancy rate of the wires 30a, 30b.

[0080] 3, the winding portion 30 is formed up to the 22nd turn 36a, 36b, and the nozzle draws out the ends of the first wire 30a and the second wire 30b to the first flange portion 24. Furthermore, both ends of the first wire 30a are fixed to the first electrode portion 61 and the third electrode portion 63, and both ends of the second wire 30b are fixed to the second electrode portion 62 and the fourth electrode portion 64. Note that one end of the first wire 30a and the second wire 30b may be fixed or temporarily fixed to the electrode portions 61 to 64 before the winding portion 30 is formed.

[0081] Finally, exterior resin 15 as shown in Figs. 1 and 2 is formed on the outer periphery of winding portion 30, and winding portion 30 is covered with exterior resin 15 to obtain coil device 10 shown in Figs. 1 to 8.

[0082] As shown in Figs. 3 to 8, the coil device 10 according to the present invention has not only a first portion 31 in which the first wire 30a and the second wire 30b of the same turn are wound adjacent to each other in the same layer, but also a second portion 32 in which the first wire 30a and the second wire 30b of the same turn are wound not adjacent to each other but in different layers. In such a coil device 10, it is possible to reduce the gaps where the wires 30a and 30b are not arranged, which tend to be formed particularly near both ends of the winding core portion 22. Therefore, such a coil device 10 can improve the occupancy rate of the winding and can improve the inductance. It is also advantageous in terms of miniaturization.

[0083] Although the coil device of the present invention has been described above with reference to the embodiments, it goes without saying that the technical scope of the present invention is not limited to the above-mentioned embodiments, and may include many other embodiments and modifications. For example, as shown in Fig. 3, in the coil device 10, the winding start position is on the first flange 24 side, but the present invention is not limited to this, and the winding may start from the second flange 26 side. [Explanation of symbols]

[0084] 10, 110...Coil device 15…Exterior resin 20…Core 22…Coil 22a...First end of winding core 22b...Wind core second end 22c...Central outer circumferential surface 22d...Curved end surface 24…First flange 24a, 24b…Diagonal 26…Second flange 27…Center line 30, 130…Winding section 30a, 130a...First wire 30b, 130b...Second wire 31…Part 1 31a, 31b...1st turn (1st turn) 37a, 37b...Turn 10 (2nd turn) 32…Second part 32a: 12th turn of the first wire 30a (one of the wires) 32b: 12th turn of the second wire 30b (the other wire) 32c: 16th turn of the first wire 30a (the other wire) 32d: 16th turn of the second wire 30b (one of the wires) 33...Third part 33a, 33b…13th turn 34…4th part 34a, 34b…17th turn 36a...the 22nd turn (the third turn) of the first wire 30a 36b…22nd turn (4th turn) of the second wire 30b 41...First layer (inner layer) 42…Second layer 43...Third layer 44…4th layer 45…5th layer 46…6th layer 61...First electrode part 62…Second electrode part 63…Third electrode part 64…Fourth electrode part 190, 192…Gap

Claims

1. A coil device including a core having a winding core portion, and a winding portion in which a first wire and a second wire are wound in multiple layers around the winding core portion, The winding portion is a first portion in which the first wire and the second wire of the same turn are wound adjacent to each other in the same layer; a second portion in which the first wire and the second wire of the same turn are wound in different layers but not adjacent to each other; A coil device in which an innermost layer of the winding portion that contacts the winding core portion is composed of only the first portion.

2. A coil device including a core having a winding core portion, and a winding portion in which a first wire and a second wire are wound in multiple layers around the winding core portion, The winding portion is a first portion in which the first wire and the second wire of the same turn are wound adjacent to each other in the same layer; a second portion in which the first wire and the second wire of the same turn are wound in different layers but not adjacent to each other; The winding portion has a third portion in which the first wire and the second wire of the same turn are wound in the same layer but not adjacent to each other.

3. A coil device including a core having a winding core portion, and a winding portion in which a first wire and a second wire are wound in multiple layers around the winding core portion, The winding portion is a first portion in which the first wire and the second wire of the same turn are wound adjacent to each other in the same layer; a second portion in which the first wire and the second wire of the same turn are wound in different layers but not adjacent to each other; the winding portion has a second turn of the first wire wound in a second layer that is wound after a first turn of the first wire included in the first portion and is closer to the winding core portion than a first layer that includes the first turn of the first wire, The winding portion is wound after a first turn of the second wire, which is the same turn as the first turn of the first wire, and has a second turn of the second wire, which is the same turn as the second turn of the first wire and is wound in the second layer.

4. The coil device according to claim 3 , wherein the first turn of the first wire and the second wire is located closer to the center in the winding axis direction of the winding core than the second turn of the first wire and the second wire.

5. A coil device including a core having a winding core portion, and a winding portion in which a first wire and a second wire are wound in multiple layers around the winding core portion, The winding portion is a first portion in which the first wire and the second wire of the same turn are wound adjacent to each other in the same layer; a second portion in which the first wire and the second wire of the same turn are wound in different layers but not adjacent to each other; At least one of a third turn of the first wire, which is farthest from the winding core portion, and a fourth turn of the second wire, which is farthest from the winding core portion, intersects with a line that passes through a center position of the winding axis direction of the winding core portion and is perpendicular to the winding axis direction.

6. A coil device including a core having a winding core portion, and a winding portion in which a first wire and a second wire are wound in multiple layers around the winding core portion, The winding portion is a first portion in which the first wire and the second wire of the same turn are wound adjacent to each other in the same layer; a second portion in which the first wire and the second wire of the same turn are wound in different layers but not adjacent to each other; the winding core portion has a central outer peripheral surface that is located toward the center of the winding core portion in the winding axis direction and extends along the winding axis direction, and an end curved surface that extends from the central outer peripheral surface to a winding core first end that is one end of the winding core portion in the winding axis direction, and from the central outer peripheral surface to a winding core second end that is the other end of the winding core portion in the winding axis direction, A coil device, wherein the end curved surface has a curvature smaller than the curvature of a cross section of the first wire and the second wire perpendicular to the wire extension direction.

7. The coil device according to claim 1 , wherein the winding portion has a fourth portion in which the first wire and the second wire of the same turn are wound adjacent to each other in different layers.

8. 8. A coil device according to claim 1, wherein in the second portion, one of the first wire and the second wire of the same turn that is wound in an outer layer is located closer to the center in the winding axis direction of the winding core than the other of the first wire and the second wire of the same turn that is wound in an inner layer closer to the winding core than the outer layer.

9. A coil device described in any of claims 1 to 8, wherein the final turn of the first wire and the final turn of the second wire in the winding section are both at one end of the winding core section in the winding axis direction, and are positioned closer to the winding core second end, which is the other end in the winding axis direction, than to the winding core first end, which is the side from which the ends of the first wire and the second wire away from the winding section are pulled out.

10. The coil apparatus of claim 9 , wherein the final turn of the first wire and the final turn of the second wire are included in the first portion.

11. 11. The coil device according to claim 1, wherein the core has a first flange portion connected to a winding core first end portion, which is one end portion of the winding core portion in the winding axis direction, and a second flange portion connected to a winding core second end portion, which is the other end portion of the winding core portion in the winding axis direction.

12. The coil device described in claim 11, wherein in the second portion, one of the first wire and the second wire of the same turn that is wound in an outer layer is spaced apart from the first flange portion and the second flange portion, and the other of the first wire and the second wire of the same turn that is wound in an inner layer closer to the winding core portion than the outer layer is in contact with the first flange portion or the second flange portion.

13. the first flange portion is provided with a first electrode portion, a second electrode portion, a third electrode portion, and a fourth electrode portion which are insulated from one another; the first electrode portion and the third electrode portion to which the first wire is connected are disposed on one diagonal line of the first flange portion, The coil device according to claim 11 or 12, wherein the second electrode portion and the fourth electrode portion to which the second wire is connected are disposed on another diagonal line of the first flange portion.

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