JP2015177166A - Coil device, and manufacturing method of coil device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil device including a coil capable of easily forming a coil electrode spirally wound around a coil core.SOLUTION: A coil device 1 includes a coil 4 in which a coil core 2 is disposed inside of a wiring member 5 formed by circumferentially arraying a plurality of linear wiring electrodes 6 extending from a lower edge of an outer peripheral surface 5b through a top face 5a to a lower edge of an inner peripheral surface 5c on an outer surface, and a coil electrode 3 is formed by connecting via a connection member one end of one wiring electrode 6 on the outer surface of the wiring member 5 with another end of a wiring electrode 6 neighboring to one side of the one wiring electrode 6, respectively. Therefore, by positioning the wiring electrodes 6 on the outer surface of the wiring member 5, there is no risk of dislocating the wiring electrodes 6, and by connecting end portions of corresponding wiring electrodes 6 with each other via the connection member, the coil electrode 3 can be easily formed which is spirally wound around the coil core 2.

Description

  The present invention relates to a coil device including a coil having an annular coil core and a coil electrode spirally wound around the coil core, and a manufacturing method thereof.

  Conventionally, for example, as shown in FIGS. 22A to 22C, a coil 500 apparatus including a coil 501 formed by spirally winding a coil pattern 503 (coil electrode) around an annular coil core 502. Is manufactured. That is, first, a resin sheet 505 is prepared in which a plurality of line-shaped wiring electrodes 504 formed of metal foil are arranged in parallel on the surface. In addition, a cut 506 is formed between each wiring electrode 504 of the resin sheet 505 from the both end edges in the longitudinal direction of the wiring electrode 504 toward the center. In addition, as shown to the same figure (a), the both ends of the wiring electrode 504 are extended outside the both ends edge of the resin sheet 504, and are formed.

  Next, as shown in FIG. 22A, the resin sheet 505 rolled with the wiring electrode 504 inside is inserted into the inner hole of the coil core 502. At this time, the portion of the resin sheet 505 where the notch 506 is formed is disposed so as to protrude from the upper and lower surfaces of the coil core 502. Subsequently, as shown in FIG. 5B, the portion of the resin sheet 505 where the notch 506 is formed is expanded outward and bent, whereby wiring is provided between the inner peripheral surface, the upper surface, and the lower surface of the coil core 502. An electrode 504 is disposed.

  Subsequently, as shown in FIG. 22B, a resin sheet 508 is prepared in which a plurality of line-shaped wiring electrodes 507 formed of metal foil are arranged in parallel on the surface thereof. Further, one end of one wiring electrode 504 on the resin sheet 505 and other wiring electrode 504 adjacent to one side of the wiring electrode 504 (in the counterclockwise direction in the example shown in FIGS. 5B and 5C). Each wiring electrode 507 is disposed so as to be inclined counterclockwise with respect to the direction orthogonal to the longitudinal direction of the resin sheet 508 so that the ends are connected. Further, connection holes 509 through which both ends of each wiring electrode 504 are inserted when the resin sheet 508 is wound around the outer peripheral surface of the coil core 502 are formed at both end positions of each wiring electrode 507 of the resin sheet 508. Yes.

  Then, the resin sheet 508 is wound around the outer peripheral surface of the coil core 502 with each wiring electrode 507 facing outside, whereby both ends of each wiring electrode 504 are inserted into each connection hole 509, and both ends of each wiring electrode 504 are inserted. Each is connected to the end of the wiring electrode 507 by soldering or spot welding. Therefore, one end of one wiring electrode 504 on the resin sheet 505 and the other end of the wiring electrode 504 adjacent to one side of the wiring electrode 504 are connected by a plurality of wiring electrodes 507 on the resin sheet 508, respectively. As a result, a coil pattern 503 that spirally winds around the coil core 502 is formed. FIG. 22 is a diagram showing an example of a conventional method of manufacturing a coil device, and (a) to (c) are diagrams showing different processes.

Japanese Patent Application Laid-Open No. 61-237407 (see page 2, upper right column to page 2, lower right column, FIGS. 1 to 4)

  In the coil device 500 described above, as shown in FIG. 22B, when the both sides of the resin sheet 505 inserted through the inner hole of the coil core 502 are bent outward, the notch 506 is expanded. It is difficult to make the angle constant. That is, it is necessary to bend the wiring electrodes 504 of the resin sheet 505 one by one along the curved inner hole of the coil core 502, and if the wiring electrode 504 of the resin sheet 505 is bent slightly deviated from the bending state of the inner hole, There was a problem of easy displacement. Therefore, each wiring electrode 507 on the resin sheet 508 that is wound around the outer peripheral surface of the coil core 502, and each wiring electrode 504 on the resin sheet 505 that is disposed on the inner peripheral surface, the upper surface, and the lower surface of the coil core 502. Therefore, there is a problem that it is difficult to form the coil pattern 503 that spirally winds around the coil core 502.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a coil device including a coil that can easily form a coil electrode that spirally winds around a coil core, and a manufacturing method thereof. To do.

  In order to achieve the first object described above, a coil device according to the present invention is a coil device including a coil having an annular coil core and a coil electrode spirally wound around the coil core. And a wiring member having an upper surface, an outer peripheral surface, and an inner peripheral surface that are substantially the same in shape as the annular upper surface, outer peripheral surface, and inner peripheral surface of the coil core, and the coil core is disposed inside the coil core, The electrodes extend from the lower end edge of the outer peripheral surface of the wiring member to the lower end edge of the inner peripheral surface through the upper surface, and are arranged in the circumferential direction on the outer surface of the wiring member, and a plurality of line-shaped wiring electrodes, And a plurality of connection members formed to connect one end of the one wiring electrode and the other end of the wiring electrode adjacent to one side of the wiring electrode.

  In the invention configured as described above, the coil core is formed on the inner side of the wiring member that is formed of the insulating member and has the upper surface, the outer peripheral surface, and the inner peripheral surface that are substantially the same shape as the annular upper surface, outer peripheral surface, and inner peripheral surface of the coil core. Be placed. A plurality of line-shaped wiring electrodes extending from the lower end edge of the outer peripheral surface to the lower end edge of the inner peripheral surface are arranged on the outer surface of the wiring member in the circumferential direction. Further, one end of one wiring electrode on the outer surface of the wiring member and the other end of the wiring electrode adjacent to one side of the wiring electrode are connected by a connecting member to form a coil electrode.

  Therefore, if each wiring electrode is positioned on the outer surface of the wiring member, there is no possibility that each wiring electrode is displaced, and the ends of the corresponding wiring electrodes are easily connected by the connecting member to form the coil electrode. can do. Therefore, it is possible to provide a coil device including a coil that can easily form a coil electrode that spirally winds around the coil core.

  The coil device manufacturing method of the present invention is formed by an insulating member in a coil device manufacturing method including a coil having an annular coil core and a coil electrode spirally wound around the coil core. The coil core has an upper surface, an outer peripheral surface, and an inner peripheral surface having substantially the same shape as the annular upper surface, the outer peripheral surface, and the inner peripheral surface, respectively, and the lower end edge of the inner peripheral surface passes through the upper surface from the lower end edge of the outer peripheral surface to the outer surface Between the outer peripheral surface and the inner peripheral surface of the wiring member, and a preparation step of preparing a wiring member in which a plurality of line-shaped wiring electrodes extending in the circumferential direction are arranged in the circumferential direction and the coil core is disposed inside thereof A connecting step of forming the coil electrode by connecting the one end of the one wiring electrode and the other end of the wiring electrode adjacent to one side of the wiring electrode by a connecting member. It is characterized in that it comprises and.

  The invention configured as described above has an upper surface, an outer peripheral surface, and an inner peripheral surface that are formed of an insulating member and have substantially the same shape as the annular upper surface, outer peripheral surface, and inner peripheral surface of the coil core, and the outer surface has an outer periphery on the outer surface. A wiring member is prepared in which a plurality of line-like wiring electrodes extending from the lower end edge of the surface to the lower end edge of the inner peripheral surface through the upper surface are arranged in the circumferential direction. Further, a coil core is disposed between the outer peripheral surface and the inner peripheral surface of the wiring member, and one end of one wiring electrode on the outer surface of the wiring member and the other end of the wiring electrode adjacent to one side of the wiring electrode However, each is connected by a connecting member to form a coil electrode.

  Therefore, if each wiring electrode is positioned on the outer surface of a wiring member, there will be no possibility that each wiring electrode will shift, and the end portions of the corresponding wiring electrode can be easily connected by the connecting member. Therefore, a coil device including a coil having a coil electrode that spirally winds around the coil core can be easily manufactured.

  A plurality of cuts extending in the orthogonal direction in the circumferential direction from the lower end edge of the outer peripheral surface of the wiring member to the inner end edge of the upper surface may be arranged in the circumferential direction.

  Further, for example, the wiring member is a long insulating member having a substantially C-shaped cross section with an open lower surface, and a plurality of cuts are arranged in the longitudinal direction in a direction orthogonal to the longitudinal direction upward from the lower end on one side. After being formed, the insulating member may be formed by being rounded in an annular shape with the notches arranged on the outside.

  If it does in this way, a wiring member can be formed easily.

  A plurality of outer cuts extending in a direction orthogonal to the circumferential direction from the lower edge of the outer peripheral surface of the wiring member to the outer edge of the upper surface are arranged in the circumferential direction, and the lower edge of the inner peripheral surface of the wiring member A plurality of inner cuts extending in the orthogonal direction in the circumferential direction from the inner edge of the upper surface to the inner edge of the upper surface may be arranged in the circumferential direction.

  In addition, for example, the wiring member is integrated with an annular portion, a plurality of outer tongue pieces integrally formed at an outer end edge of the annular portion at predetermined intervals, and an inner end edge of the annular portion at predetermined intervals. The insulating member having a plurality of formed inner tongue pieces may be formed by bending the outer tongue pieces and the inner tongue pieces downward.

  The connecting member may be formed by a line-shaped wiring electrode pattern formed on the insulating substrate.

  If it does in this way, the practical coil apparatus with high versatility which can further mount other parts on an insulating substrate can be provided.

  The connecting member may be formed of a bonding wire.

  If it does in this way, the length of the whole coil electrode can be adjusted only by adjusting the length of a bonding wire, the shape of a mountain, etc. In addition, the inductance and impedance of the coil can be easily adjusted by adjusting the length of the entire coil electrode. Therefore, the coil apparatus which can adjust the coil characteristic of a coil easily can be provided. Further, by using the wire bonding process, even if there is a slight misalignment between the wiring electrodes on the outer surface of the wiring member, the corresponding ends of the wiring electrodes can be easily connected to each other. .

  Another wiring formed of an insulating member and having a lower surface, an outer peripheral surface, and an inner peripheral surface that have substantially the same shape as the annular lower surface, outer peripheral surface, and inner peripheral surface of the coil core, and the coil core is disposed inside A member may be further provided, and the plurality of connecting members may be disposed on a surface of the other wiring member.

  In this way, it is possible to easily connect the corresponding end portions of the respective wiring electrodes on the outer surface of the wiring member only by arranging another wiring member on the lower side of the coil core.

  Further, both end portions of the wiring electrode may be formed wider than the central portion.

  In this case, since both end portions of each wiring electrode are formed wider than the central portion thereof, the connectivity between each end portion of each wiring electrode and the connecting member can be improved.

  The wiring electrode may be formed of a metal pin.

  If it does in this way, a wiring electrode can be easily formed only by arranging and arranging a plurality of metal pins on the outer surface of a wiring member.

  Moreover, it is good for each both ends of the said metal pin to be bent so that the lower end edge of each outer peripheral surface and inner peripheral surface of the said wiring member may be followed.

  By doing so, each end of each metal pin is bent, and thus the connection area between each end of each metal pin and each connection member is expanded. Connectivity can be improved.

  According to the present invention, the coil core is formed on the outer surface of the wiring member formed by arranging a plurality of line-shaped wiring electrodes extending in the circumferential direction from the lower end edge of the outer peripheral surface to the lower end edge of the inner peripheral surface. Is arranged, and one end of one wiring electrode on the outer surface of the wiring member is connected to the other end of the wiring electrode adjacent to one side of the wiring electrode by a connecting member to form a coil electrode. . Therefore, if each wiring electrode is positioned on the outer surface of the wiring member, there is no possibility that each wiring electrode is displaced, and by connecting the ends of the corresponding wiring electrodes with the connecting member, the periphery of the coil core is It is possible to provide a coil device including a coil that can easily form a coil electrode that is spirally wound.

It is a perspective view which shows the coil apparatus concerning 1st Embodiment of this invention. It is a top view of the coil apparatus of FIG. It is a figure which shows an example of the manufacturing method of the coil apparatus of FIG. 1, Comprising: It is a figure which shows the tape-shaped resin sheet in which the some metal pin was arranged. It is a figure which shows an example of the manufacturing method of the coil apparatus of FIG. 1, Comprising: It is a perspective view which shows the state by which both sides in the width direction of the tape-shaped resin sheet of FIG. 3 were bent. It is a figure which shows an example of the manufacturing method of the coil apparatus of FIG. 1, Comprising: It is a perspective view which shows the wiring member formed by the insulating member shown in FIG. It is a figure which shows an example of the manufacturing method of the coil apparatus of FIG. 1, Comprising: It is a perspective view which shows the state by which the coil core is arrange | positioned inside the wiring member of FIG. It is a figure which shows an example of the manufacturing method of the coil apparatus of FIG. 1, Comprising: It is a top view which shows an insulated substrate. It is a figure for demonstrating the modification of a wiring electrode. It is a figure which shows an example of the manufacturing method of the coil apparatus concerning 2nd Embodiment of this invention, Comprising: It is a figure which shows the annular | circular shaped resin sheet in which the several metal pin was arranged radially. It is a perspective view which shows the wiring member formed by bending the outer tongue piece part and the inner tongue piece part of the resin sheet of FIG. It is a perspective view which shows the state by which the coil core is arrange | positioned inside the wiring member of FIG. It is a figure for demonstrating the modification of a wiring electrode. It is sectional drawing which shows the coil apparatus concerning 3rd Embodiment of this invention. It is a figure for demonstrating the wiring electrode arrange | positioned at the outer surface of the wiring member with which the coil apparatus concerning 4th Embodiment of this invention is provided. It is a figure for demonstrating the wiring electrode arrange | positioned at the outer surface of the wiring member with which the coil apparatus concerning 5th Embodiment of this invention is provided. It is a figure which shows the tape-shaped resin sheet in which the several metal pin was arranged in order to form the wiring member with which the coil apparatus concerning 6th Embodiment of this invention is equipped, Comprising: (a) is arrange | positioned above a coil core. The resin sheet for forming the wiring member which forms is shown, (b) shows the resin sheet for forming the other wiring member arrange | positioned under a coil core. It is a perspective view which shows the state by which the both sides in the width direction of the resin sheet shown in FIG. 16 were bent, (a) shows the insulating member for forming the wiring member arrange | positioned above a coil core, (b ) Shows an insulating member for forming another wiring member arranged below the coil core. It is a figure which shows the tape-shaped resin sheet in which the several metal pin was arranged in order to form the wiring member with which the coil apparatus concerning 7th Embodiment of this invention is equipped, Comprising: (a) is arrange | positioned above a coil core. The resin sheet for forming the wiring member which forms is shown, (b) shows the resin sheet for forming the other wiring member arrange | positioned under a coil core. It is a perspective view which shows the state by which the both sides in the width direction of the resin sheet shown in FIG. 18 were bent, Comprising: (a) shows the insulating member for forming the wiring member arrange | positioned above a coil core, (b ) Shows an insulating member for forming another wiring member arranged below the coil core. It is a figure which shows the resin sheet in which the several metal pin was arranged in order to form the wiring member with which the coil apparatus concerning 8th Embodiment of this invention is provided. It is a perspective view which shows the state by which the resin sheet shown in FIG. 20 was bent along the folding line. It is a figure which shows an example of the manufacturing method of the conventional coil apparatus, Comprising: (a)-(c) is a figure which shows a respectively different process.

<First Embodiment>
A coil device according to a first embodiment of the present invention will be described.

(Schematic configuration of the coil device)
A schematic configuration of the coil device 1 will be described with reference to FIGS. 1 and 2. FIG. 1 is a perspective view showing a coil device according to a first embodiment of the present invention, and FIG. 2 is a plan view of the coil device of FIG.

  As shown in FIGS. 1 and 2, the coil device 1 includes a coil 4 having an annular coil core 2 and a coil electrode 3 wound in a spiral around the coil core 2. In this embodiment, the coil 4 has an annular toroidal coil core 2. The coil core 2 is formed of a magnetic material that is generally employed as a coil core, such as ferrite or iron.

  As shown in FIG. 1, the coil device 1 is formed of an insulating member such as epoxy, polyimide, or polyester, and has an upper surface 5 a and an outer periphery that are substantially the same as the upper surface, outer peripheral surface, and inner peripheral surface of the annular coil core 2. A substantially annular wiring member 5 having a surface 5b and an inner peripheral surface 5c is provided. And the wiring core 5 is arrange | positioned between the outer peripheral surface 5b of the wiring member 5, and the internal peripheral surface 5c by arrange | positioning the wiring member 5 so that the coil core 2 may be coat | covered from an upper side. In this embodiment, a plurality of cuts 5d extending in the circumferential direction from the lower end edge of the outer peripheral surface 5b of the wiring member 5 to the inner end edge of the upper surface 5a are arranged in the circumferential direction.

  The coil electrode 3 is formed of a metal pin, extends from the lower end edge of the outer peripheral surface 5b of the wiring member 5 through the upper surface 5a to the lower end edge of the inner peripheral surface 5c, and is arranged in the circumferential direction on the outer surface of the wiring member 5 A plurality of line-shaped wiring electrodes 6 and a line-shaped wiring electrode pattern 8 (corresponding to the “connecting member” of the present invention) formed on an insulating substrate 7 disposed below the wiring member 5. I have. Then, the wiring electrode 6 adjacent to one end of the wiring electrode 6 on the outer surface of the wiring member 5 and one side of the wiring electrode 6 (in this embodiment, the counterclockwise direction in FIGS. 1 and 2). Are connected by wiring electrode patterns 8 respectively. In this way, the corresponding end portions of the wiring electrodes 6 are connected to each other, whereby the coil electrode 3 that spirally winds around the coil core 2 is formed.

  Each wiring electrode 6 is made of a metal material generally adopted as a wiring electrode, such as Cu, Au, Ag, or Al. Moreover, each wiring electrode 6 may be formed of a pin-shaped member in which Cu is plated with Ni. Further, the wiring electrode pattern 8 is formed using a metal material generally adopted as a wiring electrode, such as Cu, Au, Ag, Al, etc., in the same manner as the wiring electrodes 6. The wiring electrode pattern 8 is formed by etching a metal film (foil) using a photolithography technique or resist printing. Note that the wiring electrode pattern 8 or a bonding material such as solder for connecting the wiring electrode 6 and the wiring electrode pattern 8 is preferably plated. If it does in this way, low resistance in the connection part of the wiring electrode 6 and the wiring electrode pattern 8 can be achieved. At this time, it is preferable that the plating applied to the bonding material is directly connected to the wiring electrode 6 and the wiring electrode pattern 8.

  Further, as shown in FIG. 2, among the wiring electrodes 6, the end of the wiring electrode 6 to which the wiring electrode pattern 8 is not connected is connected to the lead-out wiring electrode pattern 9 formed on the insulating substrate 7. Therefore, it is used as a terminal for signal extraction.

  In FIGS. 1 and 2, a part of the configuration is not shown in order to simplify the drawing. For example, in FIG. 1, the wiring electrode pattern 8 is not illustrated, and in FIG. 2, the coil core 2 and the wiring electrode patterns 8 and 9 are illustrated by dotted lines, and the wiring member 5 is not illustrated.

(Manufacturing method of coil device)
An example of the manufacturing method of the coil apparatus 1 is demonstrated with reference to FIGS.

  3-7 is a figure which shows an example of the manufacturing method of the coil apparatus of FIG. 1, Comprising: It is a figure which shows each different process. 3 is a view showing a tape-shaped resin sheet in which a plurality of metal pins are arranged, and FIG. 4 is a perspective view showing a state where both sides in the width direction of the tape-shaped resin sheet of FIG. 3 are bent. . 5 is a perspective view showing the wiring member 5 formed by rounding the insulating member shown in FIG. 4 in a state where the notch 5d is arranged outside, and FIG. 6 is inside the wiring member 5 of FIG. FIG. 7 is a perspective view showing a state where the coil core 2 is arranged, and FIG.

  First, as shown in FIG. 3, a resin sheet made of an insulating member such as polyimide, polyester, or epoxy and forming the upper surface 5 a, outer peripheral surface 5 b, and inner peripheral surface 5 c of the wiring member 5 is prepared. Also, a plurality of cuts 5d extending from the lower edge of the region forming the outer peripheral surface 5b to the upper edge of the region forming the upper surface 5a in a direction orthogonal to the longitudinal direction at a predetermined position of the resin sheet Are arranged in the longitudinal direction. Further, the plurality of metal pins constituting the wiring electrode 6 are arranged in an adhesive manner in the longitudinal direction on the resin sheet while being arranged in a direction orthogonal to the longitudinal direction of the resin sheet. In this embodiment, when each metal pin is disposed at a predetermined position on the resin sheet, a metal pin having a length that slightly protrudes from both end edges in the width direction of the resin sheet is employed. . Moreover, the dashed-dotted line in the figure shows a folding line.

  Subsequently, as shown in FIG. 4, the resin sheet is bent along a folding line by pressing or the like with the surface on which the wiring electrodes 6 are arranged facing outside. As a result, a plurality of cuts 5d are arranged in the longitudinal direction in a direction orthogonal to the longitudinal direction extending upward from the lower end on the outer peripheral surface 5b side, and a long section having a substantially C-shaped cross section with the bottom surface opened. An insulating member is formed.

  Next, as shown in FIG. 5, the long insulating member of FIG. 4 is rounded into a ring shape with each notch 5 d arranged on the outside. As a result, it has an upper surface 5a, an outer peripheral surface 5b, and an inner peripheral surface 5c that are formed of an insulating member and have substantially the same shape as the upper surface, outer peripheral surface, and inner peripheral surface of the coil core 2, and the lower end of the outer peripheral surface 5b on the outer surface. A plurality of line-like wiring electrodes 6 extending from the edge to the lower edge of the inner peripheral surface 5c through the upper surface 5a are formed in the circumferential direction, and the wiring member 5 in which the coil core 2 is disposed is formed inside thereof (see FIG. Preparation step).

  Then, as shown in FIG. 6, the coil core 2 is arrange | positioned between the outer peripheral surface 5b and the internal peripheral surface 5c of the wiring member 5 (arrangement | positioning process). Note that the coil core 2 may be arranged inside the wiring member 5 by covering the coil core 2 from above while rolling the long insulating member shown in FIG. Further, in this embodiment, as shown in FIG. 6, the length of the tape-shaped resin sheet (long insulating member) is formed to be shorter than the peripheral length in the planar view shape of the coil core 2. 5 is formed in a substantially C-shape, but the wiring member 5 may be formed endlessly by forming a tape-shaped resin sheet in the same length as the circumferential length of the coil core 2.

  Subsequently, a Cu-clad insulating substrate 7 on which a Cu foil is laminated is prepared. Then, as shown in FIG. 7, the wiring electrode pattern 8 and the lead-out wiring electrode pattern 9 are formed on the insulating substrate 7 by etching using photolithography or resist printing. Next, a solder resist layer is formed on a portion excluding the connection positions at both ends of each wiring electrode 6 and a portion where the coil core 2 is disposed (not shown). Then, a solder paste is applied to a position where both ends of each wiring electrode 6 are connected.

  In this embodiment, the position where one end of each wiring electrode 6 is connected to the outer end of each wiring electrode pattern 8 is set so that the connection position with one end of each wiring electrode 6 is substantially circular. It is arranged on the circumference. Further, by setting the position where the other end inside each wiring electrode 6 is connected to the inner end of each wiring electrode pattern 8, the connection position with the other end of each wiring electrode 6 is substantially smaller. Is placed on top.

  Subsequently, the outer end of each wiring electrode 6 arranged on the outer peripheral surface 5b (outside of the coil core 2) of the wiring member 5 is the outer end of each wiring electrode pattern 8 arranged on a substantially large circumference. Connected to. And the other end of each wiring electrode 6 arrange | positioned at the inner peripheral surface 5c (inner side of the coil core 2) of the wiring member 5 is each inner edge part of each wiring electrode pattern 8 arrange | positioned on a substantially small circumference. By being connected, the coil core 2 and the wiring member 5 (wiring electrode 6) are arranged at predetermined positions on the insulating substrate 9. As a result, one end of one wiring electrode 6 on the outer surface of the wiring member 5 and the other end of the wiring electrode 6 adjacent to one side of the wiring electrode 6 are connected by the respective wiring electrode patterns 8. Then, the coil electrode 3 that spirally winds around the coil core 2 is formed (connection process). As shown in FIG. 2, the end portions of the wiring electrodes 6 that are not connected to the wiring electrode patterns 8 are connected to the lead wiring electrode patterns 9, respectively.

  The coil 4 may be embedded in the resin insulating layer by filling the insulating substrate 7 with a general thermosetting resin such as epoxy resin.

  As described above, in this embodiment, the upper surface 5a and the outer peripheral surface are formed of an insulating member such as a thermoplastic resin or a thermosetting resin and have substantially the same shape as the annular upper surface, outer peripheral surface, and inner peripheral surface of the coil core 2, respectively. Coil core 2 is arranged inside wiring member 5 having 5b and inner peripheral surface 5c. A plurality of line-like wiring electrodes 6 extending from the lower end edge of the outer peripheral surface 5b to the lower end edge of the inner peripheral surface 5c are arranged on the outer surface of the wiring member 5 in the circumferential direction. Yes. In addition, one end of one wiring electrode 6 on the outer surface of the wiring member 5 and the other end of the wiring electrode 6 adjacent to one side of the wiring electrode 6 are connected by the wiring electrode pattern 8, respectively. Is formed.

  Moreover, in this embodiment, the coil apparatus 1 is manufactured as follows. That is, it has an upper surface 5a, an outer peripheral surface 5b, and an inner peripheral surface 5c that are formed of an insulating member and have substantially the same shapes as the annular upper surface, outer peripheral surface, and inner peripheral surface of the coil core 2, and the outer surface of the outer peripheral surface 5b. A wiring member 5 is prepared in which a plurality of line-shaped wiring electrodes 6 extending from the lower end edge to the lower end edge of the inner peripheral surface 5c through the upper surface 5a are arranged in the circumferential direction. The coil core 2 is disposed between the outer peripheral surface 5 b and the inner peripheral surface 5 c of the wiring member 5, and is adjacent to one end of one wiring electrode 6 on the outer surface of the wiring member 5 and one side of the wiring electrode 6. The other end of the wiring electrode 6 to be connected is connected by the wiring electrode pattern 8 to form the coil electrode 3.

  Therefore, if each wiring electrode 6 is positioned on the outer surface of the wiring member 5, there is no possibility that each wiring electrode 6 is displaced, and the ends of the corresponding wiring electrodes 6 can be easily connected to each other by the wiring electrode pattern 8 (connection). Member). Therefore, the coil device 1 including the coil 4 having the coil electrode 3 that spirally winds around the coil core 2 can be easily manufactured and provided.

  In addition, a plurality of cuts 5d extending in the orthogonal direction in the circumferential direction from the lower end edge of the outer peripheral surface 5b of the wiring member 5 to the inner end edge of the upper surface 5a are arranged in the circumferential direction. That is, as shown in FIG. 4, the wiring member 5 is a long insulating member having a substantially C-shaped cross section with an open lower surface, and a plurality of wiring members 5 are arranged in a direction orthogonal to the longitudinal direction upward from the lower end on the outer peripheral surface 5b side. After the notches 5d are arranged in the longitudinal direction, the insulating member is formed in a circular shape with the notches 5d arranged on the outside. Therefore, the wiring member 5 in which the coil core 2 is arranged can be easily formed. Moreover, in this embodiment, since the notch 5d is provided, when the part located in the inner peripheral side of the coil core 2 of a resin sheet is bent along the inner periphery of the coil core 2, it is further possible to bend it uniformly. It becomes easy, and it becomes possible to further suppress the displacement of the wiring electrode 6 located on the outer surface.

  The wiring electrode 6 is formed of a metal pin. Therefore, the wiring electrode 6 can be easily formed simply by arranging and arranging a plurality of metal pins on the outer surface of the wiring member 5.

  Each wiring electrode 6 that forms the wiring of the coil electrode 3 in the thickness direction of the coil core 2 is formed of a metal pin. Therefore, the wiring length of the coil electrode 3 in the thickness direction of the coil core 2 can be easily increased only by increasing the length of each metal pin. Therefore, the thickness of the coil core 3 can be easily changed.

  Moreover, since the coil 4 has the toroidal type coil core 2, since it becomes a closed magnetic circuit structure where the magnetic force line which generate | occur | produces in the coil 4 mainly passes the cyclic | annular toroidal type coil core 2, the coil apparatus 1 with few leakage magnetic fluxes Can be provided.

  Further, by simply changing the thickness of the wiring member 5 or adjusting the arrangement state of the wiring electrode 6 on the outer surface of the wiring member 5, the wiring electrode 6 is formed between the wiring core 6 and the coil core 2. The arrangement relationship such as the interval can be easily adjusted. Moreover, since the resin sheet (wiring member 5) is arrange | positioned between each wiring electrode 6 and the coil core 2, each wiring electrode 6 and the coil core 2 can be arrange | positioned adjacently in the insulated state. Moreover, since the stress from each wiring electrode 6 with respect to the coil core 2 can be relieved by the resin sheet (wiring member 5), the coil characteristics can be improved.

  In addition, a line-shaped wiring in which one end of one wiring electrode 6 on the outer surface of the wiring member 5 and the other end of the wiring electrode 6 adjacent to one side of the wiring electrode 6 are formed on the insulating substrate 7. The coil device 1 is formed by being connected by the electrode pattern 8. Therefore, for example, a highly versatile practical coil device 1 that can further mount other components on the insulating substrate 7 can be provided.

  Further, when the long insulating member shown in FIG. 4 is rounded to form the wiring member 5, the interval between the wiring electrodes 6 is widened, so that the wiring electrodes 6 can be prevented from contacting each other. .

  In this embodiment, since the wiring electrode 6 is formed of a metal pin, it is possible to easily change the thickness of the wiring electrode 6 forming the coil electrode 3 only by changing the outer diameter of the metal pin. it can. Therefore, for example, as shown in FIG. 8, the following effects can be achieved by arranging a metal pin formed on one end side so as to be thicker in a tapered shape on the resin sheet. That is, the resistance of the coil electrode 3 formed by the wiring electrode 6 is increased by increasing the thickness of the wiring electrode 6 on the outer peripheral surface 5b side where the wiring electrode 6 has a larger space than the inner peripheral surface 5c side of the wiring member 5. Can be achieved. In addition, the connectivity between the one end of the wiring electrode 6 on the outer peripheral surface 5 b side and the wiring electrode pattern 8 on the insulating substrate 7 can be improved. FIG. 8 is a view for explaining a modification of the wiring electrode, and shows a tape-like resin sheet in which a plurality of metal pins are arranged in the same manner as in FIG. is there.

Second Embodiment
A coil device according to a second embodiment of the present invention will be described with reference to FIGS.

  FIG. 9 is a view showing an example of a method of manufacturing a coil device according to the second embodiment of the present invention, and is a view showing an annular resin sheet in which a plurality of metal pins are arranged radially. 10 is a perspective view showing a wiring member formed by bending the outer tongue piece portion and the inner tongue piece portion of the resin sheet shown in FIG. 9, and FIG. 11 shows a coil core disposed inside the wiring member shown in FIG. FIG.

  The wiring member 15 of this embodiment is different from the wiring member 5 of the coil device 1 described with reference to FIGS. 1 and 3 to 5 as shown in FIGS. 9 and 10. 15a is formed in an annular shape, and a plurality of outer notches 15d extending in the circumferential direction from the lower end edge of the outer peripheral surface 15b to the outer end edge of the upper surface 15a are arranged in the circumferential direction. It is. In addition, a plurality of inner cuts 15e extending in the circumferential direction from the lower end edge of the inner circumferential surface 15c of the wiring member 15 to the inner edge of the upper surface 15a are arranged in the circumferential direction. In the following description, different points from the above-described first embodiment will be described, and other configurations are the same as those of the above-described first embodiment, so that the description of the configuration will be omitted by citing the same reference numerals. .

  An example of the manufacturing direction of the wiring member 15 will be described.

  First, as shown in FIG. 9, an annular resin sheet made of an insulating member such as a liquid crystal polymer is prepared. And the annular part 10 which comprises the upper surface 15a of the wiring member 15 is set to the substantially center part in the width direction orthogonal to the circumferential direction of an annular | circular shaped resin sheet. A plurality of outer cuts 15d are formed in the circumferential direction in a direction orthogonal to the circumferential direction from the outer edge of the resin sheet to the outer edge of the annular portion 10. As a result, a plurality of outer tongue pieces 11 are formed integrally with the outer edge of the annular portion 10 at predetermined intervals to form the outer peripheral surface 15 b of the wiring member 15. Also, a plurality of inner cuts 15e are formed in the circumferential direction in a direction orthogonal to the circumferential direction from the inner edge of the resin sheet to the inner edge of the annular portion 10. As a result, a plurality of inner tongue pieces 12 are formed integrally with the inner edge of the annular portion 10 at predetermined intervals to form the inner peripheral surface 15 c of the wiring member 15.

  Further, the plurality of metal pins constituting the wiring electrode 6 are arranged in the circumferential direction on the resin sheet in a state of being arranged in a direction orthogonal to the circumferential direction of the resin sheet. In this embodiment, when each metal pin is arranged at a predetermined position on the resin sheet, the metal pin has a length that slightly protrudes from the outer edge and the inner edge of the resin sheet. Has been. Moreover, the dotted line which shows the cyclic | annular part 10 in the figure shows a folding line.

  Subsequently, as shown in FIG. 10, each outer tongue piece portion 11 and each inner tongue piece portion 12 are bent downward along a folding line by pressing or the like. As a result, it has an upper surface 15a, an outer peripheral surface 15b, and an inner peripheral surface 15c that are formed of an insulating member and have substantially the same shape as the upper surface, outer peripheral surface, and inner peripheral surface of the coil core 2, and the lower end of the outer peripheral surface 15b on the outer surface. A plurality of line-shaped wiring electrodes 6 extending from the edge to the lower edge of the inner peripheral surface 15c through the upper surface 15a are formed in the circumferential direction, and the wiring member 15 in which the coil core 2 is disposed is formed inside thereof (see FIG. Preparation step). At this time, when the insulating member is, for example, a liquid crystal polymer, the insulating member can be reliably plastically deformed by being heated at a temperature of about 80 ° C. for about 10 seconds.

  Subsequently, as shown in FIG. 11, the coil core 2 is disposed between the outer peripheral surface 15b and the inner peripheral surface 15c of the wiring member 15 (arrangement step). Then, similarly to the first embodiment described above, corresponding end portions of the respective wiring electrodes 6 are connected to each other by the wiring electrode pattern 8 to complete the coil device 1.

  As described above, in this embodiment, the plurality of outer cuts 15d extending from the lower end edge of the outer peripheral surface 15b of the wiring member 15 to the outer end edge of the upper surface 15a in the direction orthogonal to the circumferential direction are arranged in the circumferential direction. A plurality of inner cuts 15e extending from the lower end edge of the inner peripheral surface 15c of the wiring member 15 to the inner end edge of the upper surface 15a in the direction orthogonal to the circumferential direction are arranged in the circumferential direction. That is, as shown in FIG. 9, the wiring member 15 includes an annular portion 10, a plurality of outer tongue pieces 11 integrally formed on the outer edge of the annular portion 10 at predetermined intervals, and an inner end of the annular portion 10. An insulating member having a plurality of inner tongue pieces 12 integrally formed on the edge at predetermined intervals is prepared, and each outer tongue piece 11 and each inner tongue piece 12 are bent downward and formed. Therefore, the wiring member 15 in which the coil core 2 is arranged can be easily formed.

  Further, similarly to the first embodiment described above, since the wiring electrode 6 is formed of a metal pin, the thickness of the wiring electrode 6 forming the coil electrode 3 can be easily changed only by changing the outer diameter of the metal pin. Can be changed. Therefore, for example, as shown in FIG. 12, the following effects can be obtained by arranging a metal pin formed on one end side so as to be thickened in a tapered shape on the resin sheet. That is, the resistance of the coil electrode 3 formed by the wiring electrode 6 is increased by increasing the thickness of the wiring electrode 6 on the outer peripheral surface 15b side where the wiring electrode 6 has a larger space than the inner peripheral surface 15c side of the wiring member 15. Can be achieved. In addition, the connectivity between the one end of the wiring electrode 6 on the outer peripheral surface 15 b side and the wiring electrode pattern 8 on the insulating substrate 7 can be improved. FIG. 12 is a view for explaining a modification of the wiring electrode, and is a view showing an annular resin sheet in which a plurality of metal pins are arranged in the same manner as FIG. 9 in order to form the wiring member 15. .

<Third Embodiment>
A coil device according to a third embodiment of the present invention will be described with reference to FIG. FIG. 13: is sectional drawing which shows the coil apparatus concerning 3rd Embodiment of this invention.

  The coil device 1a of this embodiment is different from the coil device 1 described in the first embodiment described above, as shown in FIG. 13, one end outside the one wiring electrode 6 on the outer surface of the wiring member 5. And the other inner end of the wiring electrode 6 adjacent to one side of the wiring electrode 6 are connected by a bonding wire 18 (corresponding to the “connecting member” of the present invention) to form the coil electrode 3. It is a point. In this embodiment, the coil 4 (coil core 2, wiring member 5, wiring electrode 6) is embedded in the resin insulating layer 13. In the following description, different points from the above-described first embodiment will be described, and other configurations are the same as those of the above-described first embodiment, so that the description of the configuration will be omitted by citing the same reference numerals. .

  An example of the manufacturing method of the coil apparatus of this embodiment is demonstrated.

  First, in place of the insulating substrate 7 on which the wiring electrode pattern 8 is formed, a release sheet provided with a support layer formed of an adhesive thermosetting resin is prepared. And like the above-mentioned 1st Embodiment, the wiring member 5 is arrange | positioned in the state by which the coil core 2 is arrange | positioned inside the predetermined position on the support layer provided in the release sheet. The release sheet may be any type of release sheet such as a sheet in which a release layer is formed on a resin sheet such as polyethylene terephthalate, polyethylene naphthalate, or polyimide, or a sheet in which a resin sheet such as a fluororesin itself has a release function. A mold sheet may be used.

  Subsequently, the coil core 2 and the wiring member 5 (wiring electrode 6) are resin-sealed using the same resin as the support layer on the release sheet to form the resin insulating layer 13 including the support layer. In addition, you may resin-seal using resin different from a support layer. Next, after the release sheet is peeled off, the resin on the one main surface 13a of the resin insulating layer 13 is removed by polishing or grinding so that both ends of each wiring electrode 6 (metal pin) are exposed.

  Subsequently, as shown in FIG. 13, on one main surface 13 a of the resin insulating layer 13, one end outside the one wiring electrode 6 on the outer surface of the wiring member 5 is adjacent to one side of the wiring electrode 6. The other end on the inner side of the wiring electrode 6 is connected by a bonding wire 18 to complete the coil device 1a.

  In this embodiment, the bonding wire 18 is formed of an Au wire. Therefore, Ni / Au plating layers (not shown) are formed on both end surfaces of each wiring electrode 6 exposed on the one main surface 13a of the resin insulating layer 13 in order to improve the connectivity with the bonding wires 18. ing.

  As described above, in this embodiment, since a part of the coil electrode 3 is formed by the bonding wire 18, the entire length of the coil electrode 3 can be increased only by adjusting the length of the bonding wire 18 or the shape of the chevron. Can be adjusted. Moreover, the inductance and impedance of the coil 4 can be easily adjusted by adjusting the entire length of the coil electrode 3. Therefore, the coil apparatus 1a which can adjust the coil characteristic of the coil 4 easily can be provided. Further, by using the wire bonding process, even if there is a slight displacement in each wiring electrode 6 on the outer surface of the wiring member 5, the corresponding ends of each wiring electrode 6 are easily connected to each other. be able to.

  Further, since the corresponding end portions of each wiring electrode 6 are connected to each other by the bonding wire 18, each wiring electrode 6 of the coil electrode 3 can be adjusted by adjusting the length or the mountain shape of each bonding wire 18. It is possible to easily form a three-dimensional (three-dimensional) wiring at a portion connecting the two. Therefore, when compared with the wiring electrode pattern 8 formed planarly (two-dimensionally) on the one main surface 13a of the insulating substrate 7 or the resin insulating layer 13, each bonding wire 18 is wired three-dimensionally, The wiring density of each bonding wire 18 can be improved while preventing the bonding wires 18 from contacting each other. Therefore, the pitch between the coil electrodes 3 can be reduced, and the coil characteristics can be improved by increasing the number of turns of the coil 4. In addition, by reducing the pitch between the coil electrodes 3, the coil 4 can be reduced in size, and the coil device 1a can be reduced in size.

  In the second embodiment described above, corresponding ends of each wiring electrode 6 may be connected to each other by the bonding wire 18. Also in this case, instead of the insulating substrate 7, the resin insulating layer 13 may be formed after the wiring member 15 (coil core 2) is arranged at a predetermined position on the support layer provided on the release sheet. In addition, corresponding end portions of each wiring electrode 6 may be connected by a plurality of bonding wires 18. In this way, the resistance of the coil electrode 3 can be further reduced.

<Fourth embodiment>
A coil device according to a fourth embodiment of the present invention will be described with reference to FIG. FIG. 14 is a view for explaining wiring electrodes arranged on the outer surface of the wiring member provided in the coil device according to the fourth embodiment of the present invention.

  The wiring electrode 16 of the coil device of this embodiment is different from the wiring electrode 6 described with reference to FIG. 3 in the first embodiment described above, as shown in FIG. The connection region 16a is formed by soldering at both ends of each wiring electrode 16 formed. Thereby, both end portions of each wiring electrode 16 are formed wider than the central portion. Since other configurations are the same as those in the first embodiment, description of the configurations is omitted by citing the same reference numerals.

  In this case, since both end portions of each wiring electrode 16 are formed wider than the center portion thereof, each end portion (connection region 16a) of each wiring electrode 16 and wiring electrode on the insulating substrate 7 are provided. The connectivity with the pattern 8 and the bonding wire 18 can be improved.

<Fifth Embodiment>
A coil device according to a fifth embodiment of the present invention will be described with reference to FIG. FIG. 15 is a view for explaining wiring electrodes arranged on the outer surface of the wiring member provided in the coil device according to the fifth embodiment of the present invention.

  The wiring electrode 26 of the coil device of this embodiment is different from the wiring electrode 16 described with reference to FIG. 14 in the above-described fourth embodiment, as shown in FIG. Both ends of each electrode 26 are bent along the lower edge of each of the outer peripheral surface 5b and the inner peripheral surface 5c of the wiring member 5 to form a connection region 26a. Since the other configuration is the same as that of the fourth embodiment described above, the description of the configuration is omitted by citing the same reference numerals.

  In this way, a large-area connection region 26a can be easily formed by bending both end portions of each metal pin forming each wiring electrode 26. Accordingly, it is possible to improve the connectivity between each end portion (connection region 26a) of each metal pin and the wiring electrode pattern 8 or the bonding wire 18 on the insulating substrate 7.

<Sixth Embodiment>
A coil device according to a sixth embodiment of the present invention will be described with reference to FIGS. 16 and 17.

  FIG. 16 is a view showing a tape-shaped resin sheet in which a plurality of metal pins are arranged to form a wiring member included in a coil device according to a sixth embodiment of the present invention, and (a) is an upper side of the coil core. The resin sheet for forming the wiring member arrange | positioned in (2) is shown, (b) shows the resin sheet for forming the other wiring member arrange | positioned under a coil core. 17 is a perspective view showing a state in which both sides in the width direction of the resin sheet shown in FIG. 16 are bent, and (a) is an insulating member for forming a wiring member disposed on the upper side of the coil core. (B) shows the insulating member for forming the other wiring member arrange | positioned under a coil core.

  The coil device of this embodiment is different from the first embodiment described above, as shown in FIG. 17B, which is formed of an insulating member such as a liquid crystal polymer and has a lower surface, an outer peripheral surface and an inner peripheral surface of the annular coil core 2. This is the point that another substantially circular annular wiring member 25 (corresponding to “another wiring member” of the present invention) having a lower surface 25a, an outer peripheral surface 25b, and an inner peripheral surface 25c having substantially the same shape as each of the surfaces is provided. The wiring member 25 is disposed so as to cover the coil core 2 from below, so that the coil core 2 is disposed between the outer peripheral surface 25b and the inner peripheral surface 25c. Further, as shown in FIG. 17B, the outer surface of the wiring member 25 has one end outside the one wiring electrode 16 on the outer surface of the wiring member 5 shown in FIG. A plurality of connecting members 28 that connect the other inner end of the wiring electrode 16 adjacent to one side of the wiring 16 are arranged.

  In this embodiment, the wiring member 5 including the wiring electrode 16 described with reference to FIG. 14 in the above-described fourth embodiment, and the wiring member 25 including the connection member 28 having substantially the same configuration as the wiring electrode 16 are provided. Is prepared. Moreover, the wiring member 5 arrange | positioned above the coil core 2 is formed by the elongate insulating member shown to Fig.17 (a) being rolled circularly in the state which distribute | arranged each notch 5d on the outer side. Moreover, the wiring member 25 arrange | positioned under the coil core 2 is formed by the elongate insulating member shown in FIG.17 (b) being rolled circularly in the state which distribute | arranged each notch 25d on the outer side. Further, as will be described later, the wiring members 5 and 25 have a substantially plane-symmetric structure in a state where they are arranged on the upper side and the lower side of the coil core 2, respectively.

  In the following description, different points from the above-described first embodiment will be described, and other configurations are the same as those of the above-described first embodiment. .

  An example of a method for manufacturing the wiring members 5 and 25 will be described.

  First, a resin sheet shown in FIG. 16A, which is made of an insulating member such as polyimide, polyester, or epoxy and forms the upper surface 5a, outer peripheral surface 5b, and inner peripheral surface 5c of the wiring member 5, is prepared, and the lower surface 25a of the wiring member 25 is prepared. A resin sheet shown in FIG. 16 (b), which forms the outer peripheral surface 25b and the inner peripheral surface 25a, is prepared. Next, a plurality of positions extending from the lower edge of the region forming the outer peripheral surface 5b in the direction orthogonal to the longitudinal direction to the upper edge of the region forming the upper surface 5b at a predetermined position of the resin sheet shown in FIG. The notches 5d are arranged in the longitudinal direction. Also, a plurality of positions extending from the upper edge of the region forming the outer peripheral surface 25b in the direction orthogonal to the longitudinal direction to the lower edge of the region forming the upper surface 25b at a predetermined position of the resin sheet shown in FIG. The notches 25d are formed in the longitudinal direction.

  Subsequently, the plurality of metal pins constituting the wiring electrode 16 are arranged in the longitudinal direction on the resin sheet in a state where the metal pins are arranged in a direction perpendicular to the longitudinal direction of the resin sheet shown in FIG. Be placed. Further, the plurality of metal pins constituting the connection member 28 are arranged in the longitudinal direction on the resin sheet in a state where the metal pins are arranged in a direction perpendicular to the longitudinal direction of the resin sheet shown in FIG. Is done.

  Further, as shown in FIG. 16A, as in the example shown in FIG. 14, connection regions 16a are formed by solder at both ends of each wiring electrode 16 formed of metal pins, metal foils, or the like. . Further, as shown in FIG. 16B, as in the example shown in FIG. 14, connection regions 28a are formed by solder at both ends of each connection member 28 formed by metal pins. Further, as shown in FIG. 16A, the wiring electrodes 16 disposed on both sides in the longitudinal direction of the resin sheet are connected to the connection terminals 16b for external connection so as to be disposed on the upper surface 5a of the wiring member 5, respectively. Is formed. In addition, the dashed-dotted line in FIG. 16 (a), (b) shows a fold line.

  Subsequently, as illustrated in FIG. 17A, the resin sheet is bent along a folding line by pressing or the like with the surface on which the wiring electrodes 6 are arranged facing outside. As a result, a plurality of cuts 5d are arranged in the longitudinal direction in the direction perpendicular to the longitudinal direction from the lower end on the outer peripheral surface 5b side, and the long insulation having a substantially C-shaped cross section with the bottom surface opened. A member is formed. Further, as shown in FIG. 17B, the resin sheet is bent along a folding line by pressing or the like with the surface on which each connection member 28 is disposed on the lower side. As a result, a plurality of cuts 25d are arranged in the longitudinal direction in a direction perpendicular to the longitudinal direction from the upper end on the outer peripheral surface 25b side, and a long section having a substantially C-shaped cross section with an open top surface. An insulating member is formed.

  Next, the insulating member shown in FIG. 17A is rounded in a ring shape with the notches 5d arranged on the outside. As a result, it has an upper surface 5a, an outer peripheral surface 5b, and an inner peripheral surface 5c that are formed of an insulating member and have substantially the same shape as the upper surface, outer peripheral surface, and inner peripheral surface of the coil core 2, and the lower end of the outer peripheral surface 5b on the outer surface. A plurality of line-shaped wiring electrodes 6 extending from the edge to the lower edge of the inner peripheral surface 5c through the upper surface 5a are formed in the circumferential direction, and the wiring member 5 in which the coil core 2 is disposed is formed inside thereof.

  Further, the insulating member shown in FIG. 17B is rounded in a state where the notches 25d are arranged outside. As a result, the lower surface 25a, the outer peripheral surface 25b, and the inner peripheral surface 25c are formed of an insulating member and have substantially the same shape as the lower surface, outer peripheral surface, and inner peripheral surface of the coil core 2, and the upper end of the outer peripheral surface 25b is formed on the outer surface. A plurality of line-like wiring electrodes 6 extending from the edge to the upper edge of the inner peripheral surface 5c through the upper surface 5a are formed in the circumferential direction, and a wiring member 25 in which the coil core 2 is disposed is formed inside thereof.

  The coil core 2 is covered from the upper side by the wiring member 5 and from the lower side by the wiring member 25, and the connection regions 16a at both ends of each wiring electrode 16 and the connection regions 28a at both ends of each connection member 28 are provided. Are connected to complete the coil device. At this time, one end on the outer side of one wiring electrode 16 on the outer surface of the wiring member 5 and the other end on the inner side of the wiring electrode 16 adjacent to one side of the wiring electrode 16 each have a plurality of connecting members 28. Connected by

  As described above, in this embodiment, the corresponding end portions of the respective wiring electrodes 16 on the outer surface of the wiring member 5 are easily connected to each other only by disposing the other wiring member 25 on the lower side of the coil core 2. be able to.

<Seventh embodiment>
A coil device according to a seventh embodiment of the present invention will be described with reference to FIGS. 18 and 19.

  FIG. 18 is a view showing a tape-shaped resin sheet in which a plurality of metal pins are arranged to form a wiring member included in the coil device according to the seventh embodiment of the present invention, and (a) is an upper side of the coil core. The resin sheet for forming the wiring member arrange | positioned in (2) is shown, (b) shows the resin sheet for forming the other wiring member arrange | positioned under a coil core. 19 is a perspective view showing a state in which both sides in the width direction of the resin sheet shown in FIG. 18 are bent, and (a) is an insulating member for forming a wiring member arranged on the upper side of the coil core. (B) shows the insulating member for forming the other wiring member arrange | positioned under a coil core.

  The coil device of this embodiment differs from the sixth embodiment described above in that the wiring described in the fifth embodiment with reference to FIG. 15 as shown in FIGS. 18 (a) and 19 (a). The wiring member 5 including the electrode 26 is provided. Moreover, as shown to Fig.18 (a), like the resin sheet shown to Fig.16 (a) of 6th Embodiment mentioned above, in the wiring electrode 26 arrange | positioned at the both sides in the longitudinal direction of a resin sheet, respectively, A connection terminal 26b for external connection is formed so as to be disposed on the upper surface 5a of the wiring member 5.

  Further, as shown in FIGS. 18B and 19B, the wiring member 25 of this embodiment has substantially the same configuration as the wiring electrode 26 described with reference to FIG. 15 in the fifth embodiment. The connecting member 38 is provided. That is, as shown in the figure, the both end portions of each connection member 38 formed of metal pins are bent along the upper edge of each of the outer peripheral surface 25b and the inner peripheral surface 25c of the wiring member 25. Thus, a connection region 38a is formed.

  Since the other configuration is the same as that of the first embodiment described above, the description of the configuration is omitted by citing the same reference numerals.

  In the sixth and seventh embodiments, the example in which the connection members 28 and 38 are formed by metal pins on the outer surface of the wiring member 25 has been described with reference to FIGS. 17B and 19B. The method for forming the connection member is not limited to the method described above. That is, the connection member may be formed by etching a metal film formed on the surface of the wiring member 25 using photolithography or resist printing, or a conductive paste is used on the surface of the wiring member 25. The connecting member may be formed by screen printing.

  In the sixth and seventh embodiments, the coil device including the wiring member 25 having the same configuration as the wiring member 5 illustrated in FIG. 5 described in the first embodiment is described as an example. As another wiring member of the invention, a wiring member having the same configuration as that of the wiring member 15 shown in FIG. 10 described in the second embodiment may be adopted. Moreover, it may replace with the wiring member 5 of FIG. 5, and may employ | adopt the wiring member 15 of FIG.

<Eighth Embodiment>
A coil device according to an eighth embodiment of the present invention will be described with reference to FIGS. 20 and 21. FIG. FIG. 20 is a view showing a resin sheet in which a plurality of metal pins are arranged to form a wiring member included in the coil device according to the eighth embodiment of the present invention, and FIG. 21 is a fold line of the resin sheet shown in FIG. It is a perspective view which shows the state bent along.

  The coil device of this embodiment is different from the first embodiment described above, as shown in FIGS. 20 and 21, in which the wiring electrode 36 and the connection member 48 are integrally formed by metal pins, and the wiring member 35 is formed. Is formed. Further, as shown in FIG. 20, the wiring electrode 36 is formed in the region of the resin sheet comprising the upper surface 35a, the outer peripheral surface 35b, and the inner peripheral surface 35c having substantially the same shape as the upper surface, outer peripheral surface, and inner peripheral surface of the annular coil core 2, respectively. The connecting member 48 is disposed in an upper region of the resin sheet that is disposed and is integrally formed in the region and forms the lower surface 35 d of the wiring member 35. In the following description, different points from the above-described first embodiment will be described, and other configurations are the same as those of the above-described first embodiment, and therefore the description thereof will be omitted by citing the same reference numerals.

  An example of a method for manufacturing the wiring member 35 will be described.

  First, a resin sheet shown in FIG. 20 is prepared, which is made of an insulating member such as a liquid crystal polymer, and includes an upper surface 35a, an outer peripheral surface 35b, an inner peripheral surface 35c, and a lower surface 35d of the wiring member 35. Next, although not shown, a cut similar to the cut 5d shown in FIG. 3 or the like is formed in a region other than the region forming the inner peripheral surface 35c of the resin sheet.

  Subsequently, the plurality of metal pins forming the wiring electrode 36 and the connecting member 48 are arranged in the longitudinal direction on the resin sheet in a state where the metal pins are slightly inclined in the direction orthogonal to the longitudinal direction of the resin sheet shown in FIG. Adhesive placement.

  As shown in FIG. 20, as in the example shown in FIG. 15, the end on the outer peripheral surface 35 b side of each wiring electrode 36 formed of metal pins is the lower end of the outer peripheral surface 35 b of the wiring member 35, respectively. The connection region 36a is formed by being bent along the edge. Further, as shown in FIG. 20, in the same manner as the wiring electrode 36, the end portions on the upper edge side of the respective resin sheets of the respective connection members 48 formed by metal pins are respectively along the edge of the resin sheet. A connection region 48a is formed by bending. In addition, connection terminals 48b for external connection are formed on both sides in the longitudinal direction of the region forming the lower surface 35d of the wiring member 35 of the resin sheet. In addition, the dashed-dotted line in FIG. 20 shows a fold line.

  Subsequently, with the surface on which each wiring electrode 36 and each connection member 48 is disposed facing outside, along the folding line set at the boundary between the outer peripheral surface 35b and the upper surface 35a and the boundary between the inner peripheral surface 35c and the upper surface 3a. Can be bent. As a result, a plurality of incisions (not shown) formed in the upward direction from the lower end on the outer peripheral surface 5b side are arranged in the longitudinal direction, and a long section having a substantially C-shaped cross section with an open bottom surface. An insulating member is formed. Next, the long insulating member is rounded into a ring shape with the respective cuts arranged on the outside. As a result, it has an upper surface 35a, an outer peripheral surface 35b, and an inner peripheral surface 35c that are formed of an insulating member and have substantially the same shape as the upper surface, outer peripheral surface, and inner peripheral surface of the coil core 2, and the coil core 2 is disposed on the inner side. A wiring member 35 is formed.

  Then, as shown in FIG. 21, after the coil core 2 is arranged inside the wiring member 35, the region that forms the lower surface 35 d of the resin sheet is bent in the direction of the outer peripheral surface of the coil core 2, and the connection region of each wiring electrode 36. 36a and the connection region 48a of each connection member 48 are connected to complete the coil device. At this time, one end on the outer side of one wiring electrode 36 on the outer surface of the wiring member 35 and the other end on the inner side of the wiring electrode 36 adjacent to one side of the wiring electrode 36 are respectively connected to the plurality of connecting members 48. Thus, the coil electrode 3 is formed.

  The present invention is not limited to the above-described embodiments, and various modifications other than those described above can be made without departing from the spirit of the present invention. You may combine. For example, in the above-described embodiment, the wiring member formed of an insulating resin sheet has been described as an example, but the insulating member forming the wiring member is not limited to thermoplastic or thermosetting resin, for example, The wiring member may be formed using paper which is an insulating member. In each of the above embodiments, the wiring electrode on the outer surface of the wiring member is formed of a metal pin. However, the wiring electrode is formed by screen printing using a conductive paste, photolithography or resist. The metal film (foil) may be formed by etching using printing.

  In addition, when forming a wiring electrode by the etching process using photolithography or resist printing, a wiring electrode can be formed as follows, for example. That is, first, a resin sheet on which a metal film (foil) such as Cu is formed is prepared, and a resist layer is formed by printing a resist resin. Next, the metal film is etched using an acid such as HCL to form a wiring electrode.

  Subsequently, the resist layer is removed with an alkali such as NaOH 2 and neutralization is performed. Subsequently, a cut is formed at a predetermined position of the resin sheet, and the resin sheet is bent by pressing or the like. At this time, when the resin sheet is formed of, for example, a liquid crystal polymer so that the resin sheet is favorably plastically deformed, the resin sheet is heated at about 80 ° C. for about 10 seconds. Then, the bent resin sheet is rounded into an annular shape, and the coil core is disposed inside thereof. Then, the corresponding end portions of the wiring electrodes are connected to each other by the connecting member by various methods as described above, thereby completing the coil device.

  Further, as described above, the connecting member may be configured in any way as long as the corresponding ends of the wiring electrodes can be connected to each other. For example, as described with reference to FIG. 13 in the third embodiment described above, in the case of a configuration in which both ends of each wiring electrode 6 are exposed to one main surface 13a of the resin insulating layer 13 in which the coil 4 is embedded. The connection member formed on the one main surface 13a by screen printing using a conductive paste, or the metal film (foil) formed by etching by photolithography or resist printing was formed on the one main surface 13a. The corresponding ends of the wiring electrodes 6 may be connected to each other by the connecting member. Moreover, the wiring electrode pattern may be formed on the insulating substrate by screen printing using a conductive paste. In all the embodiments described above, the coil 4 may be built in the resin insulating layer.

  Further, in each of the above-described embodiments, the wiring electrode disposed on the inner side of the coil core 2 having a limited arrangement space compared to the outer side of the coil core 2 is formed with a smaller diameter than the wiring electrode disposed on the outer side of the coil core 2. May be. If it does in this way, the further narrow pitch of the coil electrode 3 can be aimed at by narrowing a pitch of a wiring electrode.

  In each of the above embodiments, the toroidal type coil core 2 has been described as an example. However, the shape of the coil core is not limited to the toroidal type, but is linear or substantially C-shaped. The coil device can also be formed by using coil cores of various shapes such as those of the above. For example, it is possible to form a coil device in which the wiring member 35 shown in FIG. Moreover, the coil provided with various functions, such as a common mode noise filter and a choke coil, can be comprised with the coil with which a coil apparatus is provided.

  In the above-described embodiment, the wiring member is formed by bending the resin sheet after the line-shaped wiring electrode is formed on the resin sheet by metal pins or the like. However, after the resin sheet is bent and the wiring member is formed, a line-shaped wiring electrode may be formed on the surface by a metal pin or the like.

  And this invention is widely applicable to a coil apparatus provided with the coil which has an annular coil core, and the coil electrode wound helically around the coil core, and its manufacturing method.

1, 1a Coil device 2 Coil core 3 Coil electrode 4 Coil 5, 15, 35 Wiring member 5a, 15a, 35a Upper surface 5b, 15b, 35b Outer peripheral surface 5c, 15c, 35c Inner peripheral surface 5d Notch 15d Outer notch 15e Inner notch 6, 6, 26, 36 Wiring electrode 7 Insulating substrate 8 Wiring electrode pattern (connection member)
DESCRIPTION OF SYMBOLS 10 Annular part 11 Outer tongue piece part 12 Inner tongue piece part 18 Bonding wire (connection member)
25 Wiring members (other wiring members)
25a Lower surface 25b Outer peripheral surface 25c Inner peripheral surface 28, 38, 48 Connection member

Claims (12)

In a coil device comprising a coil having an annular coil core and a coil electrode spirally wound around the coil core,
A wiring member formed of an insulating member, having an upper surface, an outer peripheral surface and an inner peripheral surface having substantially the same shape as the annular upper surface, outer peripheral surface and inner peripheral surface of the coil core, and the coil core being disposed inside;
The coil electrode is
A plurality of line-shaped wiring electrodes formed from the lower end edge of the outer peripheral surface of the wiring member to the lower end edge of the inner peripheral surface through the upper surface and arranged in the circumferential direction on the outer surface of the wiring member; A coil device comprising: a plurality of connecting members formed to connect one end of a wiring electrode and the other end of the wiring electrode adjacent to one side of the wiring electrode.   The coil according to claim 1, wherein a plurality of cuts extending in a direction orthogonal to the circumferential direction from the lower end edge of the outer peripheral surface of the wiring member to the inner end edge of the upper surface are arranged in the circumferential direction. apparatus.   A plurality of outer notches extending in a direction orthogonal to the circumferential direction from the lower end edge of the outer peripheral surface of the wiring member to the outer end edge of the upper surface are arranged in the circumferential direction, and are formed from the lower end edge of the inner peripheral surface of the wiring member to the upper surface. The coil device according to claim 1, wherein a plurality of inner cuts extending in a direction orthogonal to the circumferential direction are arranged in the circumferential direction to the inner edge of the coil device.   The coil device according to any one of claims 1 to 3, wherein the connecting member is formed by a line-shaped wiring electrode pattern formed on an insulating substrate.   The coil device according to any one of claims 1 to 3, wherein the connecting member is formed of a bonding wire. Another wiring member that is formed of an insulating member and has a lower surface, an outer peripheral surface, and an inner peripheral surface that have substantially the same shape as the annular lower surface, outer peripheral surface, and inner peripheral surface of the coil core, and the coil core is disposed inside. In addition,
The coil device according to any one of claims 1 to 3, wherein the plurality of connecting members are arranged on a surface of the other wiring member.   The coil device according to claim 1, wherein both end portions of the wiring electrode are formed wider than the center portion.   The coil device according to any one of claims 1 to 7, wherein the wiring electrode is formed of a metal pin.   The coil device according to claim 8, wherein both end portions of the metal pin are bent along the lower end edges of the outer peripheral surface and the inner peripheral surface of the wiring member. In a method of manufacturing a coil device comprising a coil having an annular coil core and a coil electrode wound spirally around the coil core,
Formed by an insulating member, and having an upper surface, an outer peripheral surface and an inner peripheral surface having substantially the same shape as the annular upper surface, outer peripheral surface and inner peripheral surface of the coil core, and the outer surface of the coil core through the upper surface from the lower end edge of the outer peripheral surface A preparation step of preparing a wiring member in which a plurality of line-shaped wiring electrodes extending to the lower end edge of the inner peripheral surface are arranged in the circumferential direction, and the coil core is disposed inside thereof,
An arrangement step of arranging the coil core between an outer peripheral surface and an inner peripheral surface of the wiring member;
A connecting step of connecting one end of the one wiring electrode and the other end of the wiring electrode adjacent to one side of the wiring electrode with a connecting member to form the coil electrode. Production method. The wiring member is
After forming a plurality of cuts in the longitudinal direction in a direction perpendicular to the longitudinal direction from the lower end on one side to a long insulation member having a substantially C-shaped cross section with an open bottom surface, the insulation The method of manufacturing a coil device according to claim 10, wherein the member is formed by being circularly rolled with the respective notches arranged on the outside. The wiring member is
An annular portion, a plurality of outer tongue pieces integrally formed at predetermined intervals on the outer edge of the annular portion, and a plurality of inner tongue pieces integrally formed at predetermined intervals on the inner edge of the annular portion The method for manufacturing a coil device according to claim 10, wherein each of the outer tongue pieces and each of the inner tongue pieces is bent downward.

Images