Method for manufacturing coil component

Patent metadata

Field	Value
Publication number	US-11640872-B2
Application number	US-201916715760-A
Country	US
Kind code	B2
Filing date	Dec 16, 2019
Priority date	Dec 28, 2018
Publication date	May 2, 2023
Grant date	May 2, 2023

Abstract

A method for manufacturing a coil component includes: a first winding step to wind a first conductive wire around a winding core in a single layer from a first flange part toward a second flange part; and a second winding step to wind a second conductive wire around the winding core on the first conductive wire by the same number of turns and in the same direction as in the first winding step in a single layer in a manner that center B of the cross-section of the second conductive wire closest to the first flange part is positioned closer to the first flange part than is center A of the cross-section of the first conductive wire closest to the first flange part, and that the distance in the axial direction, between centers A and B is smaller than the radius of the wire.

First claim

We claim:

1. A method for manufacturing a coil component, comprising:
a step to prepare a drum core that includes a straight winding core, a first flange part provided on one end of the winding core in an axial direction, and a second flange part provided on an other end of the winding core in the axial direction;
a first winding step where a first conductive wire, being a round wire, is wound around the winding core by a multiple number of turns in a single layer, from the first flange part toward the second flange part, in a manner that adjacent winding segments of the first conductive wire are contacting each other; and
a second winding step where a second conductive wire, being a round wire, is wound around the winding core on an outer periphery of the first conductive wire by a same number of turns as in the first winding step in a single layer, from the first flange part toward the second flange part, in a manner that adjacent winding segments of the second conductive wire are contacting each other;
wherein, in the second winding step, the second conductive wire is wound around the winding core in a manner that a center of an axial-direction cross-section of the second conductive wire at a second proximate winding segment which is a winding segment at a start of winding closest to the first flange part, is positioned closer to a first flange part side in the axial direction than a center of an axial-direction cross-section of the first conductive wire at a first proximate winding segment which is a winding segment at a start of winding closest to the first flange part in the first winding step, and that a distance in the axial direction, between the center of the cross-section of the first conductive wire at the first proximate winding segment and the center of the cross-section of the second conductive wire at the second proximate winding segment, becomes more than zero but smaller than an equivalent radius of the first conductive wire on the cross-section.

2. The method for manufacturing a coil component, according to claim 1 , wherein:
the step to prepare a drum core comprises having the winding core have a concaved part positioned at a distance away from the first flange part and concaved along a direction crossing the axial direction;
the first winding step comprises arranging the first proximate winding segment to fit in the concaved part; and
the second winding step comprises arranging the second proximate winding segment to contact the first flange part.

3. The method for manufacturing a coil component, according to claim 1 , wherein:
the step to prepare a drum core comprises having the winding core have a projecting part contacting the first flange part and projecting in a direction crossing the axial direction;
the first winding step comprises arranging the first proximate winding segment to contact a side face, which crosses the axial direction, of the projecting part; and
the second winding step comprises arranging the second proximate winding segment to contact the first flange part.

4. The method for manufacturing a coil component, according to claim 1 , wherein:
the step to prepare a drum core comprises having the winding core have a concaved part that includes a face sloped so that a diameter of the winding core decreases for points further away from the first flange part;
the first winding step comprises arranging the first proximate winding segment to fit in the concaved part; and
the second winding step comprises arranging the second proximate winding segment to contact the first flange part.

5. The method for manufacturing a coil component, according to claim 1 , wherein:
the step to prepare a drum core comprises having an interior face, to which the winding core is connected, of the first flange part have a slope so that a thickness of the first flange part in the axial direction increases for points closer to the winding core;
the first winding step comprises arranging the first proximate winding segment to contact the interior face of the first flange part; and
the second winding step comprises arranging the second proximate winding segment to contact the interior face of the first flange part.

6. The method for manufacturing a coil component, according to claim 1 , wherein:
a step to form a spacer part in contact with the first flange part around the winding core is provided before the first winding step;
a step to remove the spacer part is provided after the first winding step and before the second winding step;
the first winding step comprises arranging the first proximate winding segment to contact a side face, which crosses the axial direction, of the spacer part that has been formed in contact with the first flange part around the winding core; and
the second winding step comprises arranging the second proximate winding segment to contact the first flange part after the spacer part has been removed.

7. A method for manufacturing a coil component comprising:
(i) winding a first round conductive wire around a straight winding core in a single layer in an axial direction from a first flange part provided on one end of the winding core, toward a second flange part provided on another end of the winding core; and
(ii) winding a second round conductive wire around the winding core on the first round conductive wire in the axial direction by the same number of turns and in the same direction as in step (i) in a single layer in a manner that center B of a cross-section of the second round conductive wire closest to the first flange part is positioned closer to the first flange part than center A of the cross-section of the first round conductive wire closest to the first flange part, and that a distance in the axial direction between centers A and B is greater than zero but smaller than a radius of the first round conductive wire.

Assignees

• Taiyo Yuden Kk

Inventors

• Sato Kazuyoshi
• Tsukui Masashi
• Mogi Masashi

Classifications

• H01F27/292 Primary

  Surface mounted devices · CPC title

• H01F2017/0093

  Common mode choke coil · CPC title

• H01F41/073

  Winding onto elongate formers · CPC title

• H01F17/045

  with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core · CPC title

• H01F27/2828

  Construction of conductive connections, of leads · CPC title