JP3932089B2 - Coil device manufacturing method and core assembly - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a coil device and a core assembly used therefor. In the present invention, the coil device means a device including both a coil and a core combined therewith. The coil device may include other elements such as a capacitor, a resistor, a transistor, or the like as long as it includes a combination of the coil and the core as described above.
[0002]
[Prior art]
A coil device such as a transformer or a choke coil is used for a power supply circuit of an industrial device or a consumer device. This type of coil device is configured by combining a coil and a core. The coil is constituted by a winding or a coil pattern. The core may be composed of a single core member or an assembly of a plurality of core members. Furthermore, if necessary, a spacer is combined with the core. Such a coil device is known from, for example, Japanese Patent Laid-Open Nos. 2000-223332 and 6-314619.
[0003]
When manufacturing this type of coil device, in the prior art, the core of each coil device is manufactured as a single product. And a coil apparatus is comprised combining a coil for every core. Such a conventional technique causes the following problems when mass producing coil devices.
[0004]
One problem is that since the core of each coil device is manufactured as a single product, the manufacturing cost of the core cannot be reduced even when the coil device is mass-produced.
[0005]
Another problem is that even when the coil device is mass-produced, coils must be combined for each core, and the assembly cost of the coil device cannot be reduced.
[0006]
As a result, in the above-described conventional technology, the mass production cost of the coil device increases.
[0007]
In recent years, with the spread of small portable devices such as mobile phones and portable computers, coil devices mounted on these devices have been downsized. Along with this, the core of the coil device is also downsized.
[0008]
However, in the above-described prior art, since each core is manufactured as a single product, even if the core is downsized, the manufacturing cost of the core does not decrease. As a result, the ratio of the core manufacturing cost to the entire manufacturing cost of the coil device increases.
[0009]
Moreover, when the coil device is miniaturized and the core is miniaturized, it is difficult to combine the coils for each core. For this reason, the assembly cost of a coil apparatus increases.
[0010]
As a result, the above-described conventional technology increases the cost of mass-producing a small coil device.
[0011]
[Problems to be solved by the invention]
The subject of this invention is providing the manufacturing method of the coil apparatus which can reduce the manufacturing cost of a core, and the core aggregate used for it, when mass-producing a coil apparatus.
[0012]
Another object of the present invention is to provide a method of manufacturing a coil device that can reduce the assembly cost of the coil device in mass production of the coil device, and a core assembly used therefor.
[0013]
Still another object of the present invention is to provide a method of manufacturing a coil device that can reduce the mass production cost of the coil device, and a core assembly used therefor.
[0014]
Yet another object of the present invention is to provide a method of manufacturing a coil device that can reduce the cost of mass-producing a small-sized coil device, and a core assembly used therefor.
[0015]
[Means for Solving the Problems]
In order to solve the above-described problem, in the method for manufacturing a coil device according to the present invention, a plurality of coil devices are manufactured using a core assembly. This manufacturing method includes a first step and a second step.
[0016]
The core assembly has a plurality of first protrusions, the plurality of first protrusions are arranged in at least one row, and the first protrusions belonging to the same row are spaced from each other. Are arranged apart from each other.
[0017]
The first step is a step of configuring a coil device assembly by combining a coil with each of the plurality of first protrusions provided in the core assembly.
[0018]
The second step is a step of dividing the core assembly and separating the coil device assembly into individual coil devices after the first step.
[0019]
As described above, in the method for manufacturing a coil device according to the present invention, first, a coil device assembly is configured by combining a plurality of first protrusions provided in the core assembly with coils. Thereafter, the core assembly is divided to separate the coil device assembly into individual coil devices. Therefore, the cores provided in the plurality of coil devices can be manufactured collectively as a core assembly, and the manufacturing cost per core can be reduced.
[0020]
In the present invention, as described above, the coil device assembly is configured by combining the plurality of first protrusions provided in the core assembly with coils. Therefore, if the coils are combined with the plurality of first protrusions at the same time, the coils are combined with the cores of the plurality of coil devices at the same time, and the assembly cost of the coil devices can be reduced.
[0021]
Furthermore, in the core assembly, the plurality of first protrusions are arranged in at least one column, and the first protrusions belonging to the same column are arranged at intervals. Therefore, when the coil is combined with each of the first convex portions, the coil is easily positioned. As a result, the coils are combined with the cores of the coil devices very efficiently, and the assembly cost of the coil devices can be further reduced.
[0022]
As described above, according to the present invention, the manufacturing cost per core can be reduced, and the assembly cost of the coil device can be further reduced, thereby reducing the mass production cost of the coil device. be able to.
[0023]
In the manufacturing method of the coil device according to the present invention, a step of dividing the core assembly is required as compared with the conventional manufacturing method, but this dividing step can be performed at a low cost by automation or the like. The above effects are superior at reasonable costs.
[0024]
Next, when mass-producing a small coil device, even if the core of the coil device is small, the manufacturing cost per core can be reduced by collectively manufacturing these cores as a core assembly. it can. Moreover, even when the core of the coil device or the coil is small, the assembly of the coil device can be facilitated by simultaneously combining the coils with the cores of the plurality of coil devices. Therefore, when mass-producing a small-sized coil apparatus especially, mass production cost can be reduced.
[0025]
When mass-producing a coil device in which a spacer is combined with a core, a plurality of spacers may be combined with the core assembly at the same time, and then the core assembly may be divided. According to such a process, a spacer is combined with the cores of a plurality of coil devices at the same time, and the mass production cost of this type of coil device can be reduced.
[0026]
Other objects, configurations and advantages of the present invention will be described in more detail with reference to the accompanying drawings. The accompanying drawings are merely examples.
[0027]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a plan view of a core assembly used for carrying out a method for manufacturing a coil device according to the present invention, FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1, and FIG. FIG. 3 is a cross-sectional view taken along line 3-3. As illustrated, the core assembly includes a plurality of first convex portions 111 to 144. The illustrated core assembly has a substantially flat plate shape and has two surfaces 71 and 72. The plurality of first convex portions 111 to 144 described above are provided on one surface 71.
[0028]
In the core assembly, the plurality of first protrusions 111 to 144 are arranged in a plurality of rows (111 to 114), (121 to 124), (131 to 134), and (141 to 144). The illustrated columns (111 to 114), (121 to 124), (131 to 134), and (141 to 144) are linear columns extending in the X direction, respectively.
[0029]
The number of first protrusions and the number of rows are selected in consideration of manufacturing conditions such as the manufacturing apparatus of the coil device or the manufacturing number of the coil device. Depending on the manufacturing conditions, an arbitrary number of 2 or more is selected as the number of first protrusions, and an arbitrary number of 1 or more is selected as the number of columns. In the embodiment, 16 first convex portions and 4 rows are provided. Unlike such an embodiment, for example, eight first protrusions may be provided and only one column may be provided.
[0030]
Of the plurality of first protrusions 111 to 144 described above, the first protrusions belonging to the same row are arranged at intervals. For example, if one row (111 to 114) is representatively described, the adjacent first convex portions 111 and 112 are arranged with a distance L1 therebetween, and the adjacent first convex portions 112 and 113 are mutually connected. The first protrusions 113 and 114 that are adjacent to each other are arranged at an interval L2 and are adjacent to each other at an interval L3. The other columns (121 to 124), (131 to 134), and (141 to 144) are the same as the columns (111 to 114).
[0031]
Furthermore, among the plurality of first protrusions 111 to 144, the first protrusions belonging to the same column have substantially the same shape. For example, if one row (111 to 114) is described as a representative example, the first convex portions 111 to 114 have substantially the same shape. The shape of the illustrated first convex portions 111 to 114 is a columnar shape. The other columns (121 to 124), (131 to 134), and (141 to 144) are the same as the columns (111 to 114). Furthermore, in an Example, the 1st convex part which belongs to a different row | line | column among the some 1st convex parts 111-144 is also mutually substantially the same shape. That is, each of the plurality of first convex portions 111 to 144 has a cylindrical shape. Moreover, the shape of the 1st convex part is not limited to a cylinder. For example, unlike the embodiment, the shape of the first protrusion may be a prism.
[0032]
Furthermore, among the plurality of first protrusions 111 to 144, the first protrusions belonging to the same column have substantially the same dimensions. For example, if one row (111 to 114) is representatively described, the first convex portions 111 to 114 have substantially the same dimension L. The illustrated first convex portions 111 to 114 have a cylindrical shape as described above, and the dimension L is the diameter of the column. The other columns (121 to 124), (131 to 134), and (141 to 144) are the same as the columns (111 to 114). Furthermore, in an Example, the 1st convex part which belongs to a different row | line | column among the 1st convex parts 111-144 is also mutually substantially the dimension. That is, all the first convex portions 111 to 144 have the dimension L that is substantially equal to each other.
[0033]
Furthermore, the upper surfaces of the plurality of first convex portions 111 to 144 constitute the same plane. For example, as shown in FIG. 2, the upper surfaces of the first convex portions 111 to 114 constitute the same plane. Moreover, as shown in FIG. 3, the upper surface of the 1st convex parts 111-141 comprises the same plane.
[0034]
Furthermore, the 1st convex part which belongs to the same row among the several 1st convex parts 111-144 is arrange | positioned so that a space | interval may become substantially constant. For example, if it demonstrates typically about one row | line | column (111-114), the 1st convex parts 111-114 will be arrange | positioned so that the space | intervals L1-L3 may become substantially constant. The other columns (121 to 124), (131 to 134), and (141 to 144) are the same as the columns (111 to 114). Further, in the embodiment, the plurality of first convex portions 111 to 144 are all the rows (111 to 114), (121 to 124), (131 to 134), and (141 to 144), and the above-described intervals are Are equal.
[0035]
Among the plurality of first protrusions 111 to 144, the first protrusions 111 to 141 are arranged on the same straight line in the Y direction. The Y direction is a direction perpendicular to the aforementioned X direction. Furthermore, the 1st convex parts 111-141 are arrange | positioned at a fixed space | interval mutually on the same straight line of a Y direction. The other first convex portions 112 to 142, 113 to 143, and 113 to 143 are the same as the first convex portions 111 to 141. Thus, the plurality of first convex portions 111 to 144 are arranged in a lattice shape.
[0036]
The illustrated core assembly further includes a plurality of concave portions 41 to 44. The number of the concave portions is selected as an arbitrary number of 1 or more in consideration of conditions such as the number of the first convex portions, the number of rows by the first convex portions, or the manufacturing apparatus of the coil device. In the embodiment, the number of recesses is four, which is the same as the number of columns, in consideration of the number of columns due to the first protrusions. Unlike such an embodiment, for example, when there is only one row of the first protrusions, only one recess may be provided. Further, unlike the embodiment, in consideration of the number of first convex portions, one concave portion may be provided for each first convex portion, and 16 concave portions may be provided in total.
[0037]
The plurality of first convex portions 111 to 144 are erected on the bottom surfaces of the concave portions 41 to 44. In the embodiment, a plurality of concave portions 41 to 44 are provided, and among the plurality of first convex portions 111 to 144, the first convex portions belonging to the same row are erected on the bottom surface of the same concave portion. ing. For example, if one row (111 to 114) is representatively described, the first convex portions 111 to 114 belonging to this row (111 to 114) are erected on the bottom surface of the same concave portion 41. The other columns (121 to 124), (131 to 134), and (141 to 144) are the same as the above columns (111 to 114), and thus description thereof is omitted.
[0038]
The plurality of recesses 41 to 44 have substantially the same shape. The shape of the plurality of recesses 41 to 44 shown in the figure is a cuboid shape, specifically a flat plate shape. Further, the plurality of recesses 41 to 44 have a dimension D substantially equal to each other. The plurality of illustrated recesses 41 to 44 have a rectangular shape as described above, and the dimension D is one side of the rectangular parallelepiped. Furthermore, the bottom surfaces of the plurality of recesses 41 to 44 constitute the same plane.
[0039]
The plurality of recesses 41 to 44 are arranged at intervals D1 to D3. Specifically, the plurality of recesses 41 to 44 are arranged in a row at intervals D1 to D3 in the Y direction. These intervals D1 to D3 are substantially equal.
[0040]
The core assembly illustrated in FIGS. 1 to 3 includes a magnetic material. In the illustrated embodiment, the entire core assembly is made of a magnetic material. However, unlike the illustrated embodiment, the core assembly may include a reinforcing member such as ceramic. The magnetic material may be a metal oxide such as ferrite or a composite magnetic material.
[0041]
4 is a plan view of a coil support used in an embodiment of the method for manufacturing a coil device according to the present invention, FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 4, and FIG. FIG. As shown in FIGS. 4 to 6, the coil support 81 includes coils 211 to 214. Although the coil support body of an Example is provided with two or more coils, unlike an Example, only one coil may be sufficient.
[0042]
The shape of the illustrated coil support 81 is a shape that matches the first recess 41 of the core assembly illustrated in FIGS. 1 to 3. As described above, the shapes of the first recesses 41 to 44 are substantially equal to each other, and the coil support 81 fits all of the first recesses 41 to 44. Furthermore, the shape of the first recesses 41 to 44 is a rectangular shape, specifically, a flat plate shape. Correspondingly, the shape of the coil support 81 is also a rectangular shape, specifically, a flat plate shape. The coil support 81 has two surfaces, and the above-described coils 211 to 214 are provided on one surface of the coil support 81. Unlike this, coils may be provided on both sides of the coil support 81.
[0043]
The arrangement of the coils 211 to 214 includes the first protrusions (111 to 114), (121 to 124), (131 to 134), and (141 to 144) of the core assembly illustrated in FIGS. Fits the arrangement. Specifically, the coils 211 to 214 are arranged in a row at intervals in the X direction.
[0044]
The coil support 81 is made of a nonmagnetic material. Specifically, the coil support 81 is made of an organic circuit board material as a nonmagnetic material. The coil support 81 has holes 311 to 314. The illustrated holes 311 to 314 penetrate the coil support 81. In the embodiment, the coil support has a plurality of holes. However, unlike the embodiment, only one hole may be provided.
[0045]
The arrangement of the holes 311 to 314 conforms to the arrangement of the first convex portions (111 to 114), (121 to 124), (131 to 134), and (141 to 144) of the core assembly described above. Specifically, the holes 311 to 314 are arranged in a row at intervals in the X direction.
[0046]
Further, the shapes of the holes 311 to 314 are also the first convex portions (111 to 114), (121 to 124), (131 to 134) or (141 to 144) of the core assembly illustrated in FIGS. It conforms to the shape of For example, the holes 311 to 314 have a shape that fits the first convex portions 111 to 114, and the hole 311 has a shape that fits the first convex portion 111. As described above, the first convex portion 111 has a cylindrical shape, and the hole 311 has a circular cross-sectional shape correspondingly. The same applies to the other holes 312 to 314, and the holes 312 to 314 have a circular cross-sectional shape. Unlike the embodiment, for example, when the first convex portion has a prismatic shape, the hole of the coil support may have a polygonal cross-sectional shape.
[0047]
Furthermore, the coils 211 to 214 described above are provided on the coil support 81 around the holes 311 to 314. For example, the coil 211 is provided on the coil support 81 around the hole 311. The same applies to the other coils 212 to 214.
[0048]
The coils 211 to 214 are conductor patterns and are attached to the coil support 81. The conductor pattern may be formed on the coil support 81 by means such as plating, printing, vapor deposition or sputtering.
[0049]
The coil support 81 shown in FIGS. 4 to 6 is obtained by, for example, arranging a plurality of coils in a lattice shape on a nonmagnetic material substrate and cutting the nonmagnetic material substrate into a plurality of substrate pieces. Can do.
[0050]
FIG. 7 is a plan view for explaining one process included in the embodiment of the method for manufacturing a coil device according to the present invention, FIG. 8 is a sectional view taken along line 8-8 in FIG. 7, and FIG. It is the elements on larger scale of FIG. In the present invention, a plurality of coil devices are manufactured using the core assembly. The core assembly has already been described with reference to FIGS.
[0051]
In manufacturing a plurality of coil devices using a core assembly, first, as shown in FIGS. 7 to 9, coils 211 to 244 are provided on a plurality of first convex portions 111 to 144 provided in the core assembly. Are combined to constitute a coil device assembly. For example, the coils 211 to 214 are combined with the first protrusions 111 to 114 among the plurality of first protrusions 111 to 144. The other first convex portions 121 to 124, 131 to 134, and 141 to 144 are the same as the first convex portions 111 to 114.
[0052]
In the core assembly, one coil device element is formed each time one first convex portion is combined with a coil. For example, if the 1st convex part 111-114 is demonstrated typically, as shown in FIG. 7, FIG. 8, the 1st convex part 111-114 will be combined with the coils 211-214, and coil apparatus element Q11 will be described. To Q14 are configured. The other first convex portions 121 to 124, 131 to 134, and 141 to 144 are the same as the first convex portions 111 to 114, and coil device elements Q21 to Q44 are configured. These coil device elements Q11 to Q44 constitute a coil device assembly.
[0053]
FIG. 10 is a plan view for explaining a process after the process shown in FIGS. 7 to 9, and FIG. 11 shows a plurality of processes obtained through the process shown in FIGS. 7 to 9 and the process shown in FIG. It is sectional drawing of this coil apparatus. However, FIG. 11 corresponds to a sectional view taken along line 11-11 in FIG. After the steps shown in FIGS. 7 to 9, the core assembly is divided as shown in FIG. 10 to separate the coil device assembly into individual coil devices. For example, as shown in FIG. 11, it isolate | separates into each coil apparatus K11-K14.
[0054]
As shown in FIG. 10, the core assembly is divided so that the plurality of coil device elements Q11 to Q44 formed on the core assembly are separated from each other. For example, in order to separate the core device elements Q11 to Q14 from each other, the core assembly may be divided along the dividing lines X0 to X4. Further, in order to separate the core device elements Q11 to Q41 from each other, the core assembly may be divided along the dividing lines Y0 to Y4. In the embodiment, the core assembly is divided along the dividing lines X0 to X4 and Y0 to Y4. The core assembly may be divided, for example, by cutting the core assembly by means such as dicing.
[0055]
When the core assembly is divided as described above, the coil device elements Q11 to Q44 on the core assembly are separated from each other to form individual coil devices. For example, the coil device elements Q11 to Q14 are separated from each other as shown in FIG. 10, and become individual coil devices K11 to K14 as shown in FIG.
[0056]
Furthermore, when the core assembly is divided, the core assembly is separated into individual cores. For example, as shown in FIG. 11, the core aggregate is separated into cores 911 to 914. The coil devices K11 to K14 described above are composed of cores 911 to 914 and coils 211 to 214. FIG. 12 representatively shows an enlarged cross-sectional view of one coil device K12 among the coil devices K11 to K14.
[0057]
As shown in FIGS. 7-9, in the manufacturing method of the coil apparatus which concerns on this invention, first, combining the coils 211-244 with the some 1st convex parts 111-144 with which the core assembly was equipped. A coil device assembly is formed. For example, among the plurality of first protrusions 111 to 144, the first protrusions 111 to 114 will be described representatively. The coils 211 to 214 are combined with the first protrusions 111 to 114. Thereafter, as shown in FIGS. 10 and 11, the core assembly is divided to divide the coil device assembly into individual coil devices K11 to K14. Therefore, the cores 911 to 914 respectively provided in the plurality of coil devices K11 to K14 can be collectively manufactured as a core assembly, and the manufacturing cost per core can be reduced.
[0058]
In this invention, as shown in FIGS. 7-9, the coil apparatus assembly is comprised by combining the coils 211-244 with the some 1st convex parts 111-144 with which the core assembly was equipped, respectively. For example, the coils 211 to 214 are combined with the first convex portions 111 to 114. Therefore, if the coils 211 to 214 are combined with the plurality of first convex portions 111 to 114 at the same time, the coils 211 to 214 are combined with the cores 911 to 914 of the plurality of coil devices K11 to K14 at the same time. The assembly cost of K14 can be reduced.
[0059]
Furthermore, as shown in FIG. 1 and FIG. 2, in the core assembly, the plurality of first convex portions 111 to 144 have at least one row (111 to 114), (121 to 124), (131 to 134). , (141 to 144), and the first convex portions belonging to the same column are arranged at intervals. For example, among the plurality of first protrusions 111 to 144, the first protrusions 111 to 114 are arranged in one row (111 to 114), and in this row (111 to 114), the distances L1 to L1 are arranged. It arrange | positions across L3. Therefore, as shown in FIGS. 7 to 9, when the coils 211 to 214 are combined with the first convex portions 111 to 114, respectively, the coils 211 to 214 are easily positioned. As a result, the coils 211 to 214 are combined with the cores 911 to 914 of the coil devices K11 to K14 very efficiently, and the assembly cost of the coil devices K11 to K14 can be further reduced.
[0060]
As described above, according to the present invention, the manufacturing cost per core can be reduced, and the assembly cost of the coil device can be further reduced, thereby reducing the mass production cost of the coil device. be able to.
[0061]
In the method of manufacturing a coil device according to the present invention, a process of dividing the core assembly is required as shown in FIG. 10 as compared with the conventional manufacturing method. The above effects are superior at an overall cost.
[0062]
Next, when the mass-produced coil devices K11 to K14 are small, even if the cores 911 to 914 of the coil devices K11 to K14 are small, the cores 911 to 914 are manufactured together as a core assembly. The manufacturing cost per core can be reduced. Moreover, even when the cores 911 to 914 or the coils 211 to 214 of the coil devices K11 to K14 are small, the coils 211 to 214 are combined with the cores 911 to 914 of the plurality of coil devices K11 to K14 at the same time. Assembly of K14 can be facilitated. Therefore, when mass-producing a small-sized coil apparatus especially, mass production cost can be reduced.
[0063]
As described with reference to FIGS. 1 and 2, in the coil assembly, the plurality of first protrusions 111 to 144 include a plurality of rows (111 to 114), (121 to 124), and (131 to 134). ), (141 to 144). Therefore, as shown in FIG. 7, the coil combination operation is simultaneously performed on the plurality of rows (111 to 114), (121 to 124), (131 to 134), and (141 to 144), thereby The assembly cost of the apparatus can be further reduced.
[0064]
Furthermore, as described with reference to FIGS. 1 and 2, in the coil assembly, among the plurality of first protrusions 111 to 144, the first protrusions belonging to the same row have substantially the same shape. Are equal and have substantially the same dimensions. For example, if one row (111 to 114) is described as a representative example, the first protrusions 111 to 114 have substantially the same shape and have the same dimension L. Therefore, as shown in FIGS. 7 and 8, the coils 211 to 214 can be regularly combined with the first convex portions 111 to 114. For this reason, the assembly cost of a coil apparatus further falls. The same applies to the other columns (121 to 124), (131 to 134), and (141 to 144).
[0065]
With reference to FIGS. 7 to 9, in the embodiment, the coil supports 81 to 84 are combined with the plurality of first protrusions 111 to 144 provided in the core assembly. For example, if the 1st convex parts 111-114 are explained typically among a plurality of 1st convex parts 111-144, coil support body 81 will be combined with the 1st convex parts 111-114. As described with reference to FIGS. 4 to 6, the coil support 81 includes the coils 211 to 214. Therefore, as shown in FIGS. 7 to 9, the coils 211 to 214 can be easily combined with the first protrusions 111 to 114 by combining the coil support 81 with the first protrusions 111 to 114. it can. For this reason, the assembly cost of a coil apparatus further falls. The other first protrusions 121 to 124, 131 to 134, 141 to 144, and the other coil supports 82 to 84 are the same as the first protrusions 111 to 114 and the coil support 81. is there.
[0066]
Furthermore, as described with reference to FIGS. 4 to 6, the coil support 81 includes a plurality of coils 211 to 214. Therefore, as shown in FIGS. 7 to 9, by combining the coil support 81 with the first convex portions 111 to 114, the coils 211 to 214 can be simultaneously combined with the first convex portions 111 to 114. . For this reason, the assembly cost of a coil apparatus further falls.
[0067]
As described with reference to FIGS. 1 and 2, the core assembly further includes the concave portions 41 to 44, and the plurality of first convex portions 111 to 144 are formed on the bottom surfaces of the concave portions 41 to 44. It is erected. For example, among the plurality of first protrusions 111 to 144, the first protrusions 111 to 114 are erected on the bottom surface of the recess 41. Therefore, as shown in FIGS. 7 to 9, the coil support 81 is efficiently combined with the first protrusions 111 to 114 by combining the coil support 81 with the recess 41. For this reason, the assembly cost of a coil apparatus further falls. The step of combining the coil support 81 with the recess 41 may be performed, for example, by applying an adhesive to the bottom surface of the recess 41 and then fitting the coil support 81 into the recess 41. The same applies to the other first protrusions 121 to 124, 131 to 134, 141 to 144, and the other coil supports 82 to 84.
[0068]
Furthermore, as described with reference to FIGS. 1 and 2, the core assembly includes a plurality of first protrusions 111 to 144 in which the first protrusions belonging to the same row are the same recesses. Stands on the bottom. For example, if one row (111 to 114) is representatively described, the first convex portions 111 to 114 belonging to this row (111 to 114) are erected on the bottom surface of the same concave portion 41. Therefore, by combining the core support 81 with the recess 41, the coils 211 to 214 of the core support 81 can be combined with the first protrusions 111 to 114 belonging to one row (111 to 114) at the same time. . The same applies to the other columns (121 to 124), (131 to 134), and (141 to 144).
[0069]
As described with reference to FIGS. 4 to 6, the coil support 81 has holes 311 to 314, and the configurations of the other coil supports 82 to 84 are the same. 7 to 9, the holes of the coil supports 81 to 84 are combined with the plurality of first protrusions 111 to 144 of the core assembly. For example, the first convex portions 111 to 114 are combined with the holes 311 to 314 of the coil support 81. Thus, by combining the holes 311 to 314 of the coil support 81 with the first protrusions 111 to 114, the coil support 81 can be accurately positioned with respect to the first protrusions 111 to 114.
[0070]
Furthermore, as described with reference to FIGS. 4 to 6, in the coil support 81, the coils 211 to 214 are provided around the holes 311 to 314. Accordingly, as shown in FIGS. 7 to 9, the first convex portions 111 to 114 of the core assembly are combined with the holes 311 to 314 of the coil support 81 to support the first convex portions 111 to 114 with the coil. The coils 211 to 214 of the body 81 can be efficiently combined.
[0071]
As described with reference to FIGS. 10 and 11, after the steps shown in FIGS. 7 to 9, the core assembly is divided and the coil device assembly is separated into individual coil devices. In the embodiment, as shown in FIGS. 10 and 11, the coil supports 81 to 84 are also divided according to the division of the core assembly.
[0072]
In the embodiment shown in FIGS. 1 to 12, a coil device including only one coil is manufactured. However, unlike the embodiment, a coil device including a plurality of coils may be manufactured. In this case, a coil device such as a transformer is obtained.
[0073]
In the embodiment shown in FIGS. 1 to 12, a coil device including only a coil is manufactured as a circuit element. Unlike the embodiment, a coil including another circuit element such as a capacitor, a resistor, or a transistor. An apparatus may be manufactured. For example, if a coil support body including a resistor in addition to the coil is used, a coil device including the resistor as a circuit element can be obtained.
[0074]
FIG. 13 is a plan view of a coil support used in another embodiment of the method for manufacturing a coil device according to the present invention, and FIG. 14 is a cross-sectional view taken along line 14-14 of FIG. In comparison with the coil support 81 illustrated in FIGS. 4 to 6, the coil support 80 illustrated in FIGS. 13 and 14 includes only one coil 211.
[0075]
FIG. 15 is a plan view for explaining one process included in another embodiment of the method for manufacturing a coil device according to the present invention, and FIG. 16 is a cross-sectional view taken along line 16-16 in FIG. Also in this embodiment, the core assembly shown in FIGS. 1 to 3 is used in the same manner as the embodiment shown in FIGS. And as shown in FIG. 15, FIG. 16, the coil apparatus aggregate | assembly is comprised by combining the coil 211 with each of the some 1st convex parts 111-144 with which the core aggregate | assembly was equipped.
[0076]
In comparison with the embodiment shown in FIGS. 7 to 12, in this embodiment, the coil support 80 is combined with each of the plurality of first protrusions 111 to 144 provided in the core assembly. For example, if it demonstrates typically about the 1st convex parts 111-114 among the several 1st convex parts 111-144, the coil support body 80 will be combined with the 1st convex parts 111-114, respectively.
[0077]
As described with reference to FIGS. 13 to 14, the coil support 80 includes the coil 211. Therefore, as shown in FIGS. 15 and 16, the coil 211 can be easily combined with the first protrusions 111 to 114 by combining the coil support 80 with the first protrusions 111 to 114, respectively. it can. For this reason, the assembly cost of a coil apparatus further falls. The same applies to the other first convex portions 121 to 124, 131 to 134, and 141 to 144.
[0078]
After the steps shown in FIGS. 15 and 16, the core assembly is divided and the coil device assembly is separated into individual coil devices. In this embodiment, since the coil support 80 is combined with each of the plurality of first convex portions 111 to 144, the coil support 80 need not be divided when the coil device assembly is separated into individual coil devices. .
[0079]
FIG. 17 is a plan view for explaining one process included in still another embodiment of the method of manufacturing a coil device according to the present invention, and FIG. 18 is a cross-sectional view taken along the line 18-18 in FIG. FIG. 19 is a partially enlarged view of FIG. Also in this embodiment, the core assembly shown in FIGS. 1 to 3 is used in the same manner as the embodiment shown in FIGS.
[0080]
In contrast to the embodiment shown in FIGS. 7 to 12, in this embodiment, as shown in FIGS. 17 and 18, a plurality of conductor patterns 211 to 244 are formed in the core assembly. These conductor patterns 211 to 244 are formed around the plurality of first convex portions 111 to 144 of the core assembly, and constitute the coils 211 to 244. For example, the conductor pattern 212 is formed around the first convex portion 112 of the core assembly, and constitutes the coil 212. The conductor patterns 211 to 244 may be formed on the core aggregate by means such as plating, printing, vapor deposition, or sputtering.
[0081]
Through the above-described conductor pattern forming step, the coil device assembly can be configured by combining the plurality of first convex portions 111 to 144 of the core assembly with the coils 211 to 244 of the conductor pattern. For example, among the plurality of first protrusions 111 to 144, the first protrusions 111 to 114 are combined with the coils 211 to 214 of the conductor pattern to constitute the coil device elements Q11 to Q14. The other first convex portions 121 to 124, 131 to 134, and 141 to 144 are the same as the first convex portions 111 to 114, and coil device elements Q21 to Q44 are configured. These coil device elements Q11 to Q44 constitute a coil device assembly.
[0082]
After the steps shown in FIGS. 17 to 19, the core assembly is divided and the coil device assembly is separated into individual coil devices.
[0083]
As understood from the embodiments shown in FIGS. 17 to 19, as a method of combining the coil with the first convex portion of the core assembly, the conductor pattern is formed so as to go around the first convex portion in the core assembly. A coil may be formed.
[0084]
20 is a plan view for explaining one process included in still another embodiment of the method for manufacturing a coil device according to the present invention, and FIG. 21 is a cross-sectional view taken along line 21-21 in FIG. FIG. 22 is a partially enlarged view of FIG. In this embodiment, after the steps shown in FIGS. 7 to 9, as shown in FIGS. 20 and 21, the plurality of first protrusions 111 to 144 provided in the core assembly are combined with the combination members 51 to 51. 54 are combined. The combination members 51 to 54 are substantially equal in shape and substantially equal in size. The combination members 51 to 54 have a flat plate shape and have two plate surfaces.
[0085]
A combination of the combination members 51 to 54 with respect to the plurality of first convex portions 111 to 144 will be specifically described. For example, the combination member 51 is combined with the first convex portions 111 to 141 (see FIG. 21). Similarly, the combination members 52 to 54 are combined with the other first convex portions 112 to 142, 113 to 143, and 114 to 144. The above-mentioned combination members 51 to 54 are arranged on the core assembly so as to be spaced apart from each other in the X direction (see FIG. 20). In the embodiment, the plurality of combination members 51 to 54 are combined with the plurality of first protrusions 111 to 144, but unlike the embodiment, only one combination member may be combined with the plurality of first protrusions. Good.
[0086]
Of the combination members 51 to 54, the combination member 51 will be representatively described. As described above, the combination member 51 is combined with the first convex portions 111 to 141 of the core assembly. As described with reference to FIG. 3, the upper surfaces of the first convex portions 111 to 141 constitute the same plane. In the combination of the combination member 51 with respect to the first protrusions 111 to 141, one plate surface of the combination member 51 is brought into surface contact with the upper surface of the first protrusions 111 to 141.
[0087]
Further, as described with reference to FIGS. 7 to 9, the first convex portions 111 to 141 are combined with the coils 211 to 241 to constitute the coil device elements Q11 to Q41. As shown in FIG. 21, when the combination member 51 is combined with the first convex portions 111 to 141, the coil device elements Q <b> 11 to Q <b> 41 each include a part of the combination member 51. The other combination members 52 to 54 are the same as the combination member 51 described above.
[0088]
The combination members 51 to 54 are made of a magnetic material. The magnetic material may be a metal oxide such as ferrite or a composite magnetic material. Further, in the embodiment, the plurality of first convex portions 111 to 144 provided in the core assembly are combined with the combination members 51 to 54 made of a magnetic material, and the closed magnetic circuit is configured in each of the coils 211 to 244. . For example, if the 1st convex part 121 is typically explained among a plurality of 1st convex parts 111-144, as shown in Drawing 22, combining member 51 will be combined with the 1st convex part 121, Closed magnetic paths J1 and J2 are formed in the coil 221. In the illustrated embodiment, two closed magnetic paths J1 and J2 are configured, but the number of configured closed magnetic paths can be any number.
[0089]
FIG. 23 is a plan view for explaining a process subsequent to the process shown in FIGS. 20 to 22, and FIG. 24 is a plurality of processes obtained through the process shown in FIGS. 20 to 22 and the process shown in FIG. It is sectional drawing of this coil apparatus. However, FIG. 24 corresponds to a cross-sectional view taken along line 24-24 of FIG. After the steps shown in FIGS. 20 to 22, the core assembly is divided as shown in FIG. 23 to separate the coil device assembly into individual coil devices. For example, as shown in FIG. 24, it isolate | separates into each coil apparatus K11-K41.
[0090]
In this embodiment, similarly to the embodiments shown in FIGS. 10 and 11, the core assembly is divided so that the plurality of coil device elements Q11 to Q44 formed on the core assembly are separated from each other. . The core assembly is divided along dividing lines X0 to X4 and Y0 to Y4.
[0091]
When the core assembly is divided as described above, the coil device elements Q11 to Q44 on the core assembly are separated from each other to form individual coil devices. For example, the coil device elements Q11 to Q41 are separated from each other as shown in FIG. 23 and become individual coil devices K11 to K41 as shown in FIG.
[0092]
Furthermore, when the core assembly is divided, the core assembly is separated into individual cores. For example, as shown in FIG. 24, the core aggregate is separated into cores 911 to 941. The coil devices K11 to K41 described above are composed of cores 911 to 941 and coils 211 to 241.
[0093]
In comparison with the embodiment shown in FIGS. 10 and 11, in this embodiment, as shown in FIGS. 23 and 24, the combination members 51 to 54 are also divided according to the division of the core assembly. The combination members 51 to 54 are made of a magnetic material as described above, and are separated into individual cores when divided. For example, the combination member 51 is separated into cores 511 to 514 as shown in FIG.
[0094]
The coil devices K11 to K41 described above further include cores 511 to 514, and the cores 911 to 941 are combined with the cores 511 to 514 to constitute a core assembly. For example, in the coil device K21, the core 921 is combined with the core 512 to form a core assembly.
[0095]
In the embodiment shown in FIGS. 20 and 21, as described above, after the steps shown in FIGS. 7 to 9, the plurality of first convex portions 111 to 144 provided in the core assembly are combined with members. Combine 51-54. Unlike such an embodiment, a combination member may be combined with the plurality of first convex portions provided in the core assembly simultaneously with the steps shown in FIGS. That is, the coil device assembly may be configured by combining the coils with the plurality of first projections provided in the core assembly, and at the same time, the combination member may be combined with the plurality of first projections.
[0096]
In the embodiment shown in FIGS. 20 and 21, as described above, the combination members 51 to 54 are made of a magnetic material. Unlike such an embodiment, a combination member made of a nonmagnetic material such as an organic circuit board material may be used. In this case, an open magnetic circuit type coil device such as a magnetic sensor is obtained.
[0097]
25 is an enlarged plan view of one of the plurality of coil devices shown in FIG. 24, FIG. 26 is a cross-sectional view taken along line 26-26 of FIG. 25, and FIG. It is sectional drawing along line 27-27. 25 to 27, the coil device K21 is representatively shown among the coil devices K11 to K41 illustrated in FIG.
[0098]
As shown in FIGS. 25 to 27, the coil device K21 includes a core assembly (921, 512) and a coil support plate 821. The core assembly (921, 512) includes a core 921 and a core 512. The core 921 and the core 512 are overlapped with each other so as to face each other.
[0099]
The coil support plate 821 includes a coil 221. The coil support plate 821 is disposed between the core 921 and the core 512, and at least part of the coil support plate 821 constitutes exposed portions A1 and A2 that are exposed on the side of the core assembly (921, 512). The side portion of the core assembly (921, 512) means the side when viewed in the overlapping direction of the core 921 and the core 512.
[0100]
Further, the coil support plate 821 includes external terminals 17 and 19. The external terminals 17 and 19 are provided in the exposed portions A1 and A2 of the coil support plate 821. In the illustrated embodiment, the coil support plate 821 has a quadrangular shape, and the external terminals 17 and 19 are provided at both corners of the diagonal position. The coil 221 is provided on one surface 68 of the coil support plate 821. The outer coil end of the coil 221 continues to the terminal electrode 17. The inner coil end is led to the other surface 70 of the coil support plate 821 through the through conductor 43, further led to the one surface 68 through the through conductor, and is conducted to the terminal electrode 19.
[0101]
The core 921 includes a bottom plate portion 21 and a middle leg portion 23. One surface of the bottom plate portion 21 faces the coil support plate 821, and the middle leg portion 23 is erected on one surface of the bottom plate portion 21 and penetrates the hole 311 of the coil support plate 821. The core 921 shown in the embodiment has an E-shaped cross section including two outer leg portions 25 and 27 on both sides of the middle leg portion 23.
[0102]
The core 512 is disposed on the side opposite to the core 921 across the coil support plate 821 so as to face the distal end surface of the middle leg portion 23. The illustrated core 512 is flat and has an I-shaped cross section. In the embodiment, the core 921 is an E-type core member that includes the middle leg portion 23 and the outer leg portions 25 and 27 on the bottom plate portion 21, so that the core 512 has one surface on the middle leg portion 23 and the outer leg portions 25 and 27. In surface contact.
[0103]
FIG. 28 is a plan view for explaining one process included in still another embodiment of the method for manufacturing a coil device according to the present invention, and FIG. 29 is a sectional view taken along line 29-29 in FIG. In this embodiment, after the steps shown in FIGS. 7 to 9, as shown in FIGS. 28 and 29, the plurality of first protrusions 111 to 144 provided in the core assembly are respectively combined with the combination members 50. Combine. These combination members 50 are arranged on the core assembly so as to be spaced apart from each other in the X direction and spaced apart from each other in the Y direction.
[0104]
The combination members 50 have substantially the same shape and the same dimensions. The combination member 50 has a flat plate shape and has two plate surfaces. For example, in the combination of the combination member 50 with respect to the first protrusion 121 among the plurality of first protrusions 111 to 144, one plate surface of the combination member 50 is brought into surface contact with the upper surface of the first protrusion 121. .
[0105]
Further, as described with reference to FIGS. 7 to 9, the first convex portions 111 to 141 are combined with the coils 211 to 241 to constitute the coil device elements Q11 to Q41. As shown in FIG. 29, when the combination members 50 are combined with the first convex portions 111 to 141, the coil device elements Q11 to Q41 each include a part of the combination member 50.
[0106]
Also in this embodiment, similarly to the embodiments shown in FIGS. 20 to 24, the combination member 50 is made of a magnetic material. The magnetic material may be a metal oxide such as ferrite or a composite magnetic material. Furthermore, in an Example, the combination member 50 which consists of a magnetic material is combined with the some 1st convex parts 111-144 with which the core assembly was equipped, and a closed magnetic circuit is comprised in each coil 211-244.
[0107]
After the steps shown in FIGS. 28 and 29, the core assembly is divided to divide the coil device assembly into individual coil devices. In this embodiment, since the combination members 50 are combined with the plurality of first protrusions 111 to 144, respectively, when the coil device assembly is separated into individual coil devices, the division of the combination member 50 is not necessary.
[0108]
30 is a plan view of a coil support used in still another embodiment of the method for manufacturing a coil device according to the present invention, and FIG. 31 is an enlarged cross-sectional view taken along line 31-31 in FIG. . As shown in FIGS. 30 and 31, the coil support 81 includes a coil 211. Although the coil support 86 of the embodiment includes only one coil 211, unlike the embodiment, it may include a plurality of coils.
[0109]
The coil support 86 according to the embodiment is made of a magnetic material. The magnetic material may be a metal oxide such as ferrite or a composite magnetic material. Unlike the embodiment, the coil support may be made of a nonmagnetic material such as an organic circuit board material.
[0110]
The coil support 86 has a flat plate shape and has two plate surfaces. The coil 211 described above is provided on one plate surface of the coil support 86.
[0111]
A region P <b> 11 is set on one plate surface of the coil support 86. The region P11 is set so as to match the plurality of first convex portions 111 to 144 provided in the core assembly illustrated in FIGS. Specifically, the region P11 has a shape that conforms to the upper surfaces of the plurality of first convex portions 111 to 144. The upper surfaces of the plurality of first convex portions 111 to 144 have a circular shape, and the region P11 has a circular shape corresponding to this. The coil 211 is provided on the coil support 86 around the region P11 described above. Unlike the embodiment, for example, when the upper surfaces of the plurality of first protrusions have a rectangular shape, the region may have a rectangular shape.
[0112]
In the embodiment, the coil 211 has a conductor pattern and is attached to the coil support 86. The conductor pattern may be formed on the coil support 86 by means such as plating, printing, vapor deposition or sputtering. Unlike the embodiment, the coil may be constituted by a winding.
[0113]
The coil support 86 shown in FIGS. 30 and 31 can be obtained, for example, by arranging a plurality of coils in a lattice pattern on a magnetic material substrate and cutting the magnetic material substrate into a plurality of substrate pieces. .
[0114]
FIG. 32 is a partially broken plan view for explaining one process included in still another embodiment of the method for manufacturing a coil device according to the present invention, and FIG. 33 is a cross section taken along line 33-33 in FIG. FIG. Also in this embodiment, the core assembly shown in FIGS. 1 to 3 is used in the same manner as the embodiment shown in FIGS. Then, as shown in FIGS. 32 and 33, a coil device assembly is configured by combining a plurality of first convex portions 111 to 144 provided in the core assembly with coils 211, respectively. For example, referring to FIG. 33, the coils 211 are combined with the first convex portions 111 to 141 among the plurality of first convex portions 111 to 144, respectively.
[0115]
In this embodiment, a coil support 86 is combined with each of the plurality of first protrusions 111 to 144 provided in the core assembly. For example, referring to FIG. 33, the coil supports 86 are combined with the first convex portions 111 to 141, respectively. As described with reference to FIGS. 30 and 31, the coil support 86 includes the coil 211. Therefore, as shown in FIG. 33, the coil 211 is easily combined with each of the plurality of first protrusions 111 to 141 by combining the coil support 86 with each of the plurality of first protrusions 111 to 141. Can do. For this reason, the assembly cost of a coil apparatus further falls.
[0116]
As described with reference to FIGS. 30 and 31, the region P <b> 11 is set on the coil support 86, and the coil 211 is provided on the coil support 86 around the region P <b> 11. In the combination of the coil support body 86 with respect to the 1st convex parts 111-141, the area | region P11 of the coil support body 86 is combined with the upper surface of the 1st convex parts 111-141. The other first convex portions 112 to 142, 113 to 143, and 114 to 144 are the same as the first convex portions 111 to 141.
[0117]
As described with reference to FIGS. 30 and 31, the coil support 86 is made of a magnetic material. Further, in the embodiment, as shown in FIGS. 32 and 33, a plurality of first protrusions 111 to 144 provided in the core assembly are respectively combined with coil support bodies 86 made of a magnetic material, A closed magnetic circuit is formed in the coil 211. Referring to FIG. 33, the first convex portion 121 will be described representatively. The coil support 86 is combined with the first convex portion 121, and the closed magnetic paths J1 and J2 are configured in the coil 211. In the illustrated embodiment, two closed magnetic paths J1 and J2 are configured, but the number of configured closed magnetic paths can be any number. The other first convex portions 111, 131, and 141, and the other first convex portions 112 to 142, 113 to 143, and 114 to 144 are the same as the first convex portion 121.
[0118]
After the steps shown in FIGS. 32 and 33, the core assembly is divided and the coil device assembly is separated into individual coil devices. In this embodiment, since the coil support 86 is combined with each of the plurality of first convex portions 111 to 144, the coil support 86 is not required to be divided when the coil device assembly is separated into individual coil devices. .
[0119]
FIG. 34 is a plan view of a coil support used in still another embodiment of the method for manufacturing a coil device according to the present invention, and FIG. 35 is a cross-sectional view taken along the line 35-35 in FIG. As shown in FIGS. 34 and 35, the coil support 87 includes a plurality of coils 211 to 244.
[0120]
The coil support 87 according to the embodiment is made of a magnetic material. The magnetic material may be a metal oxide such as ferrite or a composite magnetic material. Unlike the embodiment, the coil support may be made of a nonmagnetic material such as an organic circuit board material.
[0121]
The illustrated coil support 87 has a flat plate shape and has two plate surfaces. The plurality of coils 211 to 244 described above are provided on one plate surface of the coil support 87.
[0122]
A plurality of regions P11 to P44 are set on one plate surface of the coil support 87. The plurality of regions P <b> 11 to P <b> 44 are set so as to conform to the plurality of first convex portions 111 to 144 provided in the core assembly illustrated in FIGS. 1 to 3. Specifically, the plurality of regions P11 to P44 are arranged so as to match the arrangement of the plurality of first convex portions 111 to 144. Furthermore, the plurality of regions P11 to P44 have a shape that fits the upper surfaces of the plurality of first convex portions 111 to 144. The upper surfaces of the plurality of first convex portions 111 to 144 have a circular shape, and the plurality of regions P11 to P44 also have a circular shape corresponding to this. The plurality of coils 211 to 244 are provided on the coil support 86 around the plurality of regions P11 to P44 described above. For example, the coil 221 is provided on the coil support 86 around the region P21. Unlike the embodiment, for example, when the upper surfaces of the plurality of first protrusions have a rectangular shape, the plurality of regions may have a rectangular shape.
[0123]
In the embodiment, the plurality of coils 211 to 244 have a conductor pattern and are attached to the coil support 86. The conductor pattern may be formed on the coil support 86 by means such as plating, printing, vapor deposition or sputtering. Unlike the embodiment, the coil may be constituted by a winding.
[0124]
FIG. 36 is a cross-sectional view illustrating one process included in still another embodiment of the method for manufacturing a coil device according to the present invention. However, FIG. 36 corresponds to FIG. Also in this embodiment, the core assembly shown in FIGS. 1 to 3 is used in the same manner as the embodiment shown in FIGS. And the coil apparatus aggregate | assembly is comprised by combining the coils 211-244 with the some 1st convex parts 111-144 with which the core aggregate | assembly was equipped. For example, referring to FIG. 36, coils 211 to 241 are combined with first protrusions 111 to 141 among a plurality of first protrusions 111 to 144.
[0125]
In this embodiment, a coil support 87 is combined with the plurality of first convex portions 111 to 144 provided in the core assembly. As described with reference to FIGS. 34 and 35, the coil support 87 includes a plurality of coils 211 to 244. Therefore, as shown in FIG. 36, the coils 211 to 244 can be easily combined with the first protrusions 111 to 141 by combining the coil support 87 with the plurality of first protrusions 111 to 141. . For this reason, the assembly cost of a coil apparatus further falls.
[0126]
As described with reference to FIGS. 34 and 35, a plurality of regions P11 to P44 are set on the coil support 87, and the plurality of coils 211 to 244 circulate around the plurality of regions P11 to P44. The coil support 87 is provided. In the combination of the coil support 87 with respect to the plurality of first protrusions 111 to 144, the plurality of regions P11 to P44 of the coil support 87 are combined with the upper surface of the plurality of first protrusions 111 to 144.
[0127]
As described with reference to FIGS. 34 and 35, the coil support 87 is made of a magnetic material. Furthermore, in an Example, as shown in FIG. 36, the coil support body 87 which consists of magnetic materials is combined with the some 1st convex parts 111-144 with which the core assembly was equipped, and the coils 211-244 are combined, Each constitutes a closed magnetic circuit. 36, the first convex portion 121 will be described as a representative example. The coil support 87 is combined with the first convex portion 121, and the closed magnetic paths J1 and J2 are configured in the coil 221. FIG. In the illustrated embodiment, two closed magnetic paths J1 and J2 are configured, but the number of configured closed magnetic paths can be any number. The other first convex portions 111, 131, and 141, and the other first convex portions 112 to 142, 113 to 143, and 114 to 144 are the same as the first convex portion 121.
[0128]
After the step shown in FIG. 36, the core assembly is divided to separate the coil device assembly into individual coil devices.
[0129]
【The invention's effect】
As described above, according to the present invention, the following effects can be obtained.
(A) In mass production of coil devices, it is possible to provide a method of manufacturing a coil device that can reduce the manufacturing cost of the core, and a core assembly used therefor.
(B) In mass production of coil devices, it is possible to provide a method of manufacturing a coil device that can reduce the assembly cost of the coil device, and a core assembly used therefor.
(C) It is possible to provide a method of manufacturing a coil device that can reduce the mass production cost of the coil device, and a core assembly used therefor.
(D) It is possible to provide a method of manufacturing a coil device that can reduce the cost of mass-producing a small-sized coil device, and a core assembly used therefor.
[Brief description of the drawings]
FIG. 1 is a plan view of a core assembly used in an embodiment of a method for manufacturing a coil device according to the present invention.
2 is a cross-sectional view taken along line 2-2 in FIG.
3 is a cross-sectional view taken along line 3—3 of FIG.
FIG. 4 is a plan view of a coil support used in an embodiment of the method for manufacturing a coil device according to the present invention.
FIG. 5 is a cross-sectional view taken along line 5-5 in FIG.
6 is a partially enlarged view of FIG. 5;
FIG. 7 is a plan view for explaining one process included in the embodiment of the method for manufacturing a coil device according to the present invention.
8 is a cross-sectional view taken along line 8-8 in FIG.
9 is a partially enlarged view of FIG.
10 is a plan view for explaining a step after the step shown in FIGS. 7 to 9. FIG.
11 is a cross-sectional view of a plurality of coil devices obtained through the steps shown in FIGS. 7 to 9 and the step shown in FIG.
12 is an enlarged cross-sectional view of one of the plurality of coil devices illustrated in FIG. 11. FIG.
FIG. 13 is a plan view of a coil support used in another embodiment of the method for manufacturing a coil device according to the present invention.
14 is a cross-sectional view taken along line 14-14 of FIG.
FIG. 15 is a plan view for explaining one process included in another embodiment of the method for manufacturing a coil device according to the present invention.
16 is a cross-sectional view taken along line 16-16 of FIG.
FIG. 17 is a plan view for explaining one process included in still another embodiment of the method for manufacturing a coil device according to the present invention.
18 is a cross-sectional view taken along line 18-18 in FIG.
19 is a partially enlarged view of FIG.
FIG. 20 is a plan view for explaining one process included in still another embodiment of the method for manufacturing a coil device according to the present invention.
21 is a cross-sectional view taken along line 21-21 of FIG.
22 is a partially enlarged view of FIG. 21. FIG.
FIG. 23 is a plan view for explaining a step after the step shown in FIGS. 20 to 22;
24 is a cross-sectional view of a plurality of coil devices obtained through the steps shown in FIGS. 20 to 22 and the step shown in FIG. 23;
25 is an enlarged plan view of one of the plurality of coil devices illustrated in FIG. 24. FIG.
26 is a cross-sectional view taken along line 26-26 in FIG.
FIG. 27 is a cross-sectional view taken along line 27-27 of FIG.
FIG. 28 is a plan view illustrating one process included in still another embodiment of the method for manufacturing a coil device according to the present invention.
29 is a cross-sectional view taken along line 29-29 in FIG. 28. FIG.
FIG. 30 is a plan view of a coil support used in still another embodiment of the method for manufacturing a coil device according to the present invention.
31 is an enlarged cross-sectional view taken along line 31-31 of FIG.
FIG. 32 is a partially broken plan view for explaining one process included in still another embodiment of the method for manufacturing a coil device according to the present invention.
33 is a cross-sectional view taken along line 33-33 of FIG. 32. FIG.
FIG. 34 is a plan view of a coil support used in still another embodiment of the method for manufacturing a coil device according to the present invention.
35 is a cross-sectional view taken along line 35-35 of FIG. 34. FIG.
FIG. 36 is a cross-sectional view illustrating one process included in still another embodiment of the method for manufacturing a coil device according to the present invention.
[Explanation of symbols]
111-144 1st convex part
211-244 coil

Claims (6)

A method of manufacturing a plurality of coil devices using a core assembly and a coil support , which includes a first step and a second step,
The core assembly includes at least one concave portion and a plurality of first convex portions, and the plurality of first convex portions are erected on a bottom surface of the concave portion and arranged in at least one row. The first protrusions belonging to the same row are spaced apart from each other,
The coil support has a shape that fits into the recess of the core assembly, and has a plurality of holes, and the coil support is placed in a mode in which a plurality of coils circulate around the plurality of holes, respectively. And
In the first step, a coil device assembly is formed by combining the plurality of coils with the plurality of first protrusions of the core assembly by combining the coil support with the recess of the core assembly. Is the process of configuring
The manufacturing method, wherein the second step is a step of dividing the core assembly and separating the coil device assembly into individual coil devices after the first step. A manufacturing method according to claim 1,
The said coil support body is a manufacturing method comprised with a nonmagnetic material. The manufacturing method according to claim 1 or 2 , further comprising a third step,
The third step is performed at the same time as or after the first step and before the second step, at least one combination of the plurality of first protrusions provided in the core assembly. A manufacturing method which is a process of combining members. A manufacturing method according to claim 3 , wherein
The said combination member is a manufacturing method comprised with a magnetic material.   A coil device assembly obtained by the manufacturing method according to claim 1.   A coil device obtained by the manufacturing method according to claim 1.

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