Coil parts

Abstract

To reduce cost in manufacturing by reducing cost of parts and reducing man-hours in assembly and to improve uniformity and quality by reducing variations among parts or variations in the assembly during the manufacturing.SOLUTION: A coil component comprises a cylindrical insulator unit 4 configured by combining a pair of insulator half parts 5 and 6 which can be respectively fitted from right and left side faces to a coil part 2. The insulator half parts 5 and 6 include: semi-cylindrical outer insulation portions 5m and 6m which cover an outer peripheral surface 2o of the coil pat 2; and a plurality of inner insulation portions 5s... and 6s... which protrude from inner peripheral surfaces 5mi and 6mi of the outer insulation portions 5m and 6m to the inside of the coil part 2, in which at least partial tip ends 5s..., 5ss..., 6s... and 6ss... protrude inward from an inner peripheral surface 2i of the coil part 2 just by a predetermined length Li, and which are in contact with all turn parts T... positioned in a crossing direction to an axial center Ki of the coil part 2. The insulator half parts are integrally formed by an insulation material D.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a coil component including a coil portion wound with a conductor wire, and a core portion having core surfaces facing the inner circumferential surface, the outer circumferential surface, and both end surfaces of the coil portion. [Background technology]

[0002] Conventionally, coil components have been known that include a coil portion wound with a conductor made of a conductive material, and a core portion having core surfaces facing the inner peripheral surface, outer peripheral surface, and both end surfaces of the coil portion, and the applicant has already proposed a coil component suitable for this type of coil component and a method for manufacturing the same in Patent Document 1.

[0003] The coil component described in the same document 1 aims to reduce the number of manufacturing steps, reduce manufacturing costs, and downsize the coil component, while also improving the overall heat dissipation performance. Specifically, the coil component comprises a coil main body using a flat wire and a coil portion having integral coil terminal portions at both ends of the flat wire derived from the coil main body, and the coil portion is manufactured by bending a coil base material obtained by punching out portions corresponding to the coil main body and the coil terminal portions as a single unit from a plate base material having a predetermined thickness made of a conductive material, and a separator member having one or more insulating piece portions formed from an insulating material and arranged at predetermined intervals to provide electrical insulation between the turn portions by being inserted between the turn portions of the coil main body. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-42021 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the coil component described in Patent Document 1 above has the following problems to be solved.

[0006] That is, since this type of coil component is used with a relatively large current and is often used in a harsh environment with vibrations, etc., not only the magnetic and electrical performance of the coil component itself but also its insulating performance is an important performance factor. For this reason, in the case of Patent Document 1, a total of four insulating parts, namely, two separator members with one or more insulating pieces provided at a predetermined interval, and a coil bobbin having a first bobbin divided portion and a second bobbin divided portion, are assembled to the necessary locations where insulation is required.

[0007] As a result, the number of parts in the entire coil component increases, leading to an increase in the cost of the parts that make up the coil component, and in addition, there is a drawback in that the manufacturing cost increases due to an increase in the number of steps required during assembly.

[0008] Furthermore, since the number of parts increases, variations between parts in each production lot and variations in assembly during production are likely to occur, which is disadvantageous in terms of the uniformity of the coil parts.

[0009] An object of the present invention is to provide a coil component that solves the problems present in the background art. [Means for solving the problem]

[0010] In order to solve the above-mentioned problems, the present invention provides a coil component 1 including a coil portion 2 wound with a conductive wire W made of a conductive material E, and a core portion 3 having core surfaces 3i, 3o, 3u, and 3d opposed to an inner peripheral surface 2i, an outer peripheral surface 2o, and both end surfaces 2u and 2d of the coil portion 2, the coil component 1 including a cylindrical insulator unit 4 formed by combining a pair of insulator half portions 5 and 6 that can be fitted into the coil portion 2 from the left and right side surfaces, respectively, and the insulator half portions 5 and 6 are wound around the outer peripheral surface 2o of the coil portion 2. and a plurality of inner insulating parts 5s..., 6s... which protrude from inner surfaces 5mi, 6mi of the outer insulating parts 5m, 6m toward the inside of the coil part 2, with at least some of the tip parts 5s..., 5ss..., 6s..., 6ss... protruding inward from the inner surface 2i of the coil part 2 by a predetermined length Li, and which contact all the turn parts T... located in the direction intersecting with the axis Ki of the coil part 2, and which are integrally formed from an insulating material D.

[0011] In this case, according to a preferred embodiment of the invention, the core portion 3 can be formed by combining a pair of core halves 3x, 3y formed in an E shape. By being positioned radially outward of the coil portion 2 in the radial direction Fd, the outer insulating portions 5m, 6m can be set to a thickness Lo that provides insulation between the outer peripheral surface 2o of the coil portion 2 and the core surface 3o facing the outer peripheral surface 2o. The length of the inner insulating portions 5s, 6s protruding inward from the inner peripheral surface 2i of the coil portion 2 to their tip ends 5ss, 6ss can be set to a length Li that provides insulation between the inner peripheral surface 2i of the coil portion 2 and the core surface 3i facing the inner peripheral surface 2i. The inner insulating portions 5s, 6s can also be set to a thickness Lt that provides insulation between the turn portions T of the coil portion 2. The inner insulating portions 5s..., 6s... can be set to a thickness Lu that provides insulation between one end face 2u of the coil portion 2 and the core surface 3u facing this end face 2u, and the inner insulating portions 5s..., 6s... can be set to a thickness Ld that provides insulation between the other end face 2d of the coil portion 2 and the core surface 3d facing this other end face 2d. In addition, the outer peripheral surface 4f of the insulator unit 4 can be formed with a groove-like bobbin-shaped portion 7 around which the secondary coil portion 8 can be wound. [Effects of the Invention]

[0012] The coil component 1 according to the present invention has the following remarkable effects.

[0013] (1) Basically, the two insulator halves 5 and 6 ensure the overall insulating function, which reduces the number of parts, thereby reducing costs. It also reduces manufacturing costs by reducing the number of assembly steps. Furthermore, because the number of parts can be reduced (by half), it is possible to reduce variations between parts in each production lot and variations in assembly during production, thereby improving the uniformity and quality of coil components.

[0014] (2) In a preferred embodiment, when constructing the core portion 3, it is constructed by combining a pair of core halves 3x and 3y formed in an E-shape. By combining the core halves 3x and 3y, which are identical parts, a closed-circuit core portion 3 can be constructed. This contributes to reducing parts costs and improves ease of manufacturing, thereby contributing to reducing manufacturing costs.

[0015] (3) In a preferred embodiment, when setting the thickness of the outer insulating parts 5m, 6m, by positioning them radially outward in the direction Fd of the coil part 2, the thickness is set to Lo, which insulates between the outer peripheral surface 2o of the coil part 2 and the core surface 3o facing this outer peripheral surface 2o. Therefore, sufficient insulating performance can be ensured simply by setting the thickness of the outer insulating parts 5m, 6m formed from the insulating material D, and insulation between the outer peripheral surface 2o of the coil part 2 and the core surface 3o can be easily and reliably achieved.

[0016] (4) In a preferred embodiment, when forming the inner insulating portions 5s..., 6s..., the length from the inner circumferential surface 2i of the coil portion 2 to the tip portions 5ss..., 6ss... protruding inward is set to a length Li that forms an air space Ai that provides insulation between the inner circumferential surface 2i of the coil portion 2 and the core surface 3i facing this inner circumferential surface 2i. Therefore, sufficient insulation performance can be ensured simply by setting the length of the inner insulating portions 5s..., 6s..., and therefore insulation between the inner circumferential surface 2i of the coil portion 2 and the core surface 3i can be easily and reliably achieved, and since they also function as a coil bobbin, a separate coil bobbin is not required.

[0017] (5) In a preferred embodiment, when setting the thickness of the inner insulating portions 5s..., 6s..., if the thickness is set to a thickness Lt that insulates between the turn portions T... in the coil portion 2, the spacing between each turn portion T... can be set by the inner insulating portions 5s..., 6s..., and the insulating performance between each turn portion T... can be easily and reliably ensured. This eliminates the need for insulating paint to be applied to the surface of the coil portion 2, and ensures uniformity and stability of the gaps between each turn portion T.... Moreover, because the insulating paint to be applied to the surface of the coil portion 2 is no longer necessary, the overall heat dissipation performance can be improved even for coil components 1 that are used with large currents.

[0018] (6) In a preferred embodiment, if the insulation between one (upper) end face 2u of the coil portion 2 and the core surface 3u facing this one end face 2u is set by the thickness Lu of the inner insulating portions 5s..., 6s... located at one end (top end), sufficient insulation performance can be ensured with just the thickness of the inner insulating portions 5s..., 6s... at the end, so insulation between one end face 2u of the coil portion 2 and the core surface 3u can be easily and reliably achieved. Moreover, because it also functions as a barrier portion or insulating sheet corresponding to the coil bobbin, a separate coil bobbin that would otherwise be required can be eliminated.

[0019] (7) In a preferred embodiment, if the insulation between the other (lower) end face 2d of the coil portion 2 and the core surface 3d facing this other end face 2d is set by the thickness Ld of the inner insulating portions 5s..., 6s... located at the other end (lower end), sufficient insulation performance can be ensured with just the thickness of the inner insulating portions 5s..., 6s... at the end, so insulation between the other end face 2d of the coil portion 2 and the core surface 3d can be easily and reliably achieved. Moreover, because it also functions as a barrier portion or insulating sheet corresponding to the coil bobbin, a separate coil bobbin that would otherwise be required can be eliminated.

[0020] (8) In a preferred embodiment, by forming a groove-shaped bobbin-shaped portion 7 around which the secondary coil portion 8 can be wound on the outer surface 4f of the insulator unit 4, the insulator unit 4 can be used as a coil bobbin when providing the secondary coil portion 8, and therefore, the insulator unit 4 can be provided as a coil component 1 with excellent versatility and expandability, such as being able to construct a transformer. [Brief explanation of the drawings]

[0021] [Figure 1] FIG. 1 is a partially cross-sectional plan view showing a part of a coil component according to a preferred embodiment of the present invention, in which a virtual line is drawn; [Figure 2] FIG. 2 is a partial cross-sectional front view showing a part of the coil component with a virtual line; [Figure 3] 5 is a cross-sectional front view of the insulator half of the coil component taken along line BB in FIG. 4; [Figure 4] 3. A cross-sectional plan view of half of the insulator taken along line AA in FIG. [Figure 5] FIG. 2 is a plan view showing a core portion of the coil component in phantom lines; [Figure 6] FIG. 2 is a front view showing a core portion of the coil component in phantom lines; [Figure 7] A development diagram including a partial cross section of the components of the coil part as seen from the front, [Figure 8] 4A is a view of a modified example of the half insulator portion from the direction of arrow C in FIG. [Figure 9] 5 is a bottom perspective view of a modified example of the insulator half from the direction C in FIG. 4. [Figure 10]10 is a front view for explaining other functions of the coil part; DETAILED DESCRIPTION OF THE INVENTION

[0022] Next, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[0023] First, the main components of a coil device 1 according to this embodiment will be described with reference to FIGS.

[0024] 7 shows an exploded view of the components of the coil device 1. The coil device 1 includes a coil portion 2, an insulator unit 4 formed by combining a pair of insulator half portions 5 and 6, and a core portion 3 formed by combining a pair of core half portions 3x and 3y.

[0025] As shown in Fig. 2, the coil portion 2 includes a coil body 2m wound with a rectangular wire W made of a conductive material E such as copper. The upper and lower ends of the coil body 2m are formed as extensions 2pu and 2pd, respectively, extending forward in the front direction, as shown in Fig. 1, and the tips of the extensions 2pu and 2pd form coil terminals 2su and 2sd (see Fig. 7). The illustrated coil body 2m has 6.5 turns. In the figure, one turn is indicated by a turn portion T.

[0026] On the other hand, as shown in Figures 5 to 7, the insulator unit 4 is formed by combining a pair of insulator halves 5 and 6 that can be fitted into the coil section 2 from the left and right sides, respectively. The specific shapes of the insulator halves 5 and 6 are matched to the shape of the coil section 2, but the basic shape is bilaterally symmetrical. As a result, when the insulator halves 5 and 6 are combined, they form a cylindrical shape. The insulator halves 5 and 6 are each integrally molded from an insulating material D such as a synthetic resin material.

[0027] In this case, one of the insulator half portions 5, that is, the insulator half portion 5 located on the left side when viewed from the front, comprises an outer insulating portion 5m and an inner insulating portion 5s... which are integrally formed, as shown in Figures 3 and 4.

[0028] The outer insulating part 5m has an intermediate insulating part 21 formed in a semi-cylindrical shape that covers the outer peripheral surface 2o of the coil part 2 at its vertically intermediate position, and the outer insulating part 5m has an upper insulating part 22 and a lower insulating part 23 above and below the intermediate insulating part 21. In this case, as an example, the axial (vertical) lengths of the upper insulating part 22 and the lower insulating part 23 are selected to be approximately the same as those of the intermediate insulating part 21, and the circumferential lengths are selected to be approximately two-thirds of the overall length of the intermediate insulating part 21, and they are provided at the circumferentially intermediate position of the intermediate insulating part 21.

[0029] 8, a bobbin-shaped half portion 24 having a recessed groove shape (channel shape) is formed in the circumferential direction (half the circumference) on the outer surface (outer peripheral surface) of the intermediate insulating portion 21. As a result, when the insulator half portions 5 and 6 are combined to form an insulator unit 4 as shown in FIG. 10, a recessed ring-shaped bobbin-shaped portion 7 around which the secondary coil portion 8 can be wound is formed on the outer peripheral surface 4f of the insulator unit 4. By forming the recessed groove-shaped bobbin-shaped portion 7 around which the secondary coil portion 8 can be wound on the outer peripheral surface 4f of the insulator unit 4 in this way, the insulator unit 4 can be used as a coil bobbin when providing the secondary coil portion 8, and therefore a coil component 1 having excellent multifunctionality and expandability can be provided, for example, to construct a transformer.

[0030] As shown in Figures 1 and 2, this outer insulating part 5m is attached to the coil unit 2 from the left side. Therefore, when the outer insulating part 5m is attached to the coil unit 2, it is located on the left side of the coil unit 2, outward in the radial direction Fd, and in particular, the intermediate insulating part 21 of the outer insulating part 5m covers half of the outer peripheral surface 2o of the left side of the coil unit 2. Therefore, when setting the thickness of the outer insulating part 5m, as shown in Figure 1, it is set to a thickness Lo that provides insulation between the outer peripheral surface 2o of the coil unit 2 and the core surface 3o facing this outer peripheral surface 2o. By setting it in this way, sufficient insulation performance can be ensured simply by setting the thickness of the outer insulating part 5m made of insulating material D, making it possible to easily and reliably insulate between the outer peripheral surface 2o of the coil unit 2 and the core surface 3o.

[0031] As shown in Figures 1 to 4, the inner insulating portions 5s... (including 5sx and 5sy) protrude from the inner circumferential surface 5mi of the outer insulating portion 5m toward the inside of the coil portion 2, and their tip portions 5ss... protrude inward by a length Li from the inner circumferential surface 2i of the coil portion 2. A plurality of inner insulating portions 5s... (eight in the example) are provided on the inner circumferential surface 5mi in the axial direction (vertical direction) at intervals corresponding to the turn portions T... of the coil portion 2. Therefore, when assembled to the coil portion 2, each inner insulating portion 5s... comes into contact with all the turn portions T... located in the direction intersecting the axial center Ki of the coil portion 2, as shown in Figure 2.

[0032] In this case, the multiple (six in the example) inner insulating portions 5s... located in the intermediate area, i.e., each of the inner insulating portions 5s... except for the inner insulating portions 5sx and 5sy located at one end (upper end) and the other end (lower end), protrudes inward from the inner circumferential surface 2i of the coil portion 2 by a length Li, as shown in Figures 1 and 2, and its tip end 5ss... abuts against the core surface 3i facing this inner circumferential surface 2i. Therefore, the protruding length Li is set to a length that forms an air space Ai that provides insulation between the inner circumferential surface 2i of the coil portion 2 and the opposing core surface 3i. Note that in the embodiment, as an example, all of the inner insulating portions 5s... are formed to have the same shape, but it is also possible to form the air space Ai with at least two spaced-apart inner insulating portions 5s, 5s or with only the inner insulating portions 5sx and 5sy. Therefore, the present invention can be implemented using inner insulating portions 5s... (including 5sx and 5sy) of various shapes that can form the air space Ai. As shown in Figure 1, each inner insulating portion 5s... is formed by two spaced apart triangular mountain-shaped protruding portions, with the apex of the tip becoming the tip portion 5ss.... By setting it in this way, sufficient insulating performance can be ensured simply by setting the length of the inner insulating portion 5s..., so insulation between the inner circumferential surface 2i of the coil portion 2 and the core surface 3i can be easily and reliably achieved, and since it also functions as a coil bobbin, a separate coil bobbin is not required.

[0033] Furthermore, the thickness of each inner insulating portion 5s is set to a thickness that insulates between the turn portions T in the coil portion 2. This setting allows the spacing between the turn portions T to be set by the inner insulating portions 5s, easily and reliably ensuring the insulation performance between the turn portions T. This eliminates the need for insulating paint to be applied to the surface of the coil portion 2, and ensures uniformity and stability of the gaps between the turn portions T. Furthermore, because the need for insulating paint to be applied to the surface of the coil portion 2 is eliminated, the overall heat dissipation performance can be improved even for coil components 1 used with large currents. In other words, the shape and configuration of the inner insulating portions 5s ensures the thickness Lt that insulates between the turn portions T and also ensures air spaces Ai, resulting in fewer parts than conventional insulation structures, resulting in weight and cost savings.

[0034] Furthermore, as shown in Fig. 2, the inner insulating portion 5sx located at one end (upper end) of the inner insulating portions 5s... is set to a thickness Lu that provides insulation between the end face 2u at one end (upper end) of the coil portion 2 and the core surface 3u facing this end face 2u. By setting it in this way, sufficient insulation performance can be ensured with just the thickness of the inner insulating portion 5s... at the end, so insulation between one end face 2u of the coil portion 2 and the core surface 3u can be easily and reliably achieved. Moreover, because it also functions as a barrier portion or insulating sheet corresponding to the coil bobbin, a separate coil bobbin that would otherwise be required is unnecessary.

[0035] Similarly, the inner insulating portion 5sd located at the other end (lower end) of the inner insulating portions 5s... is set to a thickness Ld that insulates between the end face 2d at the other end (lower end) of the coil portion 2 and the core surface 3d facing this end face 2d, as shown in Figure 2. By setting it in this way, sufficient insulation performance can be ensured with just the thickness of the inner insulating portions 5s... at the end, so insulation between the other end face 2d of the coil portion 2 and the core surface 3d can be easily and reliably achieved. Moreover, because it also functions as a barrier portion or insulating sheet corresponding to the coil bobbin, a separate coil bobbin that would normally be required can be eliminated.

[0036] 8 and 9 respectively show a view seen from the direction of the arrow C in FIG. 4 and a bottom perspective view seen from the direction C in FIG. 4 according to a modified example of the insulator half 5. FIGS. 8 and 9 show an overall image of the insulator half 5, and the detailed shape and configuration differ from those of the insulator half 5 shown in FIGS. 1 to 7.

[0037] One insulator half 5 has been described in detail above, but the other insulator half 6 can be configured in the same way. That is, as shown in Figures 1 to 7, the other insulator half 6 is assembled to the right side surface of the coil portion 2, and therefore, while its specific configuration matches the configuration and shape of the one insulator half 5 assembled to the left side surface, its basic configuration is the same as that of the one insulator half 5, except for the fact that they are bilaterally symmetrical. In the figures, in the insulator half 6, 6m indicates the outer insulating portion, 6mi indicates the inner surface of the outer insulating portion, 6s indicates the inner insulating portion, 6ss indicates the tip end of the inner insulating portion, 6sx indicates the uppermost inner insulating portion, and 6sy indicates the lowermost inner insulating portion.

[0038] On the other hand, as shown in Figure 7 (Figures 5 and 6), the core unit 3 is constructed by combining an upper core half 3x and a lower core half 3y. Each of the pair of core halves 3x and 3y is formed into an E-shape. This allows the core unit 3 to be constructed as a closed circuit by combining the core halves 3x and 3y, which are identical parts, which contributes to reducing parts costs and also improves ease of manufacturing, thereby contributing to reducing manufacturing costs.

[0039] Next, a method for manufacturing the coil component 1 according to this embodiment will be described with reference to FIGS.

[0040] First, each component part is separately manufactured and prepared in advance, as shown in Fig. 7. In this case, the pair of core halves 3x and 3y that make up the core part 3 can be manufactured by, for example, a sintering process using a magnetic material. In this case, multiple core halves 3x are prepared, and one is used as core half 3x, and the other core half 3x can be used as core half 3y by flipping it over.

[0041] The pair of insulator halves 5, 6 constituting the insulator unit 4 can be manufactured as integral molded products by, for example, a molding process using a synthetic resin material. Furthermore, the coil portion 2 is formed by forming a rectangular wire W from a conductive material E such as copper, and then by a winding process including a bending process.

[0042] During manufacturing, the coil portion 2 is expanded in the axial direction, and one insulator half 5 is attached to the left side surface of the coil portion 2 as shown by arrow F1 in FIG. 7 , and the other insulator half 6 is attached to the right side surface of the coil portion 2 as shown by arrow F2. At this time, each inner insulating portion 5s is placed between each turn T of the coil portion 2, with the inner circumferential surface 5mi of the outer insulating portion 5m abutting against the outer circumferential surface 2o of the coil portion 2, and each inner insulating portion 6s is placed between each turn T of the coil portion 2, with the inner circumferential surface 6mi of the outer insulating portion 6m abutting against the outer circumferential surface 2o of the coil portion 2. As a result, an insulator unit 4 is formed by combining the insulator half 5 and the insulator half 6, and is attached to the coil portion 2, as shown in FIGS. 5 and 6 .

[0043] Thereafter, core half 3y is attached to the lower half of coil section 2 from below as shown by arrow F3 in Fig. 7, and core half 3x is attached to the upper half of coil section 2 from above as shown by arrow F4 in Fig. 7. This allows core halves 3x and 3y to be assembled as shown by the imaginary lines in Figs. 5 and 6, thereby forming core section 3 that becomes a closed magnetic circuit.

[0044] In this way, it is possible to obtain the desired coil device 1. As described above, the coil device 1 according to this embodiment uses the two insulator halves 5 and 6 as insulating means, and therefore the entire coil device 1 can be manufactured extremely easily.

[0045] As described above, the insulator unit 4 is formed with bobbin-shaped half portions 24... that are grooved (channel-shaped) in the circumferential direction, and the outer peripheral surface 4f of the insulator unit 4 is provided with the groove-shaped bobbin-shaped portion 7 around which the secondary coil portion 8 can be wound, so that the insulator unit 4 can also be used as a coil bobbin when providing the secondary coil portion 8. As a result, as shown in Fig. 10, by providing the secondary coil portion 8 by winding the secondary coil portion 8 around the bobbin-shaped portion 7, a transformer 10 can be constructed from the coil portion 2 (coil device 1) that constitutes the primary coil portion and the secondary coil portion 8, and the coil component 1 can be provided as one that is highly multifunctional and expandable.

[0046] Therefore, according to the coil component 1 of this embodiment, as a basic configuration, it has a cylindrical insulator unit 4 formed by combining a pair of insulator half portions 5, 6 that can be fitted into the coil portion 2 from the left and right side surfaces, respectively, and the insulator half portions 5, 6 have semi-cylindrical outer insulating portions 5m, 6m that cover the outer peripheral surface 2o of the coil portion 2 and a plurality of inner insulating portions 5s..., 6s... that protrude inward from the inner peripheral surfaces 5mi, 6mi of these outer insulating portions 5m, 6m into the coil portion 2, with their tip portions 5ss..., 6ss... protruding inward from the inner peripheral surface 2i of the coil portion 2 by a length Li, and that contact all of the turn portions T... located in the direction intersecting the axis Ki of the coil portion 2, and are integrally formed from the insulating material D, so that the number of parts can be reduced, thereby reducing costs in terms of parts, and the manufacturing costs can also be reduced by reducing the labor required during assembly. Furthermore, since the number of parts can be reduced (halved), variations between parts in each production lot and variations in assembly during production can be reduced, thereby improving the uniformity and quality of coil components.

[0047] Although the preferred embodiment has been described in detail above, the present invention is not limited to such an embodiment, and the detailed configuration, shape, material, quantity, method, etc. can be changed, added, or deleted as desired within the scope that does not deviate from the gist of the present invention.

[0048] For example, while the core portion 3 is shown as being formed by combining a pair of E-shaped core halves 3x and 3y, it may also be formed by combining an E-shaped first core segment and an I-shaped second core segment. Furthermore, while the coil portion 2 is shown as being wound with a rectangular wire W, this does not preclude the use of other types of conductor wire, such as round wire. The conductive material E and insulating material D are not limited to these examples, and various materials having similar functions (characteristics) can be used. Furthermore, various magnetic materials having similar functions (characteristics) can also be selected for the magnetic material. Furthermore, the outer insulating portions 5m and 6m and the inner insulating portions 5s... and 6s... can be implemented in various shapes, dimensions, configurations, etc., as long as they exhibit similar functions. [Industrial Applicability]

[0049] The coil component according to the present invention can be used as various coil components such as inductors and transformers, which have a coil portion using a conductor wire. [Explanation of symbols]

[0050] 1: coil part, 2: coil part, 2i: inner peripheral surface of coil part, 2o: outer peripheral surface of coil part, 2u: end face of coil part, 2d: end face of coil part, 3: core part, 3i: core surface, 3o: core surface, 3u: core surface, 3d: core surface, 3x: core half part, 3y: core half part, 4: insulator unit, 4f: outer peripheral surface of insulator unit, 5: insulator half part, 5m: outer insulating part, 5mi: inner peripheral surface of outer insulating part, 5s...: inner insulating part ,5ss: Tip of inner insulating part, 6: Half of insulator, 6m: Outer insulating part, 6mi: Inner surface of outer insulating part, 6s...: Inner insulating part, 6ss: Tip of inner insulating part, 7: Bobbin shape part, 8: Secondary coil part, E: Conductive material, D: Insulating material, W: Conductor (flat wire), Ki: Axis center of coil part, T...: Turn part, Li: Length, Lo: Thickness, Lt: Thickness, Lu: Thickness, Ld: Thickness, Ai: Air space, Fd: Radial direction

Claims

1. A coil component comprising a coil portion wound with a conductor made of a conductive material, and a core portion having core surfaces facing the inner peripheral surface, outer peripheral surface, and both end surfaces of the coil portion, characterized in that the coil component comprises a cylindrical insulator unit formed by combining a pair of insulator half portions that can be fitted into the coil portion from the left and right side surfaces, respectively, wherein the insulator half portions have a semi-cylindrical outer insulating portion that covers the outer peripheral surface of the coil portion, and a plurality of inner insulating portions that protrude inward from the inner peripheral surface of this outer insulating portion, at least some of whose tip portions protrude inward from the inner peripheral surface of the coil portion by a predetermined length, and that contact all of the turn portions located in a direction intersecting the axis of the coil portion, and are integrally formed from an insulating material.

2. 2. The coil component according to claim 1, wherein the core portion is formed by combining a pair of core halves formed in an E-shape.

3. The coil component according to claim 1, characterized in that the outer insulating portion is positioned radially outward of the coil portion, and has a thickness that provides insulation between the outer peripheral surface of the coil portion and the core surface facing this outer peripheral surface.

4. 2. The coil component according to claim 1, wherein the inner insulating portion has a predetermined length from the inner circumferential surface of the coil portion to the tip end thereof that protrudes inward, the predetermined length being such that an air space that provides insulation between the inner circumferential surface of the coil portion and the core surface that faces this inner circumferential surface is formed.

5. 2. The coil component according to claim 1, wherein the inner insulating portion has a thickness that insulates the turns of the coil portion from each other.

6. 2. The coil component according to claim 1, wherein the inner insulating portion has a thickness that provides insulation between one end face of the coil portion and the core surface facing the one end face.

7. 2. The coil component according to claim 1, wherein the inner insulating portion has a thickness that provides insulation between the other end face of the coil portion and the core surface facing the other end face.

8. 2. The coil component according to claim 1, wherein the insulator unit has a bobbin-shaped recess formed on its outer circumferential surface, around which the secondary coil can be wound.

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