JP2010003954A - Coil component, and manufacturing method of coil component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil component capable of simplifying a manufacturing process, high in reliability of electrical connection from a coil to a terminal, and preventing resistance from increasing; and a manufacturing method of the same. <P>SOLUTION: Penetration parts 32 and 33 penetrate terminal through-holes 80b and 80g, respectively, and are electrically connected to terminals 81A and 81I, respectively. Penetration parts 62 and 63 penetrate terminal through-holes 80c and 80g, respectively, and are electrically connected to terminals 81B and 81I, respectively. Penetration parts 42 and 43 penetrate terminal through-holes 80e and 80i, respectively, and are electrically connected to terminals 81E and 81H, respectively. Penetration parts 52 and 53 penetrate terminal through-holes 80j and 80f, respectively, and are electrically connected to terminals 81H and 81G, respectively. Penetration parts 72 and 73 penetrate terminal through-holes 80h and 80d, respectively, and are electrically connected to terminals 81C and 81D, respectively. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a coil component and a method for manufacturing the coil component, and in particular, is an inductance component such as a transformer or a choke coil used in a power supply device or the like, including an inductance component including a plurality of coils and a core through which the plurality of coils are inserted. This invention relates to a coil component and a method for manufacturing the coil component.

Inductor parts such as transformers and choke coils are mainly composed of a core and a coil. Based on the mutual electromagnetic induction between the coils, AC voltage is transformed, insulation between the input circuit and the output circuit, etc. Conventionally, it has been known as a coil component which is an electronic component used when performing the above. As such a coil component, for example, a plurality of coils are laminated, the plurality of laminated coils are electrically connected to each other through through holes, and the coils are laminated to each other through through holes. The thing of the structure electrically connected to the land pattern and terminal provided in the one end or the other end in the lamination direction of this coil is known. Such a coil component is described in, for example, Japanese Patent Application Laid-Open No. 2004-6897.
JP 2004-6897 A

  However, as described above, in the configuration in which the coil is electrically connected to the land pattern or the terminal through the through hole, the through hole is formed or a large current is passed through the through hole for use as a transformer. It is necessary to fill the hole with a conductor or to form a plating, which complicates the manufacturing process.

  Further, since the coil and the through hole are electrically connected, the reliability of this electrical connection becomes a problem. In addition, as described above, when filling a through hole with a conductor or forming a plating in order to flow a large current into the through hole for use as a transformer, poor filling of the conductor or poor plating formation occurs. The problem that resistance becomes high arises.

  Therefore, the present invention provides a coil component and a method for manufacturing the coil component that can simplify the manufacturing process, have high electrical connection reliability from the coil to the terminal, and prevent the resistance from increasing. The purpose is to provide.

  In order to achieve the above-mentioned object, the present invention provides a coil main body portion in which a conductor is arranged in a spiral shape so as to form a central space, and a through portion that forms an end portion of the conductor and a portion near the end portion. A plurality of coils that are stacked on each other in a positional relationship in which the central spaces substantially coincide with each other, and coil through holes that are respectively provided between the plurality of coils and through which the through portions of the coils pass. An insulating resin layer having a core through hole formed at a position facing the central space; a core disposed so as to pass through the central space and the core through hole; the plurality of coils and the insulating resin; A case for housing the layer, and the through portion provides a coil component made of the same material as that of the coil main body.

  Since the penetrating portion is made of the same material as that constituting the coil main body portion, the penetrating portion can be configured to penetrate the coil through hole, and a conductor is filled in the through hole or plating is formed. There is no need, and the manufacturing process can be simplified. Further, since it is not necessary to fill the through hole with a conductor or to form a plating, it is possible to prevent the problem that the resistance becomes high when a poor filling of the conductor or a poor plating formation occurs. Further, it is not necessary to electrically connect the coil and the through hole, and the reliability of this electrical connection is not a problem.

  Here, it is preferable that the coil is formed of a flat wire. Since the coil is formed of a flat wire, it is possible to reduce the thickness of the coil component in the stacking direction of the plurality of coils.

  The plurality of coils have a plurality of primary coils and at least one secondary coil, and the plurality of primary coils have a positional relationship with the secondary coil sandwiched in the stacking direction of the plurality of coils. It is preferable.

  The plurality of coils have a plurality of primary coils and at least one secondary coil, and the plurality of primary coils have a positional relationship with the secondary coil sandwiched in the stacking direction of the plurality of coils. The magnetic coupling of the secondary coil can be improved, and the leakage inductance can be reduced.

  The plurality of coils include a primary coil and a secondary coil, and the diameter of the conductor constituting the primary coil is preferably different from the diameter of the conductor constituting the secondary coil. The plurality of coils have a primary coil and a secondary coil, and the diameter of the conductor constituting the primary coil is different from the diameter of the conductor constituting the secondary coil. It is not necessary to change the inner diameter of the through hole in accordance with the conductor of the thick coil main body. On the other hand, the conductor which comprises a penetration part can be made thin like the conductor of a coil main-body part.

  Further, in the plane of the plurality of coil main body portions in which conductors are arranged in a spiral shape in a substantially planar shape, the plurality of coil main body portions each have a substantially point-symmetric shape around the axis of the coil main body portion, In the plane of the plurality of coil main body portions in which conductors are arranged in a spiral shape in a substantially planar shape, the coil main body portion has a symmetrical relationship with respect to a virtual straight line passing through the axis of the coil main body portion. It is preferable that a coil penetration space is formed at a position facing the coil penetration hole of the insulating resin layer on each of the inner side and the outer side.

  In the plane of the plurality of coil body portions in which the conductors are arranged in a spiral shape in a substantially planar shape, the plurality of coil body portions each have a substantially point-symmetric shape about the axis of the coil body portion, and the conductors in a substantially planar shape. In the planes of the plurality of coil body portions arranged in a spiral shape, an insulating resin layer is provided on each of the inner side and the outer side of the coil body portion in a line-symmetrical positional relationship around a virtual straight line passing through the axis of the coil body portion. Since the coil penetration space is formed at a position opposite to the coil penetration hole, by forming the coil penetration hole in the prepreg sheet corresponding to all the penetration parts, all the prepreg sheets have the same shape, Can be used in common regardless of front, back, left or right.

  Moreover, it is preferable to provide the terminal which is arrange | positioned at the end in the lamination direction of this some laminated | stacked coil, and the part of this penetration part which makes the edge part of this coil was each electrically connected.

  Since a plurality of stacked coils are arranged at one end in the stacking direction and each of the through portions forming the ends of the coils is provided with electrically connected terminals, the external terminals can be easily connected together from the one end side. It can be pulled out and can be easily mounted on the board.

  Moreover, it is preferable that this penetration part makes an external terminal. Since the penetration part forms an external terminal, it is not necessary to connect the penetration part to the terminal, the manufacturing process can be facilitated, and the number of members constituting the coil component can be reduced.

  In addition, the present invention provides a coil body portion in which conductors are spirally arranged in a substantially planar shape so that a central space is formed, and extends from the coil body portion in a direction substantially perpendicular to the plane, and ends of the conductors And a plurality of prepreg sheets each having a coil through hole and a core through hole through which the through part of the coil passes, respectively, The coil, so that the through-hole is passed through the coil through-hole, the core through-hole and the central space face each other, and the prepreg sheet is disposed between the plurality of coils. And a step of laminating the prepreg sheet, a terminal block provided with a plurality of terminals at one end in the laminating direction of the laminated coils, and a portion of the penetrating portion forming the end of the coil Each A step of connecting to the terminal in manner, provides a method for manufacturing a coil component having a core arrangement step of arranging the core so as to penetrate the central space and the core holes.

  A coil body portion in which a conductor is arranged in a spiral shape so as to form a central space, and a penetration extending from the coil body portion in a direction substantially perpendicular to the plane and the end portion of the conductor and the vicinity of the end portion. A plurality of coils each having a portion, a step of preparing a plurality of prepreg sheets each having a coil through-hole and a core through-hole through which the through-hole of the coil passes, and a through-hole through the coil A step of laminating the coil and the prepreg sheet so that the core through-hole and the central space face each other and the prepreg sheet is disposed between the plurality of coils, and lamination of the plurality of laminated coils A terminal block provided with a plurality of terminals at one end in the direction, and electrically connecting each of the portions of the through portions forming the ends of the coils to the terminals. It is not necessary or form a plated or filled with a conductor in the Le, it is possible to simplify the manufacturing process. Further, since it is not necessary to fill the through hole with a conductor or to form a plating, it is possible to prevent the problem that the resistance becomes high when a poor filling of the conductor or a poor plating formation occurs. Further, it is not necessary to electrically connect the coil and the through hole, and the reliability of this electrical connection is not a problem.

  Here, it is preferable to perform a step of heat-curing the prepreg sheet before the core placement step or after the core placement step.

  Since the step of heat-curing the prepreg sheet before or after the core arrangement step is performed, the prepreg sheet can be cured to form an insulating resin layer between the coils.

  Moreover, it is preferable to perform the process which heat-hardens this prepreg sheet simultaneously with this core arrangement | positioning process.

  Since the step of heat-curing the prepreg sheet at the same time as the core placement step is performed, the manufacturing process of the coil component can be simplified, and the manufacturing time can be shortened.

  As described above, according to the present invention, the manufacturing process can be simplified, the reliability of the electrical connection from the coil to the terminal is high, and the resistance is prevented from increasing. Can be provided.

  A coil component and a method of manufacturing the coil component according to the embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 1, the coil component 1 is more specifically a planar transformer for a 65 W adapter having a substantially rectangular parallelepiped shape. As shown in FIG. 2, the first primary winding 30, 2 primary winding 60, first secondary winding 40, second secondary winding 50, resin case 21, resin case lid 22, bias winding 70 (drive winding) ), An insulating resin terminal block 80, a prepreg sheet 90, a first magnetic core 11, and a second magnetic core 12. The first primary winding 30, the second primary winding 60, the first secondary winding 40, the second secondary winding 50, and the bias winding 70 correspond to coils, and the first 1 The secondary winding 30 and the second primary winding 60 correspond to the primary coil, and the first secondary winding 40 and the second secondary winding 50 correspond to the secondary coil. The resin case 21 and the resin case lid 22 correspond to a case. The first magnetic core 11 and the second magnetic core 12 correspond to the core.

  Since the first magnetic core 11 and the second magnetic core 12 have the same shape, only the first magnetic core 11 will be described, and the members of the second magnetic core 12 that are the same as the members of the first magnetic core 11 will be described later. The reference numeral “12” is used in place of the reference numeral “11” of each member, and is illustrated. More specifically, the first magnetic core 11 is a conductive ferrite core made of Mn—Zn. The first magnetic core 11 has a flat plate portion 11A (FIG. 2) that has a substantially rectangular plate shape, and extends from the top surface of the flat plate portion 11A over the entire pair of short sides of the substantially rectangular flat plate portion 11A in FIG. The edge protrusion part 11B which protrudes upwards is provided. In addition, a columnar central protruding portion 11C that protrudes upward from FIG. 2 from the upper surface is provided at the center position of the upper surface of the flat plate portion 11A. As shown in FIG. 1, when the coil component 1 is assembled, the protruding end face of the end protruding portion 11B of the first magnetic core 11 and the protruding end of the end protruding portion 12B of the second magnetic core 12 shown in FIGS. The end surfaces are in contact with each other so that the protruding end surface of the central protruding portion 11C of the first magnetic core 11 and the protruding end surface of the central protruding portion 11C of the second magnetic core 12 are in contact with each other.

  As shown in FIG. 2, the resin case 21 has a resin case plate-like portion 21A having a substantially rectangular plate shape having a circular portion 21B swelled in a circular shape at the center thereof. In the center of the circular portion 21B, a circular resin case through-hole 21a that opens coaxially with the circular portion 21B is formed. Resin that protrudes upward in FIG. 2 from the upper surface of the resin case plate portion 21A over the entire periphery of the opening, on the upper surface of the resin case plate portion 21A and around the opening of the resin case through hole 21a. A case opening wall 21C is provided. Further, at the periphery of the circular portion 21B and the periphery of the resin case plate-like portion 21A, resin case edge walls 21D projecting upward from FIG. 2 from the upper surfaces of the circular portion 21B and the resin case plate-like portion 21A, respectively. Is provided. The upper end of the resin case edge wall 21D forms an opening.

  Each of the first primary winding 30, the second primary winding 60, the first secondary winding 40, the second secondary winding 50, and the bias winding 70 is formed by punching a copper plate as a conductor. Thus, the cross section is a spiral shape made of a rectangular wire having a substantially rectangular shape. Since it is constituted by a flat wire in this manner, the first primary winding 30, the second primary winding 60, the first secondary winding 40, the second secondary winding 50, the bias winding It is possible to reduce the thickness of the coil component 1 in the stacking direction of the wires 70.

  As shown in FIG. 3, the spirals of the first primary winding 30, the first secondary winding 40, the second secondary winding 50, the second primary winding 60, and the bias winding 70 The portions forming a shape constitute coil body portions 31, 41, 51, 61, 71, respectively, and further from the coil body portions 31, 41, 51, 61, 71 arranged in a substantially spiral shape, respectively. Through portions 32, 33, 42, 43, 52, 53, 62, 63, 72, 73 extending in a direction perpendicular to the plane are provided.

  The through portions 32 and 33 and the coil main body 31 are integrally formed of the same material, and the through portions 42 and 43 and the coil main body 41 are integrally formed of the same material, and the through portion 52, 53 and the coil main body 51 are integrally formed of the same material, and the through portions 62 and 63 and the coil main body 61 are integrally formed of the same material. The through portions 72 and 73 and the coil main body are integrally formed. The unit 71 is integrally formed of the same material. The through portions 32, 33, 42, 43, 52, 53, 62, 63, 72, and 73 are the ends and end portions of the flat wire bent with respect to the coil body portions 31, 41, 51, 61, and 71, respectively. It is comprised by the vicinity part. The through portions 32, 33, 42, 43, 52, 53, 62, 63, 72, and 73 can pass through the coil through hole 90a of the prepreg sheet 90 as described later, and the first primary as described later. Insulating resin terminal block in the stacking direction in which the winding 30, the first secondary winding 40, the second secondary winding 50, the second primary winding 60, the bias winding 70, and the prepreg sheet 90 are stacked It is arranged at a position facing 80 terminal through holes 80b to 80j (FIG. 2), and extends in the direction of one end in the stacking direction as the direction of the insulating resin terminal block 80, that is, upward in FIG.

  More specifically, the coil body 31 of the first primary winding 30, the first secondary winding 40, the second secondary winding 50, the second primary winding 60, and the bias winding 70. , 41, 51, 61, 71 each have a spiral shape that is substantially similar to the resin case plate portion 21A (FIG. 2) of the resin case 21 in plan view, and the resin case plate portion 21A. It can be accommodated in the resin case plate-like portion 21A.

  As shown in FIG. 3, in the plan view, the first primary winding 30, the first secondary winding 40, the second secondary winding 50, the second primary winding 60, the bias winding In the central position inside the coil main body 31, 41, 51, 61, 71 of the wire 70, the circular central spaces 30a, 40a, 50a, 60a, 70a and the diameter direction of the central spaces 30a, 40a, 50a, 60a, 70a A pair of rectangular coil penetration spaces 30b, 40b, 50b, 60b, and 70b are formed respectively.

  As shown in FIG. 6, the coil penetration space 30 b is an axis of the first primary winding 30 positioned at the center of the central space 30 a in the plane of the coil main body portion 31 arranged in a substantially spiral shape. The resin case plate-like portion 21A (FIG. 2) passes through the center C and is arranged in a line-symmetrical positional relationship around a virtual straight line A that is perpendicular to the longitudinal direction. And the coil penetration space 30c is formed also in the outer side of the edge part of the left-right direction of FIG. 6 which is the longitudinal direction of the coil main-body part 31 of the 1st primary winding 30 by the same line symmetrical positional relationship. Similarly, the first secondary winding 40, the second secondary winding 50, the second primary winding 60, and the bias winding 70 have a line-symmetric shape, and the coil penetration spaces 40b, 50b, 60b, 70b and coil penetration space 30c, 40c, 50c, 60c, 70c are formed.

  The first primary winding 30, the first secondary winding 40, the second secondary winding 50, the second primary winding 60, and the bias winding 70 are all in plan view. As shown in FIG. As shown in FIG. 2 and the like, the first primary winding 30, the first secondary winding 40, the second secondary winding 50, the second primary winding 60, and the bias winding 70 are In this order, the central spaces 30a, 40a, 50a, 60a, 70a, the coil penetration spaces 30b, 40b, 50b, 60b, 70b, the coil penetration spaces 30c, 40c, 50c, 60c, The layers 70c are stacked with each other in a substantially coincident positional relationship.

  Because of this symmetrical shape, coil through-holes 90a are formed in the prepreg sheet 90 to be described later in advance corresponding to all the through portions 32, 33, 42, 43, 52, 53, 62, 63, 72, 73. By placing the plurality of prepreg sheets 90 in the same shape, they can be used in common with no distinction between the front, back, left and right. Further, in this way, the first primary winding 30 and the second primary winding 60 form a positional relationship in which the first secondary winding 40 and the second secondary winding 50 are sandwiched in the stacking direction. Therefore, the magnetic coupling between the primary windings 30 and 60 and the secondary windings 40 and 50 can be improved, and the leakage inductance can be reduced.

  The dimensions of the cross section of the flat wire of the first primary winding 30 and the second primary winding 60 are about 0.1 mm in length and about 0.3 mm in width, and the first secondary winding 40 and second The cross-sectional dimensions of the flat wire of the secondary winding 50 are about 0.2 mm long and about 1.0 mm wide, and the cross-sectional dimensions of the flat wire of the bias winding 70 are 0.1 mm long and 0.3 mm wide. Degree. That is, a larger current can flow through the first secondary winding 40 and the second secondary winding 50 than through the first primary winding 30 and the second primary winding 60. More specifically, a power of 65 W at 240 V is applied to the first primary winding 30 and the second primary winding 60, and the first secondary winding 40 and the second primary winding 60 are applied. The secondary winding 50 is applied with a power of 65 W at 20V.

  Since the diameter of the flat wire is made different in this way, it is not necessary to change the inner diameter of the through hole in accordance with the diameter of the flat wire constituting the coil as in the prior art. In contrast to the flat wire of the coil body portions 41, 51, the flat wire constituting the through portions 42, 43, 52, 53 becomes thicker than the flat wire of the thin coil body portions 31, 61, 71. The rectangular wires constituting the through portions 32, 33, 62, 63, 72, and 73 can be made thin like the rectangular wires of the coil body portions 31, 61, 71.

  The through portions 32, 33, 42, 43, 52, 53, 62, 63, 72, and 73 pass through coil through holes 90 a of the prepreg sheet 90 described later, respectively, and terminals 81 </ b> A to 81 </ b> H of the insulating resin terminal block 80. Since the coil body portions 31, 41, 51, 61, 71 are integrally formed of the same material, the through portions 32, 33, 42, 43, 52, 53, 62, 63, 72 and 73 can be configured to penetrate the coil through hole 90a, and it is not necessary to fill the through hole with a conductor or to form a plating as in the prior art, and the manufacturing process can be simplified. . Further, since it is not necessary to fill the through hole with a conductor or to form a plating, it is possible to prevent the problem that the resistance becomes high when a poor filling of the conductor or a poor plating formation occurs. Further, it is not necessary to electrically connect the coil and the through hole, and the reliability of this electrical connection is not a problem.

  The prepreg sheet 90 has a substantially similar shape to the resin case plate portion 21A of the resin case 21, and is slightly smaller than the resin case plate portion 21A. The prepreg sheet 90 is formed by impregnating a thermosetting resin into a cloth-like sheet in which fibers are knitted. As shown in FIG. The coil through-hole 90a which is four through-holes is formed along, and the circular core through-hole 90b slightly larger than the resin case through-hole 21a is formed in the center position of the longitudinal direction. Two coil through-holes 90a, each of which is a through-hole, are formed at positions in the vicinity of the core through-hole 90b and in the diameter direction of the core through-hole 90b that coincides with the longitudinal direction of the prepreg sheet 90. The prepreg sheet 90 has a point-symmetric shape with the center of the core through hole 90b as the center.

  As shown in FIG. 2 or FIG. 3, the prepreg sheet 90 includes three sheets between the first primary winding 30 and the first secondary winding 40, and the first secondary winding 40 and the first secondary winding 40. 2 between the two secondary windings 50, three between the second secondary winding 50 and the second primary winding 60, the second primary winding 60 and the bias winding. Two sheets are provided between the bias winding 70 and an insulating resin terminal block 80, which will be described later. Since these prepreg sheets 90 are heated and cured during the manufacturing process of the coil component 1 as will be described later, the coil component 1 forms a cured insulating resin layer.

  As shown in FIG. 2, the insulating resin terminal block 80 includes a terminal block plate-shaped portion 80 </ b> A that forms a substantially rectangular plate shape having a circular portion 80 </ b> B that swells in a circular shape at the center thereof. In the center of the circular portion 80B, a circular terminal block core through hole 80a that opens coaxially with the circular portion 80B is formed. Three through-holes and two terminal through-holes 80b, 80c, 80d, 80e, and 80f are formed in the vicinity of both end edges in the longitudinal direction of the terminal block plate-like portion 80A. In addition, a circular terminal block core through hole 80a slightly larger than the resin case through hole 21a is formed at the center position in the longitudinal direction. Further, two terminal penetrations, each of which is a through-hole, are provided at positions near the terminal block core through-hole 80a and approximately in the diameter direction of the terminal block core through-hole 80a that coincides with the longitudinal direction of the terminal block plate-like portion 80A. Holes 80g, 80h, 80i, and 80j are formed.

  The terminal through holes 80b, 80c, 80h, 80d, 80e, and 80f are provided with terminals 81A, 81B, 81C, 81D, 81E, and 81G that extend outward in the longitudinal direction of the insulating resin terminal block 80, respectively. The tip portions of these terminals 81A, 81B, 81C, 81D, 81E, 81G are bent in a step shape. The terminal through holes 80i and 80j are electrically connected by a terminal 81H, and the terminal 81H extends outward in the longitudinal direction of the insulating resin terminal block 80. And the front-end | tip part of the terminal 81H is bent in steps, and comprises the terminal 81F. A terminal 81I is provided in the terminal through hole 80g.

  The portions of the through portions 32 and 33 that are the ends of the flat wire constituting the first primary winding 30 penetrate the terminal through holes 80b and 80g, respectively, and are soldered to the terminals 81A and 81I, respectively. Electrically connected. The portions of the through portions 62 and 63, which are the ends of the flat wire constituting the second primary winding 60, penetrate the terminal through holes 80c and 80g, respectively, and are soldered to the terminals 81B and 81I, respectively. Electrically connected. The portions of the through portions 42 and 43, which are the ends of the flat wire constituting the first secondary winding 40, penetrate the terminal through holes 80e and 80i, respectively, and are soldered to the terminals 81E and 81H, respectively. Electrically connected. The portions of the through portions 52 and 53, which are the ends of the flat wire constituting the second secondary winding 50, pass through the terminal through holes 80j and 80f, respectively, and are soldered to the terminals 81H and 81G, respectively. Electrically connected. The portions of the through portions 72 and 73, which are the ends of the flat wire constituting the bias winding 70, pass through the terminal through holes 80h and 80d, respectively, and are electrically connected to the terminals 81C and 81D, respectively, by soldering. Has been.

  Since such an insulating resin terminal block 80 is provided, the first primary winding 30, the second primary winding 60, the first secondary winding 40, the second secondary winding 50, the bias winding are provided. The terminals 81A, 81B, 81C, 81D, 81E, and 81G can be easily pulled out as external terminals collectively from one end side in the stacking direction of the wires 70, and board mounting can be facilitated.

  The resin case lid 22 has an outer shape substantially similar to that of the prepreg sheet 90, slightly larger than the prepreg sheet 90, and has a substantially plate shape. The prepreg sheet 90, the first primary winding 30, the second primary winding 60, the first secondary winding 40, the second secondary winding 50, and the bias winding 70 are in the resin case 21. When the resin case lid 22 is disposed in the opening at the upper end of the resin case edge wall 21D in the state of being housed in the housing, the opening is closed. In the coil component 1 having the above-described configuration, the first magnetic core 11 or a part of the second magnetic core 12 is inserted into a through-hole formed in a mounting board (not shown), whereby the terminals 81A and 81B are bent in a step shape. , 81C, 81D, 81E, 81G are configured to face and electrically connect to a conductive pattern of a mounting substrate (not shown).

  In the coil component manufacturing method, first, a step of preparing a plurality of coils is performed. In the step of preparing a plurality of coils, a rectangular wire, which is a copper wire in a substantially flat shape, is spirally arranged so that a central space 30a, 40a, 50a, 60a, 70a is formed in the center by punching a copper plate. The coil body portions 31, 41, 51, 61, 71 are formed and bent from the coil body portions 31, 41, 51, 61, 71 upward in FIG. 2, which is a direction substantially perpendicular to the plane. Through holes 32, 33, 42, 43, 52, 53, 62, 63, 72, 73, which are formed by the ends of the extended rectangular wires, are formed. By this step, the first primary winding 30, the first secondary winding 40, the second secondary winding 50, the second primary winding 60, and the bias winding 70 are manufactured.

  Next, a step of preparing a plurality of prepreg sheets 90 is performed. In the step of preparing the prepreg sheet 90, the coil through-hole 90a and the core through-hole 90b are formed in a prepreg sheet material configured by impregnating a cloth-like sheet woven with fibers with a thermosetting resin. Through this process, 13 prepreg sheets 90 having the same shape are manufactured.

  Next, a step of laminating the coil and the prepreg sheet 90 is performed. In the step of laminating the coil and the prepreg sheet 90, as shown in FIG. 2 and the like, the first primary winding 30, the three prepreg sheets 90, the first secondary winding 40, and the two prepregs The sheet 90, the second secondary winding 50, the three prepreg sheets 90, the second primary winding 60, the two prepreg sheets 90, the bias winding 70, and the three prepreg sheets 90 are shown in this order. From the bottom to the top, the central spaces 30a, 40a, 50a, 60a, 70a and the core through holes 90b are opposed to each other so as to have a substantially coincident positional relationship. During lamination, the first primary winding 30, the first secondary winding 40, the second secondary winding 50, the second primary winding 60, and the through portion 32 of the bias winding 70 are used. , 33, 42, 43, 52, 53, 62, 63, 72, and 73 are passed through the coil through-hole 90a from the bottom to the top of the figure.

  Next, the insulating resin terminal block 80 is disposed opposite to the upper end of FIG. 2 which is one end in the stacking direction of the laminate formed by stacking the coil and the prepreg sheet 90, and the penetrating portion 32 of the first primary winding 30, 33 is passed through the terminal through holes 80b and 80g, the through parts 42 and 43 of the first secondary winding 40 are passed through the terminal through holes 80e and 80i, and the through parts 52 of the second secondary winding 50 are 53 is passed through the terminal through holes 80j and 80f, the through parts 62 and 63 of the second primary winding 60 are passed through the terminal through holes 80c and 80g, and the through parts 72 and 73 of the bias winding 70 are passed through the terminals. The holes 80h and 80d are penetrated. Then, the through portions 32 and 33 are electrically connected to the terminals 81A and 81I by soldering, and the through portions 42 and 43 are electrically connected to the terminals 81E and 81H by soldering, respectively. 52 and 53 are electrically connected to terminals 81H and 81G by soldering, and through portions 62 and 63 are electrically connected to terminals 81B and 81I by soldering. The portion is electrically connected to the terminals 81C and 81D by soldering.

  Next, the resin case opening wall 21 </ b> C of the resin case 21 is formed with the first primary winding 30, the first secondary winding 40, the second secondary winding 50, and the second primary winding. 60, the first primary winding 30 in the resin case 21 so as to penetrate through the central spaces 30a, 40a, 50a, 60a, 70a of the bias winding 70 and the core through hole 90b of the prepreg sheet 90. A laminated body formed by laminating a first secondary winding 40, a second secondary winding 50, a second primary winding 60, a bias winding 70, and a prepreg sheet 90, and a resin case The lid 22 closes the opening at the upper end of the resin case edge wall 21D.

  Next, a core arrangement process is performed. In the core arrangement step, the central protrusion 11C of the first magnetic core 11 and the second magnetic core 12 is formed by using the first primary winding 30, the first secondary winding 40, the second secondary winding 50, the second The central spaces 30a, 40a, 50a, 60a, 70a of the primary winding 60 and the bias winding 70, the core through hole 90b of the prepreg sheet 90, and the resin case edge wall 21D inside the resin case 21 are provided. The protruding end surfaces of the central protruding portions 11C of the first magnetic core 11 and the second magnetic core 12 are adhered to each other with an adhesive, and the edge protruding portions 11B and 11B of the first magnetic core 11 and the second magnetic core 12 are bonded. The protruding end surfaces are bonded to each other with a thermosetting adhesive. Then, by heating the laminate and the first magnetic core 11 and the second magnetic core 12, the adhesive that bonds the first magnetic core 11 and the second magnetic core 12 and the thermosetting resin in the prepreg are cured, While fixing the 1st magnetic core 11 and the 2nd magnetic core 12 to a laminated body, the insulating resin layer by which the prepreg sheet | seat 90 is solidified is formed. The above is the core placement process.

  Coil body parts 31, 41, 51, 61, 71 and coil body parts 31, 41, in which flat wires are spirally arranged in a substantially flat shape so that the central spaces 30a, 40a, 50a, 60a, 70a are formed. , 51, 61, 71 extending in a direction substantially perpendicular to the plane, penetrating portions 32, 33, 42, 43, 52, 53, 62, 63, 72, 73 consisting of the ends of the flat wire and the vicinity thereof. A first primary winding 30, a first secondary winding 40, a second secondary winding 50, a second primary winding 60, and a bias winding 70 are prepared as a plurality of coils each having A plurality of coil through-holes 90a and core through-holes 90b through which the through portions 32, 33, 42, 43, 52, 53, 62, 63, 72, 73 of the plurality of coils respectively penetrate. Prepare prepreg sheet 90 The process, the through portions 32, 33, 42, 43, 52, 53, 62, 63, 72, 73 are passed through the coil through hole 90a, the core through hole 90b and the central spaces 30a, 40a, 50a, 60a, 70a The coil and the prepreg sheet 90 are stacked so that the prepreg sheet 90 is disposed between the plurality of coils, and a plurality of terminals at one end in the stacking direction of the stacked coils The insulating resin terminal block 80 provided with 81A to 81G is arranged, and the portions of the through portions 32, 33, 42, 43, 52, 53, 62, 63, 72, 73 forming the end portions of the coils are electrically connected. And the step of connecting to the terminals 81A to 81G, it is not necessary to fill the through hole with a conductor or to form a plating as in the prior art, thus simplifying the manufacturing process. It can be. Further, since it is not necessary to fill the through hole with a conductor or to form a plating, it is possible to prevent the problem that the resistance becomes high when a poor filling of the conductor or a poor plating formation occurs. Further, it is not necessary to electrically connect the coil and the through hole, and the reliability of this electrical connection is not a problem.

  Moreover, since the process of heat-curing the prepreg sheet 90 is performed simultaneously with the core arrangement process, the manufacturing process of the coil component 1 can be simplified, and the manufacturing time can be shortened.

  The coil component and the method for manufacturing the coil component of the present invention are not limited to the above-described embodiments, and various modifications and improvements can be made within the scope described in the claims. For example, although the insulating resin terminal block 80 is provided in the coil component 1 in the present embodiment, such an insulating resin terminal block 80 may not be provided. In this case, the penetrating portions 32, 33, 42, 43, 52, 53, 62, 63, 72, and 73 are configured to be longer, and the penetrating portions 32, 33, 42, 43, and the end portions of the flat wire are formed. The portions 52, 53, 62, 63, 72, and 73 may constitute the external terminals as they are. By doing in this way, it is not necessary to connect penetration parts 32, 33, 42, 43, 52, 53, 62, 63, 72, and 73 to terminals 81A-81G like this embodiment. The manufacturing process can be facilitated, and the number of members constituting the coil component 1 can be reduced.

  Moreover, in the core arrangement step, the adhesive and the thermosetting resin in the prepreg were cured by heating the laminated body and the first magnetic core 11 and the second magnetic core 12, but the method is not limited to this. The prepreg sheet 90 may be cured by heating after fixing the first magnetic core 11 and the second magnetic core 12 to the laminate using an adhesive that cures at room temperature instead of a thermosetting adhesive, or the prepreg After the sheet 90 is heated and cured, the first magnetic core 11 and the second magnetic core 12 may be fixed to the laminate using an adhesive. By doing in this way, the prepreg sheet 90 can be hardened and the insulating resin layer between coils can be comprised.

  In addition, the positional relationship in which the first secondary winding 40 and the second secondary winding 50 are sandwiched between the first primary winding 30 and the second primary winding 60 in the stacking direction of the stacked body. However, it may be configured so as not to be sandwiched in this way, and the primary winding may not be configured by the two coils of the first primary winding 30 and the second primary winding 60. Also good.

  The ends of the rectangular wires constituting the first primary winding 30, the second primary winding 60, the first secondary winding 40, the second secondary winding 50, and the bias winding 70 The through portions 32, 33, 42, 43, 52, 53, 62, 63, 72, 73 made of are electrically connected to the terminal through holes 80 b to 80 j by soldering. For example, ultrasonic welding or laser welding may be used.

  In addition, the core portion of the first primary winding 30, the second primary winding 60, the first secondary winding 40, the second secondary winding 50, and the bias winding 70 is made of a copper plate. Although it was comprised by extracting, it is not limited to this, For example, you may comprise by etching a copper plate, and you may comprise by winding the wire which consists of conductors. When the wire is wound in this way, the wire may be provided with an insulating coating.

  Moreover, although the 1st magnetic core 11 and the 2nd magnetic core 12 were comprised by the electroconductive ferrite core which consists of Mn-Zn, it is not limited to this. For example, it may be composed of a conductive core such as a metal dust core or a Ni-based ferrite core.

  The coil component of the present invention is particularly useful in the field of inductance components such as transformers and choke coils used in power supply devices.

The perspective view which shows the coil components by embodiment of this invention. The disassembled perspective view which shows the coil components by embodiment of this invention. The disassembled perspective view which shows the coil components by embodiment of this invention. The disassembled front view which shows the coil components by embodiment of this invention. The disassembled side view which shows the coil components by embodiment of this invention. The top view which shows the 1st primary winding of the coil components by embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coil component 11 1st magnetic core 12 2nd magnetic core 30 1st primary winding 30a, 40a, 50a, 60a, 70a Central space 30b, 30c, 40b, 40c, 50b, 50c, 60b, 60c, 70b, 70c Coil Through space 31, 41, 51, 61, 71 Coil main body 32, 33, 42, 43, 52, 53, 62, 63, 72, 73 Through part 40 First secondary winding 50 Second secondary winding Line 60 Second primary winding 70 Bias winding 80A, 80B, 80C, 80D, 80E, 80F, 80G, 80H, 80I Terminal 90 Pre-preg sheet 90a Coil through-hole A Virtual straight line C Axis center

Claims (10)

Each has a coil body portion in which conductors are spirally arranged in a substantially planar shape so that a central space is formed, and a through portion that forms an end portion of the conductor and a portion near the end portion, and the central space is substantially A plurality of coils stacked on each other in a matching positional relationship;
An insulating resin layer provided between each of the plurality of coils, and having a coil through hole through which the through portion of the coil passes and a core through hole formed at a position facing the central space;
A core disposed so as to penetrate the central space and the core through hole;
A case for accommodating the plurality of coils and the insulating resin layer,
The penetration part is made of the same material as that constituting the coil main body, and the coil component is characterized in that   The coil component according to claim 1, wherein the coil is made of a flat wire.   The plurality of coils have a plurality of primary coils and at least one secondary coil, and the plurality of primary coils have a positional relationship sandwiching the secondary coils in the stacking direction of the plurality of coils. The coil component according to claim 1, wherein the coil component is characterized by the following.   The plurality of coils have a primary coil and a secondary coil, and a diameter of the conductor constituting the primary coil is different from a diameter of the conductor constituting the secondary coil. The coil component according to claim 1 or 2. In the plane of the plurality of coil main body portions in which conductors are arranged in a spiral shape in a substantially planar shape, the plurality of coil main body portions each have a substantially point-symmetric shape about the axis of the coil main body portion,
In the plane of the plurality of coil main body portions in which conductors are arranged in a spiral shape in a substantially planar shape, the coil main body portion has a symmetrical relationship with respect to a virtual straight line passing through the axis of the coil main body portion. The coil component according to any one of claims 1 to 4, wherein a coil penetration space is formed at a position facing the coil penetration hole of the insulating resin layer on each of the inner side and the outer side.   2. The device according to claim 1, further comprising: a terminal that is disposed at one end in the stacking direction of the plurality of stacked coils, and each of the through portions forming the ends of the coils are electrically connected to each other. The coil component according to any one of 5.   The coil component according to any one of claims 1 to 5, wherein the through portion forms an external terminal. A coil main body portion in which conductors are arranged in a spiral shape so as to form a central space, and an end portion of the conductor and a portion near the end portion extending from the coil main body portion in a direction substantially perpendicular to the plane. Preparing a plurality of coils each having a through portion made of
Preparing a plurality of prepreg sheets each having a coil through hole and a core through hole through which the through part of the coil passes, and
The coil and the prepreg sheet are passed through the coil through hole so that the core through hole and the central space face each other and the prepreg sheet is disposed between the plurality of coils. Laminating steps;
A step of disposing a terminal block provided with a plurality of terminals at one end in the stacking direction of the plurality of stacked coils, and electrically connecting portions of the through portions forming the ends of the coils to the terminals; ,
And a core arranging step of arranging the core so as to penetrate the central space and the core through hole.   9. The method of manufacturing a coil component according to claim 8, wherein a step of heat-curing the prepreg sheet is performed before the core arranging step or after the core arranging step.   9. The method of manufacturing a coil component according to claim 8, wherein a step of heat-curing the prepreg sheet is performed simultaneously with the core placement step.

Images