Coil bobbins and coil components

Abstract

A coil bobbin (10) comprises: a winding (120); a first bobbin (111); and a second bobbin (112). The first bobbin (111) and the second bobbin (112) are arranged side by side such that the axial directions are aligned with each other. The winding (120) is wound on the first bobbin (111) and the second bobbin (112) in a continuous manner, and is passed from the first bobbin (111) through an internal space (130), which is held between the first bobbin (111) and the second bobbin (112) arranged side by side, to the second bobbin (112). In addition, the winding (120) has a slacking part (121) in the internal space (130).

Description

[Technical Field]

[0001] The present invention relates to a coil bobbin having a plurality of bobbins around which a winding is wound continuously, a coil component including such a coil bobbin, and a method for manufacturing such a coil bobbin. [Background technology]

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

[0003] Regarding this type of technology, Patent Document 1 below discloses an inductor component in which a single winding (9, 10) is wound continuously around two coil bobbins (21, 22) arranged side by side with their axial directions aligned with each other. As shown in Figure 1(b) of Patent Document 1, the windings (9, 10) are wound from the bottom to the top of one (e.g., the left) coil bobbin (21), passed from the left coil bobbin (21) to the right coil bobbin (22), and wound from the top to the bottom of the right coil bobbin (22). More specifically, the windings (9, 10) wound from the bottom to the top of the left coil bobbin (21) are routed over the flange (24) on the top side of the left coil bobbin (21). The windings (9, 10) run along the outer periphery of the inductor component, passing over the flange (24), passed from the left coil bobbin (21) to the right coil bobbin (22), and wound from the top to the bottom of the right coil bobbin (22). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2000-182844 Summary of the Invention [Problem to be solved by the invention]

[0005] A winding device is generally used to wind the wire onto the bobbin. Specifically, the wire is wound around the bobbin by rotating a wire supply unit, such as a nozzle for unwinding the wire, or the bobbin, which serves as the winding core. Simultaneously with the winding of the wire, the wire supply unit or the bobbin is moved in the axial direction of the bobbin to wind the wire in parallel on the bobbin. When winding a continuous wire around two coil bobbins (21, 22) arranged side by side with their axial directions aligned, as in Patent Document 1, when winding a wire around one of the coil bobbins, interference can occur between the other coil bobbin adjacent to the coil bobbin and a part of the winding device, such as a wire supply unit. For example, if winding is attempted while rotating one coil bobbin with the position of the wire supply unit of the winding device fixed, the other coil bobbins located radially adjacent to the first coil bobbin will rotate around the axis of the first coil bobbin as the first coil bobbin rotates, interfering with the wire supply unit of the winding device. Furthermore, even when winding a wire around one coil bobbin by moving the wire supply unit around the axis of the first coil bobbin while fixing the position of the coil bobbin, the wire supply unit, which moves circumferentially around the first coil bobbin, will interfere with the other coil bobbins located nearby. To prevent interference between the wire supply unit and the coil bobbin, it is necessary to provide a gap between the two coil bobbins so that the wire supply unit can pass between them when winding the winding. However, providing a gap between the coil bobbins increases the overall size of the coil component. To reduce the size of the coil component without providing a gap between the coil bobbins, it is necessary to wind the winding using a special winding method while avoiding interference between the wire supply unit and the coil bobbin, which reduces the efficiency of the winding process.

[0006] The present invention has been made in consideration of the above-mentioned problems, and provides a method for manufacturing a coil bobbin that reduces interference between a winding device and a coil bobbin during the winding process and that enables a highly efficient winding process, as well as a coil bobbin that enables such manufacturing. [Means for solving the problem]

[0007] According to the present invention, a winding includes a first bobbin and a second bobbin arranged side by side so that their axial directions are aligned with each other, the first bobbin and the second bobbin each have a winding shaft portion around which the winding is wound, and a flange portion at least at one end thereof that protrudes from the winding shaft portion in a direction intersecting the axial direction and extends in a circumferential direction of the winding shaft portion, The winding is wound continuously around the first bobbin and the second bobbin, and passes through an inner space sandwiched between the first bobbin and the second bobbin arranged side by side. At the one end The bobbin is connected from the first bobbin to the second bobbin, and has a slack portion in the inner space. The first bobbin and the second bobbin have concave-convex engaging portions that engage with each other when arranged side by side so that the axial direction is along each other, on the sides of the flange portion at the one end that abut each other, and the concave-convex engaging portions are a combination of at least a pair of engaging convex portions and engaging concave portions having concave shapes corresponding to the engaging convex portions, the engaging convex portions are provided so as to protrude radially from the side of the flange portion, and the engaging concave portions are formed so as to be recessed from the periphery of the side of the flange portion in the axial direction and penetrate the flange portion, and the shape of the engaging convex portions becomes monotonously narrower in width in the protruding direction of the engaging convex portions when viewed in the axial direction. A coil bobbin is provided.

[0008] a winding, and a first bobbin and a second bobbin arranged side by side so that their axial directions are aligned with each other. A coil component including a coil bobbin, and a core formed by combining a plurality of magnetic members, the core having magnetic legs inserted into the first bobbin and the second bobbin in the winding axis direction of the winding, wherein the first bobbin and the second bobbin each have a winding shaft portion on which the winding is wound, and a pair of magnetic members formed at one end and the other end of the first bobbin and the second bobbin, respectively, protruding from the winding shaft portion in a direction intersecting with the axial direction. extending in the circumferential direction of the winding shaft portion a flange portion; the winding is wound continuously around the first bobbin and the second bobbin, passes through an internal space between the first bobbin and the second bobbin arranged side by side, and is passed from the first bobbin to the second bobbin at the one end, and has a slack portion in the internal space; A flange portion at one end of each of the first bobbin and the second bobbin teeth At least one of the magnetic members is disposed across the flange of the first bobbin and the flange of the second bobbin, and the protrusion is disposed around the magnetic member. The protrusion provided on the flange of the first bobbin and the protrusion provided on the flange of the second bobbin are spaced apart from each other in a direction in which the first bobbin and the second bobbin are arranged side by side, and when viewed in the axial direction, the protrusion of the first bobbin and the protrusion of the second bobbin are formed at positions that are rotationally symmetrical to each other, and are spaced apart from each other in a direction perpendicular to the direction in which the first bobbin and the second bobbin are arranged side by side. The coil component is characterized in that

[0010] The coil bobbin of the above invention can be manufactured by winding the winding continuously around two bobbins arranged vertically so that they are aligned in a substantially straight line in the axial direction during the winding process, and then folding the two bobbins and arranging them horizontally so that their axial directions are aligned. When winding the winding around two bobbins arranged vertically, no other bobbins are present in the radial direction of the one bobbin around which the winding is wound, preventing interference between the winding device and the coil bobbins. [Effects of the Invention]

[0011] According to the coil bobbin, coil component, and coil bobbin manufacturing method of the present invention, interference between the winding device and the coil bobbin in the winding process can be reduced, and the efficiency of the winding process can be increased. [Brief explanation of the drawings]

[0012] The above-mentioned objects, as well as other objects, features and advantages, will become more apparent from the preferred embodiments described below and the accompanying drawings.

[0013] [Figure 1] 1 is a perspective view of a coil bobbin according to a first embodiment of the present invention (however, windings are not shown). [Figure 2] 2 is a perspective view of a coil bobbin according to the first embodiment (however, a second bobbin and a winding wound around the second bobbin are not shown). FIG. [Figure 3] FIG. 2 is a top view of the coil bobbin according to the first embodiment. [Figure 4] FIG. 2 is a front view of the coil bobbin according to the first embodiment. [Figure 5] 4 is a longitudinal cross-sectional view of the coil bobbin according to the first embodiment taken along the dashed line shown in FIG. 3, viewed in the direction of the arrow VV. [Figure 6] 6 is a cross-sectional view of the coil bobbin according to the first embodiment taken along the dashed line in FIG. 4, viewed in the direction of the arrows VI-VI. FIG. [Figure 7]FIG. 2 is a perspective view of a coil bobbin in an expanded state according to the first embodiment. [Figure 8] FIG. 2 is a side view of the coil bobbin in the deployed state according to the first embodiment, as viewed from the side on which the recess is formed. [Figure 9] FIG. 1 is a perspective view of a coil component according to a first embodiment. [Figure 10] 1 is a perspective view of a coil component according to a first embodiment (however, illustration of a terminal portion is omitted); [Figure 11] 1 is a longitudinal cross-sectional view of a coil component according to a first embodiment (however, windings and terminal portions are omitted from the illustration). DETAILED DESCRIPTION OF THE INVENTION

[0014] The various components of the coil bobbin and coil parts of the present invention do not need to be independent entities, and it is acceptable for multiple components to be formed as a single member, for one component to be formed from multiple members, for one component to be part of another component, or for part of one component to overlap with part of another component, etc. Furthermore, although the coil bobbin manufacturing method of the present invention may be described using a number of steps described in order, the order of the steps does not limit the order or timing of performing the steps. Therefore, when implementing the coil bobbin manufacturing method of the present invention, the order of the steps may be changed as long as it does not cause any problems in terms of the content, and some or all of the timing of performing the steps may overlap with each other.

[0015] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In the drawings, corresponding components are designated by common reference numerals, and duplicated descriptions will be omitted as appropriate. In this embodiment, the axial direction of the first bobbin and the second bobbin is referred to as the vertical direction, and the direction perpendicular to the vertical direction is sometimes referred to as the horizontal direction. Furthermore, when the first bobbin and the second bobbin are arranged side by side, the direction perpendicular to both the direction in which the first bobbin 111 and the second bobbin 112 are lined up and the vertical direction is sometimes referred to as the front-to-rear direction of the coil bobbin 10 and the bobbin 110. For example, the direction going back and forth between the rear and front sides of the paper in FIG. 5 and the up-to-down direction of the paper in FIG. 6 are the front-to-rear direction. Furthermore, in the folded state of the coil bobbin 10 and the bobbin 110, the side having the protruding region and the recessed portion is referred to as the "upper side," and the opposite side is referred to as the "lower side." For example, in FIGS. 5 and 11, the upper side of the paper is the "upper side," and the lower side of the paper is the "lower side."

[0016] First Embodiment (coil bobbin) FIG. 1 is a perspective view showing an example of a coil bobbin according to a first embodiment of the present invention.

[0017] First, an overview of the coil bobbin 10 of this embodiment will be described. The coil bobbin 10 has a winding 120, a first bobbin 111, and a second bobbin 112. The first bobbin 111 and the second bobbin 112 are arranged side by side with their axial directions aligned with each other. The winding 120 is wound continuously across the first bobbin 111 and the second bobbin 112, and is passed from the first bobbin 111 to the second bobbin 112 through an inner space 130 sandwiched between the first bobbin 111 and the second bobbin 112 arranged side by side. The winding 120 also has a slack portion 121 in the inner space 130.

[0018] Next, the coil bobbin 10 of this embodiment will be described in detail. Here, the coil bobbin 10 is a component that has one or more bobbins 110 and on which the winding 120 is wound. In this embodiment, a component with two bobbins 110 around which the winding 120 is wound may also be referred to as the coil bobbin 10. The bobbin 110 is a component that serves as a winding shaft around which the winding 120 is wound. The bobbin 110 is an elongated object that is long in the winding axis direction. In this embodiment, the coil bobbin 10 has a first bobbin 111 and a second bobbin 112 as the bobbins 110. The axial direction of the first bobbin 111, the second bobbin 112, and the winding shaft portion 113 described later is the extension direction of the first bobbin 111 or the second bobbin 112. In this embodiment, the bobbin 110 has a rectangular cross section, but it may also have a circular, square, or polygonal cross section. Furthermore, while the bobbin 110 in this embodiment is a straight-axis bobbin with a straight center line of the winding axis, the bobbin 110 may have a non-linear shape, such as an arc shape. For example, two bobbins may each have a semicircular shape, so that when the two bobbins 110 are arranged side by side, the two bobbins 110 together form a ring shape. The winding 120 is a wire wound around the first bobbin 111 and the second bobbin 112. The winding 120 is made of a metal conductor such as copper or aluminum. Here, the statement that the first bobbin 111 and the second bobbin 112 are arranged side by side with their axial directions aligned with each other means that the winding axis direction of one of the two bobbins (e.g., the first bobbin 111) has a winding axis direction component of the other bobbin (the second bobbin 112). Preferably, the winding axis direction of one of the first bobbin 111 and the second bobbin 112 has a winding axis direction component that is greater than a perpendicular component with respect to the winding axis direction of the other bobbin. More preferably, the first bobbin 111 and the second bobbin 112 are parallel or substantially parallel. The axial directions of the first bobbin 111 and the second bobbin 112 do not have to be completely parallel, but may intersect or be twisted. Hereinafter, the state in which the first bobbin 111 and the second bobbin 112 are arranged side by side with their axial directions aligned with each other, as shown in FIG. 1, may be referred to as a folded state. In addition, in the winding step of the coil bobbin manufacturing method described below, the first bobbin and the second bobbin are arranged in a substantially linear manner in the axial direction as shown in Figures 7 and 8, and this arrangement state may be referred to as an unfolded state.

[0019] 6, the inner space 130 is a space sandwiched between the first bobbin 111 and the second bobbin 112 when the first bobbin 111 and the second bobbin 112 are arranged side by side. In this embodiment, flanges 116 (upper flange 116 and lower flange 114) described below are formed on both ends of the first bobbin 111 and the second bobbin 112, and the upper flanges 116 and the lower flanges 114 abut against each other. The inner space 130 in this embodiment is a space sandwiched between the upper flange 116 and the lower flange 114, and also sandwiched between the winding shaft portions 113 of the first bobbin 111 and the second bobbin 112. As shown in Fig. 6, the inner space 130 has at least two opening surfaces 131 in the horizontal direction. The opening surfaces 131 are imaginary surfaces that connect the most protruding portion of the first bobbin 111 in one direction in the front-to-rear direction to the most protruding portion of the second bobbin 112 in the same direction when the two bobbins 110 are in the folded state. In this embodiment, as shown in Fig. 6, one opening surface 131 (131a) is an imaginary surface that connects the circumferential surface of the winding shaft portion 113 on the front side (lower side of the paper) of the first bobbin 111 to the circumferential surface of the winding shaft portion 113 on the front side of the second bobbin 112, and the other opening surface 131 (131b) is an imaginary surface that connects the circumferential surface of the winding shaft portion 113 on the rear side (upper side of the paper) of the first bobbin 111 to the circumferential surface of the winding shaft portion 113 on the rear side of the second bobbin 112. In this embodiment, the inner space 130 is defined by the opposing side surfaces of the first bobbin 111 and the second bobbin 112, the upper flange portion 116 and the lower flange portion 114 of the first bobbin 111 and the second bobbin 112, and the opening surface 131 (131a and 131b). When the bobbin 110 does not have the flange 116, the axial extent of the inner space 130 reaches both axial ends of the first bobbin 111 and the second bobbin 112. When the flange is provided not at the end of the bobbin 110 but at the middle of the axial direction and the winding is wound on both sides, the axial extent of the inner space 130 also reaches both axial ends of the first bobbin 111 and the second bobbin 112.

[0020] Here, winding 120 wound continuously across first bobbin 111 and second bobbin 112 means that one common winding 120 is wound around each of first bobbin 111 and second bobbin 112. Specifically, one end of winding 120 wound around first winding shaft portion 113a (winding shaft portion 113 of first bobbin 111) located at the upper end of first winding shaft portion 113a is connected to one end of winding 120 wound around second winding shaft portion 113b (winding shaft portion 113 of second bobbin 112) located at the upper end of second winding shaft portion 113b. Here, the winding 120 spanning between the first bobbin 111 and the second bobbin 112 when the first bobbin 111 and the second bobbin 112 are in a folded state is referred to as the boundary portion 123. Specifically, the boundary portion 123 is a length region of the winding 120 connecting a point on the upper end side of the winding 120 wound around the first winding shaft portion 113a where it separates from the first winding shaft portion 113a and a point on the upper end side of the winding 120 wound around the second winding shaft portion 113b where it touches the second winding shaft portion 113b. In this embodiment, the boundary portion 123 is a length region of the winding 120 from position X (see FIG. 6) where winding around the first bobbin 111 ends and the winding 120 separates from the first bobbin 111 to position Y (see FIG. 6) where the winding 120 touches the second bobbin 112 and winding around the second bobbin 112 begins. The boundary portion 123 includes a transition portion 122 (see FIG. 8) which will be described later. The winding 120 being passed from the first bobbin 111 to the second bobbin 112 through the internal space 130 means that at least a portion of the boundary 123 is present in the internal space 130. Specifically, as shown in Fig. 6 , one end of the boundary 123 present in the internal space 130 passes through one opening surface 131a of the internal space 130 and leads to the outside of the internal space 130, and the other end of the boundary 123 present in the internal space 130 passes through the other opening surface 131b of the internal space 130 and leads to the outside of the internal space 130. A portion of the boundary 123 may be present outside the internal space 130. A part of boundary 123 has a bent portion as shown in Fig. 2. In Fig. 6, a cross section of winding 120 is shown halfway along boundary 123, but this is because the bent portion protrudes outward from the cross section shown in Fig. 4. Here, the cross section of winding 120 is shown as a schematic circle, but in reality it may be elliptical.

[0021] In this embodiment, for example, the winding 120 is wound continuously around two bobbins 110 as follows: The winding 120 is wound around the first winding shaft portion 113a from the lower end to the upper end of the first bobbin 111 in the axial direction in a clockwise direction when the first bobbin 111 is viewed from above. The winding 120 then passes through the inner space 130 between the first bobbin 111 and the second bobbin (passing between the first bobbin 111 and the second bobbin 112 from the back side to the front side of the page in FIG. 4 ) and reaches the upper end of the second winding shaft portion 113b. The winding 120 is then wound around the second bobbin 112 from the upper end to the lower end of the second winding shaft portion 113b in a counterclockwise direction when the second bobbin 112 is viewed from above. The winding direction of the winding 120 is not limited to this. For example, the winding 120 may be wound around the first winding shaft portion 113a in a counterclockwise direction when the first bobbin 111 is viewed from above, and the winding 120 may be wound around the second winding shaft portion in a clockwise direction when the second bobbin 112 is viewed from above. When cores 140 (U core 142 and I core 143) described below are attached to the coil bobbin 10, the coil component 100 has a closed magnetic circuit structure. In the coil component 100, magnetic field lines generated in the coil pass through the cores to form a loop. By winding the winding 120 so that the winding directions of the winding 120 on the first winding shaft portion 113a and the second winding shaft portion 113b are opposite to each other when viewed from the same side (e.g., the top side) of the coil bobbin 10, the coil component 100 is configured in which the winding 120 is wound in the same direction as the magnetic field lines.

[0022] Here, slack portion 121 refers to a partial length region of winding 120 at or near boundary 123, which is looser than other length regions of winding 120 wound at or near the middle of winding shaft 113. Specifically, slack portion 121 refers to a length region of winding 120 at or near boundary 123 that corresponds to any of the following: a portion of winding 120 that is subjected to lower tension than winding 120 wound at the lower end of winding shaft 113, boundary 123 where winding 120 is not linear, or a portion where the winding diameter is larger than winding 120 wound at the lower end of winding shaft 113. Here, winding 120 wound at the lower end of winding shaft 113 refers to, for example, winding 120 wound at or near the middle of first winding shaft 113a or second winding shaft 113b. 2, in this embodiment, boundary portion 123 is not linear but has a bent portion. Specifically, boundary portion 123 has an excess length corresponding to the length of transition portion 122, which will be described later, and the excess length of winding 120 is folded halfway through boundary portion 123. In this embodiment, boundary portion 123 becomes slack portion 121. In this embodiment, only the boundary 123 between the first bobbin 111 and the second bobbin 112 is the slack portion 121, but this is not limiting. For example, the winding 120 wound around the first bobbin 111 or the second bobbin 112 may also become the slack portion 121. For example, if the boundary 123 has an excess length, the winding 120 may become loose in the radial direction at the upper end of the first winding shaft portion 113a or the second winding shaft portion 113b. Hereinafter, the radial direction refers to the direction extending radially from the axial center of the bobbin 110 toward the periphery. Hereinafter, the above-mentioned direction will also be referred to as the radial direction when the cross section of the winding shaft portion 113 or the flange portion 116 is polygonal rather than circular. When the winding 120 wound around the upper end of the winding shaft 113 due to loosening is wound with lower tension than the winding 120 wound around the middle part of the winding shaft 113, a partial length region of the winding 120 is also included as the slack portion 121. In this case, the winding 120 wound around the winding shaft 113 to become the slack portion 121 may or may not be in contact with the winding shaft 113. Furthermore, when the winding diameter of the winding 120 wound around the upper end of the winding shaft 113 due to loosening is larger than the winding diameter of the winding 120 wound around the middle part of the winding shaft 113, the winding 120 wound around the winding shaft 113 with a larger winding diameter than the middle part of the winding shaft 113 is also included as the slack portion 121.

[0023] In this embodiment, the slack portion 121 is twisted relative to the extending direction of the winding 120. Specifically, it is twisted by an angle that the first bobbin 111 and the second bobbin 112 rotate in a folding process described below. For example, when the first bobbin 111 and the second bobbin 112 in the unfolded state are folded 180 degrees in the folding process so that the first bobbin 111 and the second bobbin 112 are arranged side by side, a 180-degree twist occurs in the slack portion 121. When the first bobbin 111 and the second bobbin 112 are folded from their unfolded state, the transition portion 122 (described later) is also folded. As shown in FIG. 2 , in this embodiment, the transition portion 122 (see FIG. 8 ) remains folded even in the folded state. This is because the direction of rotation of the winding 120 when the slack portion 121 tries to untwist is opposite to the direction of rotation of the folded transition portion 122 when it tries to straighten itself, preventing the folded transition portion 122 from straightening. The twisted state of the slack portion 121 makes it easier to maintain the transition portion 122 (described later) in its folded state. This prevents the winding 120 wound around the winding shaft 113 from loosening due to the excess length of the winding 120 corresponding to the transition portion 122.

[0024] The twist in winding 120 may result in boundary portion 123 being approximately straight, the tension of winding 120 wound around the upper end of winding shaft 113 being equivalent to that of winding 120 wound around the middle portion of winding shaft 113, or the winding diameter of winding 120 not being larger than that of winding 120 wound around the middle portion of winding shaft 113. In this case, a partial length region of winding 120 having the twist is referred to as slack portion 121. Preferably, regardless of whether there is a twist, slack portion 121 is a portion of winding 120 on the upper end side of winding shaft portion 113 to which a lower tension is applied compared to winding 120 wound on the lower end side of winding shaft portion 113 as described above, boundary portion 123 where winding 120 is not linear, or a portion where the winding diameter is larger than that of winding 120 wound on the lower end side of winding shaft portion 113.

[0025] Since the winding 120 has a slack portion 121 and the portion spanning from the first bobbin 111 to the second bobbin 112 has excess length, it can be manufactured using a manufacturing method in which the first bobbin 111 and the second bobbin 112 are placed in an expanded state and the winding 120 is wound continuously, as described below. Furthermore, since the winding 120 passes through the inner space 130 and crosses between the first bobbin 111 and the second bobbin 112, it becomes possible to manufacture the coil spring using the manufacturing method described below, in which the winding 120 is wound continuously in the same direction from the first bobbin 111 to the second bobbin 112 in the unfolded state. By disposing a part of the slack portion 121 in the inner space 130 of the first bobbin 111 and the second bobbin 112, the slack portion 121 is prevented from being exposed to the outside of the coil bobbin 10. This makes it possible to prevent the slack portion 121 from being cut or worn, which would cause a decrease in the performance of the coil device 100 and an unexpected shortening of the insulation distance.

[0026] The first bobbin 111 and the second bobbin 112 have a winding shaft portion 113 around which the winding 120 is wound. The first bobbin 111 and the second bobbin 112 have a protruding region that extends in the circumferential direction of the winding shaft portion 113 at one end of the first bobbin 111 and the second bobbin 112. The winding shaft portion 113 is the portion of the first bobbin 111 or the second bobbin 112 around which the winding 120 is wound. If the first bobbin 111 and the second bobbin 112 have a protruding region such as a flange 116 described below, the winding shaft portion 113 is a region closer to the center in the axial direction than the protruding region such as the flange 116. If the first bobbin 111 and the second bobbin 112 have flanges 116 (upper flange 116 and lower flange 114) at both ends, the winding shaft portion 113 is a region sandwiched between the upper flange 116 and the lower flange 114. The protruding region is a region that has a protruding portion that protrudes from the winding shaft portion 113 in a direction intersecting the axial direction and extends around the winding shaft portion 113 in the circumferential direction, including the protruding portion. In this embodiment, the protruding region is formed at the tip of the first bobbin 111 and the second bobbin 112, but may also be provided midway along the axial length of the first bobbin 111 and the second bobbin 112. In this embodiment, as shown in FIG. 1 , the entire protruding region is a protruding portion, that is, the protruding region is a flange portion 116 described below, but this is not limiting. For example, only a portion of the protruding region may have a protruding portion, and the protruding region other than the protruding portion may be continuous with the circumferential surface of the winding shaft portion 113. Furthermore, the protruding region may have multiple protruding portions.

[0027] The protruding region (upper flange 116) has recess 115 formed in a concave shape extending from the outer periphery of the protruding region toward winding shaft 113. Recess 115 is provided on the protruding portion of the protruding region, and is the part of upper flange 116 that forms the concave shape. Winding 120 is passed through recess 115 in the winding process of winding 120, which will be described later. The radial height of the recess 115 relative to the circumferential surface of the winding shaft portion 113 may be lower than the height of the protrusion in the protruding region. The height may be higher than the height of the circumferential surface of the winding shaft portion 113, or may be the same height as the circumferential surface of the winding shaft portion 113. The first bobbin 111 and the second bobbin 112 are arranged so that at least a portion of each recess 115 is located inside the area sandwiched between the first bobbin 111 and the second bobbin 112. Here, "at least a portion of the recess 115 is located inside the area sandwiched between the first bobbin 111 and the second bobbin 112" means that at least a portion of the opening of the recess 115 is located inside the area sandwiched between the first bobbin 111 and the second bobbin 112. The opening of the recess 115 is the virtual periphery of the protruding portion when the recess 115 is not formed in the protruding portion. In this embodiment, the recess 115 of the first bobbin 111 and the recess 115 of the second bobbin 112 face each other. That is, the recess 115 of the first bobbin and the recess 115 of the second bobbin 112 are provided at the same height in the axial direction of the first bobbin 111 and the second bobbin 112, and face each other in the circumferential direction of the first bobbin 111 and the second bobbin 112, and the recesses 115 of the first bobbin 111 and the second bobbin 112 are connected to each other when viewed from the top surface of the coil bobbin 10. However, this is not limited thereto, and the recess 115 of the first bobbin 111 and the recess 115 of the second bobbin 112 do not have to face each other. That is, the recess 115 of the first bobbin 111 and the recess 115 of the second bobbin 112 may be provided offset from each other in the circumferential or axial direction of the first bobbin 111 and the second bobbin 112.

[0028] By providing the protruding regions and the recessed portions 115 in the protruding regions, a structure is obtained that allows for the winding step of the manufacturing method of the coil bobbin 10, which will be described later. That is, by passing the winding 120 through the recessed portions 115 of the first bobbin 111 and the second bobbin 112 in the winding step, it is possible to determine the position of the winding 120 (a transition portion 122, which will be described later) that spans from the first bobbin 111 to the second bobbin 112 in the unfolded state. This makes it possible to prevent the winding 120 from shifting sideways in the folding step in which the first bobbin 111 and the second bobbin 112 are folded so that they are arranged side by side, and allows for a structure that allows for the folding step in which the winding is folded with the transition portion 122 on the inside. The width (circumferential dimension) of recess 115 may be as narrow as the outer diameter of winding 120, or may be longer than the outer diameter of the winding. To prevent lateral shifting of winding 120 during the folding process, the width of recess 115 may be one-fourth or less of the circumferential length of the protruding region. Furthermore, to more effectively prevent lateral shifting of winding 120, the width of recess 115 may be two times or less the outer diameter of winding 120. To prevent lateral shifting of winding 120, the depth of recess 115 in the radial direction of winding shaft 113 may be equal to or greater than the diameter of the cross section of winding 120.

[0029] Furthermore, by providing the protruding region, winding 120 is locked by the protruding portion, and it is possible to prevent winding from loosening from the protruding region in the direction opposite to winding shaft portion 113. When multiple protruding portions are provided in the protruding region, it is also possible to effectively prevent winding 120 from loosening at multiple locations.

[0030] 7 and 8, when the first bobbin 111 and the second bobbin 112 are arranged linearly with their ends, where the protruding regions (upper flange portions 116) are provided, abutting against each other, the slack portion 121 has a length that allows the winding 120 to pass through the recessed portion 115 and span between the first bobbin 111 and the second bobbin 112. "The winding 120 passing through the recessed portion 115" means that the winding 120 is arranged so as to intersect with the direction in which the protruding regions extend, and that a portion of the winding 120 is surrounded by the recessed portion 115 on the surface where the protruding regions extend. More specifically, the length of slack portion 121 is equal to or greater than the total length of the height of the bottom of recess 115 of first bobbin 111 from the circumferential surface of winding shaft portion 113, the height of the bottom of recess 115 of second bobbin 112, and distance L1 (see FIG. 8) from recess 115 of first bobbin 111 to recess 115 of second bobbin 112 when first bobbin 111 and second bobbin 112 are arranged linearly with their ends having protruding regions abutting against each other. Here, the height of the bottom of recess 115 from the circumferential surface of winding shaft portion 113 refers to the height of the deepest part of recess 115 in the radial direction, with the circumferential surface of winding shaft portion 113 as the reference. Furthermore, when the first bobbin 111 and the second bobbin 112 are arranged in a straight line with their ends having protruding regions abutting against each other, the distance from the recess 115 of the first bobbin 111 to the recess 115 of the second bobbin 112 is the distance connecting one point on the winding shaft portion 113 side of each recess 115 of the first bobbin 111 and the second bobbin 112. In this embodiment, the height of the recess 115 is the same as the height of the peripheral surface of the winding shaft portion 113, so the height of the recess 115 from the peripheral surface of the winding shaft portion 113 in the first bobbin 111 and the height of the recess 115 in the second bobbin 112 are essentially zero. 7, when the first bobbin 111 and the second bobbin 112 are arranged vertically, their recesses 115 communicate with each other. In this case, the distance from the recess 115 of the first bobbin 111 to the recess 115 of the second bobbin 112 is the distance from the inner surface of the upper flange 116a of the first bobbin 111 (the surface of the flange 116 facing the winding shaft 113) to the inner surface of the upper flange 116b of the second bobbin 112. In other words, the distance from the recess 115 of the first bobbin 111 to the recess 115 of the second bobbin 112 includes the thicknesses of the upper flanges 116 (116a, 116b) of the first bobbin 111 and the second bobbin 112 and the length between the upper flange 116a of the first bobbin 111 and the upper flange 116b of the second bobbin 112.

[0031] In the winding process described below, the first bobbin 111 and the second bobbin 112 are in an unfolded state, and the winding 120 is wound, for example, around the first bobbin 111, then passes through the recess 115 of the first bobbin 111 and the recess 115 of the second bobbin 112, from the first bobbin 111 to the second bobbin 112, and is then wound around the second bobbin 112. When the first bobbin 111 and the second bobbin 112 transition to the folded state, the crossover portion 122, which is the winding 120 that was arranged between the recessed portion 115 of the first bobbin 111 and the recessed portion 115 of the second bobbin 112 in the unfolded state, becomes part of the slack portion 121. In other words, since the slack portion 121 has at least a length that enables it to pass through the recessed portion 115 in the unfolded state and cross over between the first bobbin 111 and the second bobbin 112, the coil bobbin 10 can be manufactured by a method for manufacturing the coil bobbin 10 that will be described later.

[0032] More specifically, in the unfolded state, the wire 120 wound around the first winding shaft portion 113a moves radially from the circumferential surface of the first winding shaft portion 113a onto the recessed portion 115, crosses from the recessed portion 115 of the first bobbin 111 to the recessed portion 115 of the second bobbin 112, descends from the recessed portion 115 of the second bobbin 112 onto the circumferential surface of the second winding shaft portion 113b, and is wound around the second winding shaft portion 113b. In this embodiment, because the height of the bottom of the recessed portion 115 is zero, the wire 120 wound around the first winding shaft portion 113a does not move radially onto the upper flange portion 116a, but passes from the recessed portion 115 of the first bobbin 111 to the recessed portion 115 of the second bobbin 112, and is then wound around the second winding shaft portion 113b. Slack portion 121 has a length equal to or greater than the sum of the height of the bottom of recess 115 from the circumferential surface of first winding shaft portion 113a, the height of the bottom of recess 115 from the circumferential surface of second winding shaft portion 113b, and the distance between recess 115 of first bobbin 111 and recess 115 of second bobbin 112. This allows winding 120 to move from the circumferential surface of first winding shaft portion 113a onto recess 115 of first bobbin 111, cross between recesses 115 of the first and second bobbins, and descend from recess 115 of second bobbin 112 onto the circumferential surface of second winding shaft portion 113b.

[0033] 4 and 5, the protruding region in this embodiment is a flange 116 that protrudes from the winding shaft portion 113 of the first bobbin 111 or the second bobbin 112 in a direction intersecting the axial direction. The flange 116 is a portion that protrudes from the circumferential surface of the winding shaft portion 113 over substantially the entire circumference of the protruding region. In this embodiment, the flange 116 is illustrated as protruding over the entire circumference excluding the recessed portions 115 of the protruding region, but this is not limiting. A portion of the flange 116 may not protrude and may be continuous with the circumferential surface of the winding shaft portion 113. In other words, the flange 116 may have one or more recessed portions 115. In this embodiment, the flange portion 116 projects perpendicular to the axial direction, but this is not limiting. The winding wire 120 is stretched from the first bobbin 111 to the second bobbin 112 on the winding shaft portion 113 side of the outer surface 116c of the upper flange 116. In this embodiment, the entire length of the boundary portion 123 is located on the winding shaft portion 113 side of the outer surface 116c of the upper flange 116a. That is, the winding wire 120 detaches from the first winding shaft portion 113a on the winding shaft portion 113 side of the outer surface 116c of the upper flange 116a, passes through an inner space 130 located on the winding shaft portion 113 side of the outer surface 116c of the upper flange 116, and comes into contact with the second winding shaft portion 113b on the winding shaft portion 113 side of the outer surface 116c of the upper flange 116b, thereby starting winding. Alternatively, a portion of the slack portion 121 may be located on the opposite side of the flange 116 from the winding shaft portion 113. For example, if the loose portion 121 is long, a part of the loose portion 121 may protrude above the upper flange portion 116 .

[0034] By providing upper flange 116 by protruding from approximately the entire circumference of the protruding region, it is possible to suitably lock winding 120 over approximately the entire circumference as it attempts to unwind axially outward from winding shaft 113. The radial height of flange 116 is high enough to lock winding 120. Specifically, it is preferable that the height of flange 116 be equal to or greater than the diameter of the cross section of winding 120. Furthermore, recess 115 in this embodiment is a notch formed by cutting out flange 116. Providing a notch in flange 116 allows slack 121 of winding 120 to be shorter than if flange 116 did not have a notch and the entire periphery of the protruding region protruded beyond the circumferential surface of winding shaft 113. For example, if flange 116 did not have a notch, winding 120 wound around the circumferential surface of first winding shaft 113a would ride up onto upper flange 116a of first bobbin 111, cross over to upper flange 116b of second bobbin 112, and then descend from upper flange 116b of second bobbin 112 to the circumferential surface of second winding shaft 113b, so slack 121 would need to be as long as the height of upper flange 116 (116a and 116b). Therefore, by providing a notch in the upper flange 116, the height of the upper flange 116 onto which the winding 120 rides becomes smaller or zero, and the length of the slack portion 121 required to cross from the first bobbin 111 to the second bobbin 112 can be shortened. Furthermore, since the entire length of boundary portion 123 is extended from first bobbin 111 to second bobbin 112 on the side of winding shaft portion 113 closer to outer surface 116c of flange portion 116, slack portion 121 is prevented from accidentally protruding outside the coil component and damaging or cutting the winding of slack portion 121.

[0035] As shown in FIGS. 1 and 3, the first bobbin 111 and the second bobbin 112 have concave-convex engaging portions 118 that engage with each other when they are arranged side by side so that their axial directions are aligned with each other. The concave-convex engaging portion 118 is a combination of at least one pair of engaging recessed portion 118a (see FIG. 2) and engaging protruding portion 118b (see FIG. 2). The engaging recessed portion 118a and the engaging protruding portion 118b are provided on the sides where the first bobbin 111 and the second bobbin 112 face each other when the first bobbin 111 and the second bobbin 112 are folded. The engaging protruding portion 118b is provided to protrude in the radial direction. The engaging recessed portion 118a has a concave shape corresponding to the engaging protruding portion 118b and is recessed in the axial direction from the periphery of the first bobbin 111 or the second bobbin 112. As a result, the engaging recessed portion 118a and the engaging protruding portion 118b engage with each other when the first bobbin 111 or the second bobbin 112 is folded. In this embodiment, the shape of the engaging protrusion 118b is such that the width thereof monotonically narrows in the protruding direction. For example, the shapes of the engaging protrusion 118b and the engaging recess 118a may be semicircular or triangular. The first bobbin 111 and the second bobbin 112 each have either an engaging recess 118a or an engaging protrusion 118b. That is, the first bobbin 111 and the second bobbin 112 have a total of one or more pairs of recess-protrusion engaging portions 118.

[0036] In this embodiment, as will be described later, flanges 116 (upper flange 116 and lower flange 114) are provided on both ends of the first bobbin 111 and the second bobbin 112. When the first bobbin 111 and the second bobbin 112 are in a folded state, the upper flanges 116 and the lower flanges 114 of the first bobbin 111 and the second bobbin 112 abut against each other. The engagement recess 118a or the engagement protrusion 118b is provided on the sides of the upper flange 116 and the lower flange 114 of the first bobbin 111 and the second bobbin 112 that abut against each other, but is not limited to this. The concave-convex engagement portion 118 may be provided on the winding shaft portion 113 of the first bobbin 111 and the second bobbin 112. For example, when a protruding portion such as a flange is provided midway on winding shaft portion 113 as in a modified example described below, concave-convex engaging portion 118 may be provided on the flanges of first bobbin 111 and second bobbin 112. Furthermore, when there is a portion that protrudes from the circumferential surface of winding shaft portion 113 on the axially outer side of flange portion 116, concave-convex engaging portion 118 may be provided on the protruding portion. In this embodiment, the upper flange 116 and the lower flange 114 of the first bobbin 111 and the second bobbin 112 are provided with engaging recesses 118a or engaging protrusions 118b, respectively. Specifically, the upper flange 116 is provided with two pairs of concave-convex engaging portions 118 between the first bobbin 111 and the second bobbin 112, and the lower flange 114 is also provided with two pairs of concave-convex engaging portions 118. More specifically, each flange 116 has one engaging recess 118a and one engaging protrusion 118b. The concave-convex engaging portions 118 may be provided only on the upper flange portion 116 or the lower flange portion 114, or may be provided on both the upper flange portion 116 and the lower flange portion 114. Furthermore, only one pair of the concave-convex engaging portions 118 may be provided between the abutting flange portions (116a and 114a) of the first bobbin 111 and the abutting flange portions (116b and 114b) of the second bobbin 112, or multiple pairs may be provided.

[0037] The engagement of the first bobbin 111 and the second bobbin 112 by the concave-convex engaging portion 118 prevents the first bobbin 111 and the second bobbin 112 from shifting laterally relative to the engagement direction of the concave-convex engaging portion 118. This makes it easier to stably assemble the coil device 100. Furthermore, since the engaging protrusion 118b has a shape that narrows monotonically in the protruding direction, when the first bobbin 111 and the second bobbin 112 are folded from the unfolded state to the folded state, the engaging recess 118a and the engaging protrusion 118b can engage with each other without interfering with each other.

[0038] In this embodiment, the first bobbin 111 and the second bobbin 112 have the same shape, including the shapes of the concave-convex engaging portions 118 and the protrusions 117 described below. Specifically, the concave-convex engaging portions 118 are formed at positions equidistant from the center of the side of the flange portion 116 on which the concave-convex engaging portions 118 are formed. Furthermore, the engaging recesses 118a, the engaging protrusions 118b, and the protrusions 117 on the first bobbin 111 and the second bobbin 112 are formed at positions and with shapes that are rotationally symmetrical to each other when the coil bobbin 10 is viewed from the vertical direction in the folded state. This allows the first bobbin 111 and the second bobbin 112 to be manufactured using the same manufacturing equipment, thereby increasing the productivity of the coil bobbin 10.

[0039] (coil parts) Next, a coil component 100 including the coil bobbin 10 will be described. Fig. 9 is a perspective view of the coil device 100, and Fig. 10 is a perspective view of the coil device 100 from another viewpoint. Fig. 11 is a vertical cross-sectional view of the coil device 100. The coil device 100 includes a core 140 formed by combining the above-described coil bobbin 10 and multiple magnetic members. As shown in FIG. 11 , the core 140 has magnetic legs 141 inserted into the first bobbin 111 and the second bobbin 112 in the winding axis direction of the winding 120. Here, the coil device 100 in this embodiment is a component used with the coil bobbin 10. However, the application is not limited thereto. The core 140 is made up of at least two magnetic members, which are integrally molded from a magnetic material such as ferrite. In this embodiment, the core 140 is made up of a U-shaped U core 142 and an I-shaped I core 143, but is not limited thereto. For example, the core may be made up of two U-shaped cores. The first bobbin 111 and the second bobbin 112 are provided with insertion holes in the axial direction, and one end of the U core 142 is inserted into each of the insertion holes 119 of the first bobbin 111 and the second bobbin 112 .

[0040] As described above, the first bobbin 111 and the second bobbin 112 each have a winding shaft portion 113 around which the winding 120 is wound, and flange portions (116, 114) formed on one end and the other end of the first bobbin and the second bobbin, respectively, protruding from the winding shaft portion 113 in a direction intersecting the axial direction. The upper flange portion 116 has a recess 115. The flange 116 at one end or the flange 116 at the other end of each of the first bobbin 111 and the second bobbin 112 has a protrusion 117 on an outer surface 116c opposite the winding shaft portion 113. That is, the upper flange 116a of the first bobbin 111 and the upper flange 116b of the second bobbin 112 each have the protrusion 117, or the lower flange 114a of the first bobbin 111 and the lower flange 114b of the second bobbin 112 each have the protrusion 117. In this embodiment, the upper flanges 116 of the first bobbin 111 and the second bobbin 112 are provided with the protrusions 117. Protruding portion 117 is a portion that protrudes from outer surface 116 c of flange portion 116 to the side opposite winding shaft portion 113 .

[0041] At least one of the magnetic members is disposed straddling the flange 116 of the first bobbin 111 and the flange 116 of the second bobbin 112, and a protrusion 117 is disposed around the magnetic member. Here, "the magnetic member is disposed straddling the flange 116 of the first bobbin 111 and the flange 116 of the second bobbin 112" means that a part of the magnetic member is in contact with the flange 116 of the first bobbin 111 and another part is in contact with the flange 116 of the second bobbin 112. In this embodiment, the I core 143 is in contact with the outer surface 116c of the upper flange 116 of each of the first bobbin 111 and the second bobbin 112. In this embodiment, as shown in FIG. 9, the surface of the I core 143 that contacts the upper flange 116a of the first bobbin 111 and the upper flange 116b of the second bobbin 112 is rectangular. The protrusion 117 has an L-shape formed integrally by two intersecting straight lines, and the two straight lines are arranged along the sides of the magnetic member, but this is not limited to this. It is sufficient that the protrusion 117 is arranged near each side of the I core 143 that contacts the flange 116 in a rectangular shape. For example, one protrusion 117 may be arranged on each of the four sides, or multiple protrusions 117 may be arranged in a line along the side. Furthermore, the protrusion 117 and the magnetic member (I core 143) may contact each other, or may be adjacent to each other without contacting each other.

[0042] In this embodiment, the protrusion 117 is provided on the upper flange 116, but it may be provided on the lower flange 114. When the protrusion 117 is provided on the upper flange 116, the protrusions 117 of the first bobbin 111 and the second bobbin 112 are sandwiched between the outer surfaces 116c of the upper flanges 116 of the first bobbin 111 and the second bobbin 112 in the unfolded state. Furthermore, in the folded state, the I core 143 is disposed on the outer surface 116c of the upper flange 116, and the U core 142 is inserted from the lower end side of the coil bobbin 10. On the other hand, when the protrusion 117 is provided on the lower flange 114, the outer surfaces 116c of the upper flanges 116 of the first bobbin 111 and the second bobbin 112 come into contact with each other in the unfolded state. In the folded state, the I core 143 is disposed on the outer surface 116c of the lower flange 114, and the U core 142 is inserted from the upper end side of the coil bobbin 10. By providing protrusions 117 on the lower flanges 114 of the first bobbin 111 and the second bobbin 112, the distance between the upper flanges 116 of the first bobbin 111 and the second bobbin 112 in the unfolded state is reduced, and the length of the bridge portion 122 spanning from the recess 115 of the first bobbin 111 to the recess 115 of the second bobbin 112 can be reduced. This reduces the length of the slack portion 121, making it possible to prevent the winding 120 from accidentally coming out of the coil device 100 in the folded state. When the protrusions 117 are provided on the upper flanges 116 of the first bobbin 111 and the second bobbin 112, the first bobbin 111 and the second bobbin 112 can be easily prevented from returning from the folded state to the unfolded state by inserting the U core 142 from the lower end side of the coil bobbin 10. This is because the rotation of the first bobbin 111 and the second bobbin 112 can be restricted by the U core 142 at the center where the first bobbin 111 and the second bobbin 112 are folded, that is, at the lower end side far from the upper end side where the transition portion 122 is located. Furthermore, when protruding portion 117 is provided on upper flange 116, the depth of recess 115 may be set to be at least half the height of protruding portion 117. Here, the height of protruding portion 117 refers to the height of protruding portion 117 outward in the axial direction with the surface of flange 116 as the reference. When protruding portion 117 is provided on upper flange 116, crossover portion 122 of winding 120, which will be described later, becomes longer by the height of protruding portion 117. By setting the depth of recess 115 to be at least half the height of protruding portion 117, it is possible to prevent crossover portion 122 from becoming longer due to the height of protruding portion 117.

[0043] The magnetic members are positioned on the flanges 116 of the first bobbin 111 and the second bobbin 112, and protrusions 117 are arranged around the magnetic members, thereby preventing lateral displacement of the magnetic members on the flanges 116 (116a, 114a) of the first bobbin 111 and the flanges 116 (116b, 114b) of the second bobbin 112. This facilitates stable assembly of the coil device 100.

[0044] (terminal part) 9, coil device 100 has terminal portions 150. Both ends of winding 120 are electrically connected to and mounted on an electronic board (not shown) by terminal portions 150. One example of a method for mounting on an electronic board is to mount winding 120 directly on the electronic board by soldering or the like. Specifically, terminal portion 150 is configured as follows. Terminal portion 150 has mounting base 151, which is disposed below flange 116. Both ends of winding 120 are pulled out from winding shaft 113 of first bobbin 111 or second bobbin 112 to the underside of flange 116, pass through mounting base 151, and are pulled out to the underside of mounting base 151. Mounting base 151 and coil component 100 are fixed with a sealing material such as resin, which will be described later. Both ends of winding 120 are disposed parallel to each other, and are mounted on an electronic board by soldering or the like as rod-shaped terminals 152. Alternatively, the leading end of pulled-out winding 120 can be extended to form a surface parallel to mounting base 151, and the extended surface can be mounted on an electronic board by soldering or the like as a surface-mount terminal 152. The method of mounting on the electronic board is not limited to the method of connecting the winding 120 to the electronic board as the terminal 152. For example, the coil component 100 can be provided with binding terminals electrically connected to the mounting terminals, and the winding 120 can be electrically connected to the binding terminals by binding both ends of the winding 120 to the corresponding binding terminals. The mounting terminals are joined to the electronic board by soldering or the like.

[0045] The coil bobbin 10 according to this embodiment can also be provided as two bobbins 110 (first bobbin 111 and second bobbin 112) without including the winding 120 or the core 140. As described above, the coil bobbin 10 according to this embodiment includes two bobbins 110 (first bobbin 111 and second bobbin 112). The bobbin 110 has a protruding region at one end of the bobbin 110 that extends in the circumferential direction of the winding shaft portion 113 around which the winding 120 is wound. The protruding region is provided with a recessed portion 115 that is recessed from the outer periphery toward the winding shaft portion 113 of the bobbin. The bobbin 110 has a concave-convex engaging portion 118. When the two bobbins 110 (first bobbin 111 and second bobbin 112) are arranged side by side with their axial directions aligned, and the recessed portions 115 are facing inward with respect to the space between the two bobbins 110, the concave-convex engaging portions 118 engage with each other.

[0046] The coil bobbin 10 can be easily manufactured by winding the winding 120 therearound using a method for manufacturing the coil bobbin 10, which will be described later. That is, by passing the winding 120 through the recess 115 in the winding process, the position of the winding 120 from the first bobbin 111 to the second bobbin 112 can be determined within a certain range. This prevents the winding 120 from shifting sideways in the folding process in which the first bobbin 111 and the second bobbin 112 are folded so as to be arranged side by side. Furthermore, by providing the protruding region, it is possible to prevent the winding wire 120 from loosening from the protruding region toward the opposite side of the winding shaft portion 113 . Furthermore, by providing the concave-convex engaging portion 118, the first bobbin 111 and the second bobbin 112 can be prevented from shifting laterally in the folded state, and the assembly of the coil device 100 can be facilitated.

[0047] (Manufacturing method of coil bobbin) Next, an outline of a method for manufacturing the above-mentioned coil bobbin 10 will be described. The coil bobbin 10 has a winding 120 and a first bobbin 111 and a second bobbin 112 arranged side by side, each having a winding shaft portion 113 around which the winding 120 is wound. The manufacturing method of the coil bobbin 10 includes a winding process and a folding process. In the winding process, the first bobbin 111 and the second bobbin 112 are arranged vertically so that the winding shaft portions 113 are aligned in a substantially straight line, and the winding 120 is wound continuously across the winding shaft portion 113 of the first bobbin 111 and the winding shaft portion 113 of the second bobbin 112. In the folding process, the first bobbin 111 and the second bobbin 112 are folded and arranged side by side, with a crossover portion 122, which is a length region of the winding 120 that straddles the first bobbin 111 and the second bobbin 112, facing inward.

[0048] Next, a method for manufacturing the coil bobbin 10 will be described in detail. As described above, first bobbin 111 and second bobbin 112 have, at least at one end, a protruding region that extends in the circumferential direction of winding shaft portion 113, and the protruding region has recessed portion 115 that is formed in a concave shape from the outer circumferential edge of the protruding region toward winding shaft portion 113. The protruding region is provided at one end on the side where first bobbin 111 and second bobbin 112 abut.

[0049] 7 and 8 , in the winding process, first bobbin 111 and second bobbin 112 abut one end thereof, and first bobbin 111 and second bobbin 112 are arranged linearly so that recesses 115 of first bobbin 111 and second bobbin 112 are located on the same circumferential side of winding shaft portion 113. Here, "the recesses 115 of first bobbin 111 and second bobbin 112 are located on the same circumferential side of winding shaft portion 113" means that the opening directions of recesses 115 of first bobbin 111 and second bobbin 112 are substantially the same. Specifically, when first bobbin 111 and second bobbin 112 are viewed from either lateral direction perpendicular to the winding axis direction in the expanded state of first bobbin 111 and second bobbin 112, the openings of recesses 115 of first bobbin 111 and second bobbin 112 can be seen at once. Preferably, the recesses 115 of the first bobbin 111 and the second bobbin 112 are in communication with each other. That is, when viewed in the axial direction of the first bobbin 111 and the second bobbin 112, at least a portion of the recess 115 of the first bobbin 111 and the recess 115 of the second bobbin 112 overlap. When the recesses of the first bobbin 111 and the second bobbin 112 are in communication with each other, the distance between the recess 115 of the first bobbin 111 and the recess 115 of the second bobbin 112 can be made shorter than when they are not in communication, and the length of the slack portion 121 can be made shorter. When the winding 120 is thinner than the height of the protrusion 117, the recesses 115 of the first bobbin 111 and the second bobbin 112 do not need to communicate with each other in the folded state, and may be shifted in the circumferential or radial direction.

[0050] 8, in the winding process of the winding 120, the transition portion 122 is passed through the recesses 115 of the first bobbin 111 and the second bobbin 112, and the winding 120 is wound continuously across the winding shaft portion 113 of the first bobbin 111 and the winding shaft portion 113 of the second bobbin 112. Specifically, the winding 120 is wound, for example, from one end (the left end in FIG. 8) of the first bobbin 111 to the other end (the right end in FIG. 8), and passes through the recesses 115 of the first bobbin 111 to cross from the first bobbin 111 to the second bobbin 112. The winding 120 then passes through the recesses 115 of the second bobbin 112 and is wound continuously across the second bobbin 112 from one end (the left end in FIG. 8) to the other end (the right end in FIG. 8). Here, the crossover portion 122 of the winding 120 refers to the length of the winding 120 sandwiched between the winding 120 wound around the first winding shaft portion 113a and the winding 120 wound around the second winding shaft portion 113b. In this embodiment, the crossover portion 122 is the length of the winding 120 that spans from the recess 115 of the first bobbin 111 to the recess 115 of the second bobbin 112.

[0051] In the folding process, the first bobbin 111 and the second bobbin 112 are folded so that the transition portion 122 faces inward, that is, so that the recesses 115 of the first bobbin 111 and the second bobbin 112 face inward. At this time, the first bobbin 111 and the second bobbin 112, which were arranged in a substantially linear manner, are rotated by approximately 180 degrees without being twisted until they are arranged side by side with their axial directions aligned with each other.

[0052] When the coil bobbin 10 is folded, the above-described multiple magnetic members are inserted or positioned, and the above-described terminal portion 150 is provided. As shown in FIG. 2, the winding 120 may protrude outward beyond the outer surface 116c of the flange 116 through the recess 115 (see FIG. 1). In this case, the winding 120 protruding beyond the outer surface 116c of the flange 116 prevents stable contact between the I core 143 and the outer surface 116c of the flange 116, which may result in poor adhesion between the I core 143 and the flange 116. To avoid this, it is advisable to push the winding 120 protruding outward beyond the outer surface 116c of the flange 116 toward the winding shaft portion 113, and position the I core 143 in a state where the winding 120 does not protrude above the outer surface 116c of the flange 116, as shown in FIG. 4. I core 143, which is a magnetic member, may be fixed to flange 116 with an adhesive. Also, mounting base 151 and U core 142 may be fixed to coil bobbin 10 with an adhesive. Furthermore, the parts other than terminal 152 may be covered with a sealing material such as epoxy resin or polyester resin. Both ends of the winding 120 are electrically connected to the electronic board as described above.

[0053] Here, when attempting to wind the winding 120 onto the first bobbin 111 with the first bobbin 111 and the second bobbin 112 arranged side by side, the wire supply unit of the winding device is likely to interfere with the second bobbin 112, which is located radially adjacent to the first bobbin 111. For this reason, in order to wind the winding 120 with the first bobbin 111 and the second bobbin 112 located close to each other, it is necessary to wind the winding while avoiding interference between the second bobbin 112 and the wire supply unit, which reduces the efficiency of the winding process for the winding 120. When winding wire 120 onto first bobbin 111 with winding shaft portions 113 of first bobbin 111 and second bobbin 112 aligned in a straight line, interference between second bobbin 112 and the wire supply portion is prevented because second bobbin 112 does not exist in the radial direction of first bobbin 111. This allows winding wire 120 to be wound continuously from first bobbin 111 to second bobbin 112, thereby improving the efficiency of the winding process of winding wire 120. Furthermore, after winding the winding 120, the first bobbin 111 and the second bobbin 112 are folded and placed side by side close to each other, so that the gap between the first bobbin 111 and the second bobbin 112 can be freely adjusted. In other words, the gap between the first bobbin 111 and the second bobbin 112 can be made smaller, thereby making it possible to reduce the size of the coil bobbin 10. Furthermore, when winding the winding 120 sequentially around the first bobbin 111 and the second bobbin 112 with the first bobbin 111 and the second bobbin 112 arranged side by side, it is necessary to switch the winding direction between the first bobbin 111 and the second bobbin 112. That is, it is necessary to wind the winding 120 in opposite directions around the first winding shaft portion 113a and the second winding shaft portion 113b. This is because the winding 120 is wound in the same direction as the magnetic field lines passing through the closed magnetic circuit formed by the magnetic member. On the other hand, when winding the winding 120 with the first bobbin 111 and the second bobbin 112 in an unfolded state, the winding 120 is wound in the same direction around the first bobbin 111 and the second bobbin 112, and there is no need to switch the winding direction. Furthermore, by folding the first bobbin 111 and the second bobbin 112, the winding directions of the winding 120 on the first winding shaft portion 113a and the second winding shaft portion 113b naturally become opposite to each other. Since there is no need to switch the winding direction of the winding 120 in this way, the efficiency of the winding process can be improved.

[0054] By providing recesses 115 at the ends of the first bobbin 111 and the second bobbin 112 that abut in the unfolded state, it is possible to determine within a certain range the position of the winding 120 that spans the first bobbin 111 and the second bobbin 112. This makes it possible to prevent the winding 120 from shifting sideways during the folding process, and to maintain a constant folding position of the winding 120 in the manufactured coil bobbin 10.

[0055] The present invention is not limited to the above-described embodiment, but includes various modifications and improvements as long as the object of the present invention is achieved. In the first embodiment, the first bobbin 111 and the second bobbin 112 may not have a protruding region such as the flange 116. In this case, the winding 120 passes between the first bobbin 111 and the second bobbin 112 from any portion of the first bobbin 111 and the second bobbin 112. The coil bobbin 10 may include three or more bobbins 110. That is, in the winding process, three or more bobbins 110 are arranged in a straight line and the winding 120 is wound continuously around them, and in the folding process, the bobbins may be folded at two or more locations so that the transition portions 122 are on the inside. For example, when the winding 120 is wound around three bobbins 110, the three bobbins 110 are folded so that they are arranged in a triangle, and when the winding 120 is wound around four bobbins 110, the four bobbins are folded so that they are arranged in a square. This allows the winding 120 to be wound around all sides of a polygonal closed magnetic circuit. The winding 120 may be wound in multiple layers around the bobbin 110. By winding the winding 120 in an odd number of layers, such as three or five layers, both ends of the winding 120 can be arranged at the lower end of the coil bobbin 10 to form terminal portions 150, and the winding 120 can be passed from the first bobbin 111 to the second bobbin 112 at the upper end of the coil bobbin 10. Furthermore, multiple windings 120 may be wound around bobbin 110. In this case, multiple windings 120 may be wound in an overlapping manner, or may be wound at different positions in the winding axis direction of winding shaft portion 113. That is, the winding positions on winding shaft portion 113 may be divided for each winding 120. In this case, to separate the winding positions of windings 120, a flange may be provided midway along the length of winding shaft portion 113, with one winding 120 wound on one side of the flange and another winding 120 wound on the other side of the flange. A concave-convex engagement portion 118 may be formed on this flange.

[0056] The above embodiment encompasses the following technical ideas. (1) A coil bobbin having a winding and a first bobbin and a second bobbin arranged side by side with their axial directions aligned with each other, wherein the winding is wound continuously across the first bobbin and the second bobbin and is passed from the first bobbin to the second bobbin through an inner space sandwiched between the side by side first and second bobbins, and wherein the coil has a slack portion in the inner space. (2) The coil bobbin according to (1), characterized in that the first bobbin and the second bobbin have a winding shaft portion on which the winding is wound and a protruding region extending in the circumferential direction of the winding shaft portion at one end of the first bobbin and the second bobbin, the protruding region has a recess formed in a concave shape extending from the outer circumferential edge of the protruding region toward the winding shaft portion, and the first bobbin and the second bobbin are arranged so that at least a portion of each recess is located inside the first bobbin and the second bobbin. (3) A coil bobbin as described in (2), wherein the slack portion has a length that allows the winding to pass through the recess and span between the first bobbin and the second bobbin when the first bobbin and the second bobbin are arranged in a straight line with their ends, on which the protrusion region is provided, abutting against each other. (4) The coil bobbin according to (3), characterized in that the length of the slack portion is equal to or greater than the sum of the height of the bottom of the recess from the peripheral surface of the winding shaft portion of the first bobbin, the height of the bottom of the recess in the second bobbin, and the distance from the recess of the first bobbin to the recess of the second bobbin when the first bobbin and the second bobbin are arranged in a straight line with one end thereof abutting against the other end having the protrusion region. (5) A coil bobbin according to any one of (2) to (4), characterized in that the protruding region is a flange portion that protrudes from the winding shaft portion of the first bobbin or the second bobbin in a direction that intersects with the axial direction, and the winding is passed from the first bobbin to the second bobbin on the winding shaft portion side of the outer surface of the flange portion. (6) A coil bobbin according to any one of (1) to (5), wherein the first bobbin and the second bobbin have concave-convex engaging portions that engage with each other when arranged side by side with their axial directions aligned with each other. (7) A coil component comprising the coil bobbin according to any one of (1) to (6) and a core formed by combining a plurality of magnetic members, the core having magnetic legs inserted through the first bobbin and the second bobbin in the winding axis direction of the winding, wherein the first bobbin and the second bobbin have a winding shaft portion around which the winding is wound and a flange portion formed on one end and the other end of the first bobbin and the second bobbin, respectively, protruding from the winding shaft portion in a direction intersecting with the axial direction, the flange portion at the one end of the first bobbin and the flange portion at the other end of the second bobbin each having a protrusion on an outer surface opposite to the winding shaft portion, and at least one of the magnetic members is disposed across the flange portion of the first bobbin and the flange portion of the second bobbin, and the protrusion is disposed around the magnetic member. (8) A coil bobbin including two bobbins, wherein the bobbins have a protruding region at one end of the bobbin that extends in the circumferential direction of a winding shaft portion on which a winding is wound, and the protruding region has a recess formed in a concave shape that extends from the outer peripheral edge toward the winding shaft portion of the bobbin, and the bobbins are arranged side by side with their axial directions aligned with each other, and have concave-convex engaging portions that engage with each other when the two bobbins are arranged side by side with their axial directions aligned with each other and the recesses facing inward with respect to the space sandwiched between the two bobbins. (9) A method for manufacturing a coil bobbin having a winding and a first bobbin and a second bobbin arranged side by side, each having a winding shaft portion around which the winding is wound, the method including: a winding step in which the first bobbin and the second bobbin are arranged vertically so that the winding shaft portions are aligned in a substantially straight line, and the winding is wound continuously across the winding shaft portion of the first bobbin and the winding shaft portion of the second bobbin; and a folding step in which the first bobbin and the second bobbin are folded and arranged side by side, with a crossover portion, which is a length region of the winding that spans the first bobbin and the second bobbin, on the inside. (10) The method for manufacturing a coil bobbin according to (9), wherein the first bobbin and the second bobbin have, at least at one end, a protruding region extending in the circumferential direction of the winding shaft portion, the protruding region having a recess formed in a concave shape extending from the outer circumferential edge of the protruding region toward the winding shaft portion, and in the winding step, the one end portions are abutted against each other and the first bobbin and the second bobbin are linearly arranged so that the recesses are located on the same circumferential side of the winding shaft portion, and the winding is wound continuously across the winding shaft portion of the first bobbin and the winding shaft portion of the second bobbin by passing the transition portion through the recesses of the first bobbin and the second bobbin.

Claims

1. a winding, and a first bobbin and a second bobbin arranged side by side so that their axial directions are aligned with each other; The first bobbin and the second bobbin are a winding shaft portion on which the winding is wound; a flange portion at least at one end thereof, the flange portion protruding from the winding shaft portion in a direction intersecting the axial direction and extending in a circumferential direction of the winding shaft portion, The winding The wire is wound continuously around the first bobbin and the second bobbin, the wire passes through an inner space between the first bobbin and the second bobbin arranged side by side and is passed from the first bobbin to the second bobbin at the one end; A slack portion is provided in the inner space, The first bobbin and the second bobbin are The flange portion at the one end has concave-convex engaging portions that engage with each other when arranged side by side so that the axial direction is along each other, and the concave-convex engaging portions are provided on the sides that abut each other, the concave-convex engaging portion is a combination of at least one pair of engaging protrusions and engaging recesses having recessed shapes corresponding to the engaging protrusions, the engaging protrusion is provided so as to protrude radially from the side of the flange, and the engaging recess is formed so as to be recessed axially from the periphery of the side of the flange and penetrates the flange, A coil bobbin, characterized in that, when viewed in the axial direction, the engaging protrusion has a shape that monotonically narrows in width in a protruding direction of the engaging protrusion.

2. The flange portion is a recess formed in a concave shape extending from an outer peripheral edge of the flange portion toward the winding shaft portion, The first bobbin and the second bobbin 2. The coil bobbin according to claim 1, wherein at least a portion of each of the recesses is disposed inside the first bobbin and the second bobbin.

3. The loosened portion is 3. The coil bobbin according to claim 2, wherein when the first bobbin and the second bobbin are arranged in a straight line with their ends where the flange portion is provided abutting against each other, the length of the winding is such that it can pass through the recess and span between the first bobbin and the second bobbin.

4. The length of the slack portion is 4. The coil bobbin according to claim 3, wherein the recess is equal to or greater than the sum of the height of a bottom of the recess from the peripheral surface of the winding shaft portion in the first bobbin, the height of the bottom of the recess in the second bobbin, and the distance from the recess of the first bobbin to the recess of the second bobbin when the first bobbin and the second bobbin are arranged in a straight line with their ends having the flanges abutting against each other.

5. The winding comprises:

5. The coil bobbin according to claim 2, wherein the first bobbin is connected to the second bobbin on a side closer to the winding shaft portion than the outer surface of the flange portion.

6. A coil bobbin having a winding and a first bobbin and a second bobbin arranged side by side so that their axial directions are aligned with each other; a core having magnetic legs inserted in the first bobbin and the second bobbin in a winding axis direction of the winding, the core being formed by combining a plurality of magnetic members, The first bobbin and the second bobbin are a winding shaft portion on which the winding is wound; a flange portion formed on one end and the other end of the first bobbin and the second bobbin, respectively, protruding from the winding shaft portion in a direction intersecting the axial direction and extending in a circumferential direction of the winding shaft portion, The winding The wire is wound continuously around the first bobbin and the second bobbin, the wire passes through an inner space between the first bobbin and the second bobbin arranged side by side and is passed from the first bobbin to the second bobbin at the one end; A slack portion is provided in the inner space, The flange portion at the one end of each of the first bobbin and the second bobbin includes: a protrusion on an outer surface opposite to the winding shaft portion, At least one of the magnetic members is the protrusion is disposed across the flange portion of the first bobbin and the flange portion of the second bobbin, and the protrusion is disposed around the magnetic member; the protrusion provided on the flange portion of the first bobbin and the protrusion provided on the flange portion of the second bobbin are spaced apart from each other in a direction in which the first bobbin and the second bobbin are arranged side by side, A coil component in which, when viewed in the axial direction, the protruding portion of the first bobbin and the protruding portion of the second bobbin are formed in positions that are rotationally symmetrical to each other and are spaced apart from each other in a direction perpendicular to the direction in which they are arranged side by side.

7. A coil bobbin including two bobbins, The bobbin is a flange portion extending in a circumferential direction of a winding shaft portion around which a winding is wound and projecting from the winding shaft portion in a direction intersecting the axial direction of the bobbin is provided at one end of the bobbin, The flange portion has: a recess formed in a concave shape extending from an outer circumferential edge toward the winding shaft portion of the bobbin, The bobbin The two bobbins are arranged side by side so that their axial directions are aligned with each other, and the recesses are opposed to each other inwardly with respect to the space between the two bobbins, and the flanges at the one end have concave-convex engaging portions on their respective sides that abut against each other, the concave-convex engaging portion is a combination of at least one pair of engaging protrusions and engaging recesses having recessed shapes corresponding to the engaging protrusions, the engaging protrusion is provided so as to protrude radially from the side of the flange, and the engaging recess is formed so as to be recessed axially from the periphery of the side of the flange and penetrates the flange, A coil bobbin, characterized in that, when viewed in the axial direction, the engaging protrusion has a shape that monotonically narrows in width in a protruding direction of the engaging protrusion.

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