JP6236910B2

JP6236910B2 - coil

Info

Publication number: JP6236910B2
Application number: JP2013131572A
Authority: JP
Inventors: 直也穂坂; 工藤　和秀; 和秀工藤; 雅司大室
Original assignee: Murata Manufacturing Co Ltd
Current assignee: Murata Manufacturing Co Ltd
Priority date: 2013-06-24
Filing date: 2013-06-24
Publication date: 2017-11-29
Anticipated expiration: 2033-06-24
Also published as: JP2015005695A

Description

本発明は、導体路が巻かれて構成されるコイルに関するものである。 The present invention relates to a configured coil and conductor is wound.

従来この種のコイルとしては、例えば、特許文献１に開示された折り曲げコイルがある。この折り曲げコイルは、電気絶縁性および可撓性を有したシート状基板が曲げ軸で折り曲げられて構成される。シート状基板の片面には、曲げ軸に対して、１つのパターンの端部の曲げ軸方向の位置と、隣接するパターンの別の端部の曲げ軸方向の位置とが一致するパターンで、多数の導電体が一定の間隔をおいて形成されている。このシート状基板が、導電体が形成された面を内側にして曲げ軸で曲げられ、互いに重なる導電体の端部が半田からなる接合材によって接合されることで、連続した導体路が形成されてヘリカル型巻線コイルが構成される。 Conventionally, as this type of coil, for example, there is a bending coil disclosed in Patent Document 1. This bending coil is configured by bending a sheet-like substrate having electrical insulation and flexibility with a bending axis. On one side of the sheet-like substrate, there are many patterns in which the position of the end of one pattern in the direction of the bending axis matches the position of the other end of the adjacent pattern in the direction of the bending axis with respect to the bending axis. Are formed at regular intervals. This sheet-like substrate is bent by a bending axis with the surface on which the conductor is formed inside, and the ends of the conductors that overlap each other are bonded by a bonding material made of solder, thereby forming a continuous conductor path. Helical winding coils are constructed.

また、従来、この種のコイルとして、例えば、特許文献２に開示されたボビンコイルもある。このボビンコイルは、絶縁フィルムが円筒状に湾曲されて構成される。絶縁フィルム上には、その対向する２辺に沿って複数の導体の各両端が配置され、かつ、一定のピッチで互いに隔たるように配設されて、導体列が形成されている。この絶縁フィルムが、導体列が略螺旋状に一列に繋がるように対向する２辺が合わされて円筒状に湾曲され、一方の辺に位置する導体の端部が他方の辺に位置する隣列する導体の端部に電気的に接続されることで、空芯コイル体が構成される。 Conventionally, as this type of coil, for example, there is a bobbin coil disclosed in Patent Document 2. The bobbin coil is configured by bending an insulating film into a cylindrical shape. On the insulating film, both ends of the plurality of conductors are disposed along the two opposing sides, and are arranged so as to be separated from each other at a constant pitch, thereby forming a conductor row. This insulating film is curved in a cylindrical shape with two opposite sides being combined so that the conductor rows are connected in a row in a substantially spiral shape, and the end of the conductor located on one side is adjacent to the other side. An air-core coil body is configured by being electrically connected to the end of the conductor.

特開平１１−２６５８１３号公報Japanese Patent Laid-Open No. 11-265813 特開２００２−９３６４９号公報JP 2002-93649 A

しかしながら、上記従来の特許文献１および特許文献２に開示されたいずれのコイルにおいても、複数の導電体を接合材によって接合することで、巻線状の導体路を形成している。このため、上記従来のいずれのコイルも、導電体を接合材によって接合する工程が必須となり、製品価格の低廉化を図ることができない。また、導電体の接続部が多数存在するため、コイルの製品としての接続部信頼性の低下を招く可能性が高い。従って、上記従来の各コイルは、導電体の一つ一つの各接続部の接続信頼性を向上させる構造もしくは製法がさらに必要となり、製品価格の上昇は免れ得ない。 However, in any of the coils disclosed in Patent Document 1 and Patent Document 2 described above, a winding conductor path is formed by joining a plurality of conductors with a joining material. For this reason, in any of the conventional coils described above, the step of joining the conductors with the joining material is essential, and the product price cannot be reduced. In addition, since there are a large number of conductor connection portions, there is a high possibility that the reliability of the connection portion as a coil product will be lowered. Therefore, each of the conventional coils further requires a structure or manufacturing method for improving the connection reliability of each connection portion of each conductor, and an increase in product price cannot be avoided.

本発明はこのような課題を解決するためになされたもので、
幅方向において所定のパターンで振幅し、長さ方向において前記パターンが所定回数周期的に繰り返される単一の導体路が電気絶縁性を有するシート上に形成され、厚み方向において、前記パターンが繰り返される周期でシートが曲げられて、導体路が巻かれたコイルであって、
シートの折り曲がりに嵌合する凹凸形状を一面に有する基材を備え、
導体路が、シートの連続する２つの面に形成される部分を１周期として前記パターンを繰り返し、その巻き始めおよび巻き終わりのシート両端部上に電極パットを備え、
シートが、長さ方向において上り斜面と下り斜面とが交互に現れる、連続する２つの面を１周期とする周期で折り曲げられ、基材の両側部を覆って基材の底面側に両端部が曲げ返され、内側に折り返された両端部上の電極パットを基材の底面に露出させて曲げられる
ことを特徴とするコイルを構成した。 The present invention has been made to solve such problems,
A single conductor path having a predetermined pattern in the width direction and periodically repeating the pattern a predetermined number of times in the length direction is formed on the sheet having electrical insulation, and the pattern is repeated in the thickness direction. A coil in which a sheet is bent at a period and a conductor path is wound;
A substrate having a concave and convex shape that fits into the sheet bend on one side,
Conductor path, to a portion formed on two consecutive surfaces of the sheet as one cycle repeat the pattern, an electrode pad on a sheet both ends of its winding start and winding end,
The sheet is bent in a cycle in which up and down slopes appear alternately in the length direction, with two continuous faces as one cycle, both sides of the base material are covered, and both end parts are on the bottom side of the base material A coil is configured to be bent by exposing the electrode pads on both ends that are bent back and folded inward to the bottom surface of the substrate .

本構成によれば、導体路は、長さ方向に進行するのに連れ、コイルの厚み方向において、折り曲げられたシートの上り斜面への上昇と下り斜面の下降とを交互に繰り返し、幅方向において、所定のパターンで振幅して、巻き構造を呈する。従って、単一の導体路が形成されたシートが、連続する２つの面を１周期とする周期で単に折り曲げられことで、シート上に形成された導体路が巻かれて、コイルが形成される。従って、従来のコイルのように、複数の導電体を接続してコイルを構成する導体路を形成する必要がなくなる。このため、導電体の接続部を備えること無く、巻線型コイルに似た巻き構造のコイルを形成することが可能になる。この結果、導電体を接合する工程が不要となってコイル製品価格の低廉化を図りながら、接続部信頼性の低下を招くことのない、巻線型コイルに似た巻き構造のコイルを簡単に提供することができる。 According to this configuration, as the conductor path travels in the length direction, in the thickness direction of the coil, in the thickness direction of the coil, the rising of the folded sheet and the descending slope are alternately repeated, and in the width direction. Amplified in a predetermined pattern to present a winding structure. Accordingly, a sheet on which a single conductor path is formed is simply bent at a period in which two continuous surfaces are defined as one cycle, whereby the conductor path formed on the sheet is wound to form a coil. . Therefore, it is not necessary to form a conductor path constituting the coil by connecting a plurality of conductors as in the conventional coil. For this reason, it is possible to form a coil having a winding structure similar to a wound coil without providing a connection portion of a conductor. As a result, it is easy to provide a coil with a winding structure similar to a wound coil without reducing the coil product price by eliminating the need to join the conductors and reducing the reliability of the connection part. can do.

また、シートが、連続する２つの面を１周期とする周期で鋸歯状に折り曲げられので、連続する４つの面を１周期とする周期で矩形波状に折り曲げられ、１折り曲げ周期で導体路が１周期の振幅を行う場合に比較して、少ない回数で１巻き当たりの折り曲げを行える。このため、同外形寸法のコイルにおいて、より多くの巻き数を稼ぐことができるので、大きなインダクタンスを有する巻き構造コイルを提供することができる。また、同じ巻き数のコイルにおいて、シートの折り曲げ回数を少なくすることができるので、シートの信頼性の向上を期待することができる。 Further, since the sheet is bent in a sawtooth shape with a period of two continuous surfaces as one cycle, the sheet is bent into a rectangular wave shape with a cycle of four consecutive surfaces as one cycle, and the conductor path is 1 in one folding cycle. As compared with the case where the amplitude of the period is performed, bending per winding can be performed with a small number of times. For this reason, since a larger number of turns can be obtained in the coil having the same outer dimensions, a wound structure coil having a large inductance can be provided. In addition, since the number of times the sheet is bent can be reduced in a coil having the same number of turns, an improvement in sheet reliability can be expected.

また、導体路の幅を広くすることで、斜面上に形成された導体路が厚み方向に占める高さは大きくなる。このため、巻き構造コイルの内径が小さくなってコイル内径部の断面積が小さくなり、コイル内径部を磁束が通り難くなるので、コイルのＱ値は低くなる。しかし、コイルの直流抵抗値は低くなるので、大電流を流せる巻き構造コイルが提供される。他方、導体路の幅を狭くすることで、斜面上に形成された導体路が厚み方向に占める高さは小さくなる。このため、巻き構造コイルの内径および内径部断面積の大きさを確保することができ、コイル内径部を磁束が通り易くなるので、高いＱ値を持つ巻き構造コイルが提供される。また、幅方向における導体路の振幅高さを大きくすることで、巻き構造コイルの内径部の断面積を大きくすることができる。このため、コイル内径部を磁束がさらに通り易くなるので、より高いＱ値を持つ巻き構造コイルが提供される。 Moreover, the height which the conductor path formed on the slope occupies in the thickness direction becomes large by widening the width of the conductor path. For this reason, the inner diameter of the wound structure coil is reduced, the cross-sectional area of the inner diameter portion of the coil is reduced, and the magnetic flux does not easily pass through the inner diameter portion of the coil. However, since the direct current resistance value of the coil is low, a wound structure coil capable of flowing a large current is provided. On the other hand, by reducing the width of the conductor path, the height of the conductor path formed on the slope in the thickness direction is reduced. For this reason, since the magnitude | size of the internal diameter and internal diameter part cross-sectional area of a winding structure coil can be ensured and a magnetic flux can easily pass along a coil internal diameter part, the winding structure coil with high Q value is provided. Further, by increasing the amplitude height of the conductor path in the width direction, the cross-sectional area of the inner diameter portion of the wound structure coil can be increased. For this reason, since it becomes easier for the magnetic flux to pass through the inner diameter portion of the coil, a wound structure coil having a higher Q value is provided.

本構成によれば、シートの曲げ形状が、シートの曲がりに嵌合する凹凸形状を一面に有する基材によって保たれ、強度が確保されるので、コイルの製品取り扱い性が向上する。 According to this configuration, the bending shape of the sheet is maintained by the base material having the uneven shape fitted to the bending of the sheet on one side, and the strength is ensured, so that the product handleability of the coil is improved .

本構成によれば、導体路の巻き始めおよび巻き終わりに導体路に一体に形成された電極パットが基材の底面に露出し、外部電極を構成する。このため、導電体の接続部を全く有すること無く、コイルに外部電極を備えることができ、外部電極を備えた巻き構造のコイルを安価にかつ接続信頼性高く提供することができる。また、基材の両側部で導体路が曲げ返されることで、コイルの長さ方向に外部電極形成のための寸法を取る必要がなくなり、コイルの長さ方向を全て巻線形成に使用することができる。このため、同外形寸法および同構成材料のコイルにおけるインダクタンス取得効率を上げることができる。 According to this configuration, the electrode pads formed integrally with the conductor path at the start and end of winding of the conductor path are exposed on the bottom surface of the base material, and constitute the external electrode. For this reason, an external electrode can be provided in a coil, without having any connection part of a conductor, and the coil of the winding structure provided with the external electrode can be provided cheaply and with high connection reliability. Also, since the conductor track is bent back on both sides of the base material, it is not necessary to take the dimensions for forming the external electrodes in the length direction of the coil, and the entire length direction of the coil must be used for winding formation. Can do. For this reason, the inductance acquisition efficiency in the coil of the same outer dimension and the same constituent material can be increased.

また、本発明は、
幅方向において所定のパターンで振幅し、長さ方向において前記パターンが所定回数周期的に繰り返される単一の導体路が電気絶縁性を有するシート上に形成され、厚み方向において、前記パターンが繰り返される周期でシートが曲げられて、導体路が巻かれたコイルであって、
シートが、長さ方向において上り斜面と下り斜面とが交互に現れる、連続する２つの面を１周期とする周期で折り曲げられ、
導体路が、連続する２つの面に形成される部分を１周期として前記パターンを繰り返し、
シートの周囲を囲む基材、または、シートの折り曲がりに嵌合する凹凸形状を一面に有する基材、または、シートの曲がりに下方から嵌合する凹凸形状を一面に有する下側基材およびシートの曲がりに上方から嵌合する凹凸形状を一面に有する上側基材からなる基材と、
基材の側面に露出する導体路の巻き始めおよび巻き終わりに電気的に接続され、基材の側面一面に形成される外部電極とを備える
ことを特徴とする。 The present invention also provides:
A single conductor path having a predetermined pattern in the width direction and periodically repeating the pattern a predetermined number of times in the length direction is formed on the sheet having electrical insulation, and the pattern is repeated in the thickness direction. A coil in which a sheet is bent at a period and a conductor path is wound;
The sheet is bent in a cycle with two continuous surfaces as one cycle in which an upward slope and a downward slope appear alternately in the length direction,
The pattern is repeated with a portion where the conductor path is formed on two continuous surfaces as one cycle,
A base material that surrounds the periphery of the sheet, a base material that has a concavo-convex shape that fits in a sheet bend, or a lower base material and a sheet that has a concavo-convex shape that fits in a sheet bend from below. A base material composed of an upper base material having a concave-convex shape that fits from above into a bend, and
Is connected to the end winding start and the winding conductor track exposed on the side surface of the base material electrically, characterized in that it comprises an external electrode formed on one surface side of the substrate.

本構成によれば、基材の側面に露出する導体路の巻き始めおよび巻き終わりにだけ外部電極を接続することで、基材の側面一面に外部電極を備える巻き構造のコイルを構成することができる。このため、導電体の接続箇所が２箇所で、接続信頼性の低下を招くことの懸念が極めて少ない、外部電極を備えた巻き構造のコイルを安価にかつ接続信頼性高く提供することができる。
本構成によれば、シートの曲げ形状が基材によって保たれ、強度が確保されるので、コイルの製品取り扱い性が向上する。
本構成によれば、コイルの長さ方向に外部電極形成のための寸法を取る必要がなくなり、コイルの長さ方向を全て巻線形成に使用することができる。このため、同外形寸法および同構成材料のコイルにおけるインダクタンス取得効率を上げることができる。 According to this configuration, it is possible to configure a coil having a wound structure including an external electrode on one side surface of the base material by connecting the external electrode only at the start and end of winding of the conductor path exposed on the side surface of the base material. it can. For this reason, it is possible to provide a coil having a wound structure including the external electrode at low cost and with high connection reliability, with only two conductor connection points and very little fear of causing a decrease in connection reliability.
According to this configuration, the bending shape of the sheet is maintained by the base material and the strength is ensured, so that the coil product handling property is improved.
According to this structure, it is not necessary to take the dimension for external electrode formation in the length direction of a coil, and all the length directions of a coil can be used for winding formation. For this reason, the inductance acquisition efficiency in the coil of the same outer dimension and the same constituent material can be increased.

また、本発明は、基材が、非磁性体または磁性体からなることを特徴とする。 Further, the present invention is characterized in that the substrate is made of a nonmagnetic material or a magnetic material.

本構成によれば、基材が非磁性体からなる場合には基材の透磁率が小さくなり、インダクタンスを低く抑えることができるので、高周波用途の巻き構造コイルが提供される。また、基材が磁性体からなる場合には基材の透磁率が大きくなるので、用いる磁性体の種類を選択することで、所望の大きさのインダクタンスを有する巻き構造コイルが得られる。 According to this configuration, when the base material is made of a non-magnetic material, the magnetic permeability of the base material becomes small and the inductance can be kept low, so that a wound structure coil for high frequency applications is provided. Moreover, since the magnetic permeability of a base material becomes large when the base material is made of a magnetic material, a wound structure coil having a desired magnitude of inductance can be obtained by selecting the type of magnetic material to be used.

本発明によれば、上記のように、導電体を接合する工程が不要となってコイル製品価格の低廉化を図りながら、接続部信頼性の低下を招くことのない、巻線型コイルに似た巻き構造のコイルを簡単に提供することができる。 According to the present invention, as described above, it is similar to a wound coil that does not require a process of joining conductors and reduces the coil product price, and does not cause a decrease in reliability of the connection portion. A coil having a winding structure can be easily provided.

本発明の第１，第２，第３の各実施形態によるコイルの外観斜視図である。It is an external appearance perspective view of the coil by each 1st, 2nd, 3rd embodiment of this invention. 図１に示すコイルを構成する下側基材および上側基材の外観斜視図である。It is an external appearance perspective view of the lower side base material and upper side base material which comprise the coil shown in FIG. （ａ）は、第１の実施形態によるコイルを構成するシートが折り曲げられる前の平面図、（ｂ）は、（ａ）に示すシートが折り曲げられた状態の斜視図、（ｃ）は、（ａ）に示すシートが別の態様で折り曲げられた状態の斜視図である。(A) is a top view before the sheet | seat which comprises the coil by 1st Embodiment is bent, (b) is a perspective view of the state which the sheet | seat shown to (a) was bent, (c) is ( It is a perspective view in the state where the sheet shown in a) was bent in another mode. （ａ）は、第２の実施形態によるコイルを構成するシートが折り曲げられる前の平面図、（ｂ）は、（ａ）に示すシートが折り曲げられた状態の斜視図、（ｃ）は、（ａ）に示すシートが別の態様で折り曲げられた状態の斜視図である。(A) is a top view before the sheet | seat which comprises the coil by 2nd Embodiment is bent, (b) is a perspective view of the state which the sheet | seat shown to (a) was bent, (c) is ( It is a perspective view in the state where the sheet shown in a) was bent in another mode. （ａ）は、第３の実施形態によるコイルを構成するシートが折り曲げられる前の平面図、（ｂ）は、（ａ）に示すシートが折り曲げられた状態の斜視図、（ｃ）は、（ａ）に示すシートが別の態様で折り曲げられた状態の斜視図である。(A) is a top view before the sheet | seat which comprises the coil by 3rd Embodiment is bent, (b) is a perspective view of the state which the sheet | seat shown to (a) was bent, (c) is ( It is a perspective view in the state where the sheet shown in a) was bent in another mode. （ａ）は、各実施形態によるコイルと比較されるコイルを構成するシートが折り曲げられる前の平面図、（ｂ）は、（ａ）に示すシートが折り曲げられた状態の斜視図である。(A) is a top view before the sheet | seat which comprises the coil compared with the coil by each embodiment is bent, (b) is a perspective view of the state which the sheet | seat shown to (a) was bent. 各実施形態の変形例によるコイルの外観斜視図である。It is an external appearance perspective view of the coil by the modification of each embodiment. （ａ）は、各実施形態の他の変形例によるコイルの外部電極を備える前の外観斜視図、（ｂ）は、（ａ）に示すコイルの外部電極を備えた外観斜視図である。(A) is an external appearance perspective view before providing the external electrode of the coil by the other modification of each embodiment, (b) is an external perspective view provided with the external electrode of the coil shown to (a). 図８に示す構造のコイルが得られるマザー基板の側面図である。It is a side view of the mother board | substrate from which the coil of the structure shown in FIG. 8 is obtained.

次に、本発明のコイルおよびその製造方法の実施形態について、説明する。 Next, embodiments of the coil and the manufacturing method thereof according to the present invention will be described.

図１は、本発明の第１，第２，第３の各実施形態によるコイル１の外観斜視図である。 FIG. 1 is an external perspective view of a coil 1 according to the first, second, and third embodiments of the present invention.

コイル１は、非磁性体または磁性体からなる下側基材２および上側基材３と、電気絶縁性を有するシート４とを備えて構成されており、幅Ｗ，長さＬ，厚みｔの直方体状をしている。下側基材２は、その外観が図２（ｂ）に示され、底面２ａに対向する一面２ｂに、シート４の鋸歯状の折れ曲がりに下方から嵌合する凹凸形状を、コイル１の巻き数分有する。上側基材３は、その外観が図２（ａ）に示され、上面３ａに対向する一面３ｂに、シート４の鋸歯状の折れ曲がりに上方から嵌合する凹凸形状を、コイル１の巻き数分有する。また、上側基材３は、下側基材２の両側部２ｃ，２ｃを覆って山面３ｃ，３ｃが下側基材２の底面２ａと並ぶ凸部３ｄ，３ｄを両端部に備えている。コイル１の厚みｔは、凸部３ｄ，３ｄの高さ寸法になっている。下側基材２の長さは、これら凸部３ｄ，３ｄの分、上側基材３の長さよりも短くなっている。シート４は、エポキシ、ポリイミドなどの樹脂や、セラミック等の材質からなり、これら下側基材２および上側基材３の各凹凸形状部間に挟まれて、設けられている。 The coil 1 includes a lower base material 2 and an upper base material 3 made of a nonmagnetic material or a magnetic material, and a sheet 4 having electrical insulation, and has a width W, a length L, and a thickness t. It has a rectangular parallelepiped shape. The external appearance of the lower substrate 2 is shown in FIG. 2 (b), and the concave / convex shape that fits from below into the serrated bend of the sheet 4 is formed on one surface 2 b facing the bottom surface 2 a. Have a minute. The outer appearance of the upper base material 3 is shown in FIG. 2 (a), and a concave / convex shape that fits from above into a serrated bend of the sheet 4 on one surface 3b that opposes the upper surface 3a, for the number of turns of the coil 1. Have. Further, the upper base material 3 includes convex portions 3d and 3d at both ends so as to cover both side portions 2c and 2c of the lower base material 2 and the crest surfaces 3c and 3c are aligned with the bottom surface 2a of the lower base material 2. . The thickness t of the coil 1 is the height of the convex portions 3d and 3d. The length of the lower base material 2 is shorter than the length of the upper base material 3 by the amount of the convex portions 3d and 3d. The sheet 4 is made of a resin such as epoxy or polyimide, or a material such as ceramic, and is provided between the concave and convex portions of the lower base material 2 and the upper base material 3.

図３（ａ）は、本発明の第１の実施形態によるコイル１に用いられるシート４が折り曲げられる前の平面図である。シート４上には単一の導体路５Ａが、銅、銀などの一般的な内部電極材料を用いて、印刷法やリソグラフィー技術などの一般的な電極形成法によって形成されている。この導体路５Ａは、コイル１の幅Ｗ方向において、所定の正弦波状パターンで振幅し、コイル１の長さＬ方向において、この正弦波状パターンがコイル１の巻き数に相当する所定回数周期的に繰り返されて、ミアンダ形状に形成されている。このシート４が、厚みｔ方向において、正弦波状パターンが繰り返される１周期を１周期とする周期で、図３（ｂ）の斜視図に示すように折り曲げられることで、導体路５Ａは巻き線形状を呈する。 Fig.3 (a) is a top view before the sheet | seat 4 used for the coil 1 by the 1st Embodiment of this invention is bent. A single conductor path 5A is formed on the sheet 4 by a general electrode forming method such as a printing method or a lithography technique using a general internal electrode material such as copper or silver. The conductor path 5A is oscillated with a predetermined sinusoidal pattern in the width W direction of the coil 1 and periodically in the length L direction of the coil 1 at a predetermined number of times corresponding to the number of turns of the coil 1. It is repeated to form a meander shape. The sheet 4 is bent as shown in the perspective view of FIG. 3B with a period in which one period in which the sinusoidal pattern is repeated is one period in the thickness t direction, so that the conductor path 5A has a winding shape. Presents.

シート４の上記の折り曲げは、図３（ａ）に一点鎖線で示す折り曲げ線を谷折り線ｖ、破線で示す折り曲げ線を山折り線ｍとして行われ、長さＬ方向において上り斜面Ｕと下り斜面Ｄとが交互に現れる、連続する２つの面を１周期とする周期で折り曲げられる。また、導体路５Ａは、シート４の折り曲げ線に交差して上り斜面Ｕおよび下り斜面Ｄに形成されており、正弦波振幅パターンの１周期の半周期部分が、上り斜面Ｕおよび下り斜面Ｄのそれぞれに形成されている。従って、導体路５Ａは、長さＬ方向に進行するのに連れ、コイル１の厚みｔ方向において、シート４の上り斜面Ｕでの上昇と下り斜面Ｄでの下降とを交互に繰り返し、幅Ｗ方向において、上り斜面Ｕおよび下り斜面Ｄの各斜面で、１周期の半周期の正弦波をそれぞれ描くパターンで振幅して、巻き構造を呈する。 The above folding of the sheet 4 is performed with the folding line indicated by the alternate long and short dash line in FIG. 3A as the valley fold line v and the folding line indicated by the broken line as the mountain fold line m. Bending is performed with a period in which two continuous surfaces appearing alternately as slopes D are taken as one period. Further, the conductor path 5A is formed on the ascending slope U and the descending slope D so as to intersect with the folding line of the sheet 4, and a half-cycle portion of one cycle of the sine wave amplitude pattern is formed between the ascending slope U and the descending slope D. Each is formed. Therefore, as the conductor path 5A travels in the length L direction, the rise of the sheet 4 on the rising slope U and the lowering on the down slope D are alternately repeated in the thickness t direction of the coil 1, and the width W In the direction, each of the ascending slope U and the descending slope D has an amplitude in a pattern in which a half-cycle sine wave is drawn, thereby exhibiting a winding structure.

導体路５Ａは、その巻き始めおよび巻き終わりのシート４上に電極パット５ａ，５ａを備える。シート４は、上側基材３の両端部に備えられた凸部３ｄ，３ｄの山面３ｃ，３ｃに、電極パット５ａ，５ａが露出して折り曲げられる。このため、電極パット５ａ，５ａの前の側面Ｓにおける導体路５Ａは、直線状に形成されている。なお、この側面Ｓにおける導体路５Ａは、必ずしも直線状に形成する必要は無く、上り斜面Ｕおよび下り斜面Ｄと同様に正弦波状に振幅させてもよい。 The conductor path 5A includes electrode pads 5a and 5a on the sheet 4 at the start and end of winding. In the sheet 4, the electrode pads 5 a and 5 a are exposed and bent on the crest surfaces 3 c and 3 c of the convex portions 3 d and 3 d provided at both ends of the upper base material 3. For this reason, the conductor path 5A on the side surface S in front of the electrode pads 5a, 5a is formed in a straight line. Note that the conductor path 5A on the side surface S is not necessarily formed in a straight line shape, and may be sine wave-like amplitude like the ascending slope U and the descending slope D.

図４（ａ）は、本発明の第２の実施形態によるコイル１に用いられるシート４が折り曲げられる前の平面図、同図（ｂ）は同シート４を折り曲げた状態の斜視図である。なお、同図において図３と同一または相当する部分には同一符号を付してその説明は省略する。 FIG. 4A is a plan view before the sheet 4 used in the coil 1 according to the second embodiment of the present invention is folded, and FIG. 4B is a perspective view of the state in which the sheet 4 is folded. In the figure, the same or corresponding parts as in FIG.

第２の実施形態によるコイル１では、図４（ａ）に示すように、導体路５Ｂを、コイル１の幅Ｗ方向において、所定の矩形波状パターンで振幅させ、コイル１の長さＬ方向において、この矩形波状パターンをコイル１の巻き数に相当する所定回数周期的に繰り返して、ミアンダ形状に形成する。この際、導体路５Ｂは、幅Ｗ方向において、最も低い振幅高さｈ_０から最も高い振幅高さｈ_１まで振れ、その後、最も低い振幅高さｈ_０まで戻る振幅を１振幅とした場合、上り斜面Ｕまたは下り斜面Ｄのいずれか一方に、１振幅の所定割合部分が形成される。本例では上り斜面Ｕに１振幅の１／４部分が形成される。また、上り斜面Ｕまたは下り斜面Ｄのいずれか他方に、１振幅の残りの割合部分が形成される。本例では下り斜面Ｄに１振幅の３／４部分が形成される。 In the coil 1 according to the second embodiment, as shown in FIG. 4A, the conductor path 5 B is amplified in a predetermined rectangular wave pattern in the width W direction of the coil 1, and in the length L direction of the coil 1. The rectangular wave pattern is periodically repeated a predetermined number of times corresponding to the number of turns of the coil 1 to form a meander shape. In this case, if the conductor track. 5B, which is in the width W direction, deflection from the lowest amplitude height h ₀ to the highest amplitude height h _1, then the amplitude back to the lowest amplitude height h ₀ and 1 amplitude, A predetermined proportion of one amplitude is formed on either the uphill slope U or downhill slope D. In this example, a quarter portion of one amplitude is formed on the ascending slope U. Further, the remaining proportion portion of one amplitude is formed on either the up slope U or the down slope D. In this example, a 3/4 portion of 1 amplitude is formed on the downward slope D.

この第２の実施形態によるコイル１でも、シート４は、図４（ｂ）の斜視図に示すように第１の実施形態によるコイル１と同様にして折り曲げられる。導体路５Ｂは、長さＬ方向に進行するのに連れ、コイル１の厚みｔ方向において、シート４の上り斜面Ｕでの上昇と下り斜面Ｄでの下降とを交互に繰り返し、幅Ｗ向において、上り斜面Ｕで１振幅の１／４割合分を振幅し、下り斜面Ｄで１振幅の３／４割合分を振幅して、巻き構造を呈する。 Also in the coil 1 according to the second embodiment, the sheet 4 is bent in the same manner as the coil 1 according to the first embodiment as shown in the perspective view of FIG. As the conductor path 5B travels in the length L direction, in the thickness t direction of the coil 1, the sheet 4 is alternately raised and lowered on the rising slope U and descending on the falling slope D in the direction of the width W. The uphill slope U oscillates a ratio of 1/4 of one amplitude, and the downhill slope D amplifies 3/4 ratio of 1 amplitude to present a winding structure.

図５（ａ）は、本発明の第３の実施形態によるコイル１に用いられるシート４が折り曲げられる前の平面図、同図（ｂ）は同シート４を折り曲げた状態の斜視図である。なお、同図において図３と同一または相当する部分には同一符号を付してその説明は省略する。 FIG. 5A is a plan view before the sheet 4 used in the coil 1 according to the third embodiment of the present invention is folded, and FIG. 5B is a perspective view of the sheet 4 in a folded state. In the figure, the same or corresponding parts as in FIG.

第３の実施形態によるコイル１では、図５（ａ）に示すように、導体路５Ｃを、コイル１の幅Ｗ方向において、シート４の谷折り線ｖおよび山折り線ｍに沿って形成された所定長の部分を有して、所定の矩形波状パターンで振幅させ、コイル１の長さＬ方向において、この矩形波状パターンをコイル１の巻き数に相当する所定回数周期的に繰り返して、ミアンダ形状に形成する。 In the coil 1 according to the third embodiment, as shown in FIG. 5A, the conductor path 5 C is formed along the valley fold line v and the mountain fold line m of the sheet 4 in the width W direction of the coil 1. Having a predetermined length portion, and amplifying with a predetermined rectangular wave pattern, and repeating this rectangular wave pattern periodically in the length L direction of the coil 1 a predetermined number of times corresponding to the number of turns of the coil 1. Form into shape.

この第３の実施形態によるコイル１でも、シート４は、図５（ｂ）の斜視図に示すように第１の実施形態によるコイル１と同様にして折り曲げられる。導体路５Ｃは、長さＬ方向に進行するのに連れ、コイル１の厚みｔ方向において、シート４の上り斜面Ｕでの上昇と下り斜面Ｄでの下降とを交互に繰り返し、幅Ｗ向において、谷折り線ｖに沿って振幅して、上り斜面Ｕを長さＬ方向に水平に横切った後、山折り線ｍに沿って振幅して、下り斜面Ｄを長さＬ方向に水平に横切り、巻き構造を呈する。 Also in the coil 1 according to the third embodiment, the sheet 4 is bent in the same manner as the coil 1 according to the first embodiment as shown in the perspective view of FIG. As the conductor path 5C travels in the length L direction, in the thickness t direction of the coil 1, the sheet 4 alternately rises on the rising slope U and descends on the falling slope D in the direction of the width W. Amplify along the valley fold line v and horizontally traverse the ascending slope U in the length L direction, then amplify along the mountain fold line m and traverse the descending slope D horizontally in the length L direction. , Exhibiting a wound structure.

第１，第２，第３の各実施形態では、下側基材２と上側基材３との間にシート４を挟んでプレスすることで、シート４が図３（ｂ），図４（ｂ），図５（ｂ）に示すように折り曲げられて、コイル１が製造される。この際、シート４の両面に接着剤が付けられて、プレス加工が行われる。用いる接着剤の種類は一般的な接着剤でよく、例えば、エポキシ樹脂系の接着剤などが用いられる。 In each of the first, second, and third embodiments, the sheet 4 is pressed between the lower base material 2 and the upper base material 3 so that the sheet 4 is shown in FIGS. b) As shown in FIG. 5B, the coil 1 is manufactured by bending. At this time, an adhesive is applied to both surfaces of the sheet 4 and press working is performed. The type of adhesive used may be a general adhesive, for example, an epoxy resin adhesive.

このような第１，第２，第３の各実施形態のコイル１によれば、単一の導体路５Ａ，５Ｂ，５Ｃが形成された図３（ａ），図４（ａ），図５（ａ）に示すシート４が、連続する２つの上り斜面Ｕおよび下り斜面Ｄを１周期とする周期で単に曲げられことで、シート４上に形成された導体路５Ａ，５Ｂ，５Ｃが巻かれて、コイル１が形成される。従って、従来のコイルのように、複数の導電体を接続してコイルを構成する導体路を形成する必要がなくなる。このため、導電体の接続部を備えること無く、巻線型コイルに似た巻き構造のコイル１を形成することが可能になる。この結果、導電体を接合する工程が不要となってコイル製品価格の低廉化を図りながら、接続部信頼性の低下を招くことのない、巻線型コイルに似た巻き構造のコイル１を簡単に提供することができる。 According to the coil 1 of each of the first, second, and third embodiments as described above, FIGS. 3A, 4A, and 5 in which the single conductor paths 5A, 5B, and 5C are formed. The conductor 4 5A, 5B, 5C formed on the sheet 4 is wound by simply bending the sheet 4 shown in (a) with a period of two continuous uphill slopes U and downhill slopes D as one cycle. Thus, the coil 1 is formed. Therefore, it is not necessary to form a conductor path constituting the coil by connecting a plurality of conductors as in the conventional coil. For this reason, it becomes possible to form the coil 1 having a winding structure similar to a wound coil without providing a connection portion of a conductor. As a result, the coil 1 having a winding structure similar to the winding coil can be easily obtained without reducing the coil product price while eliminating the need to join the conductors and reducing the coil product price. Can be provided.

また、第１，第２，第３の各実施形態のコイル１によれば、シート４の曲がりに下方および上方から嵌合する凹凸形状をそれぞれ一面２ｂおよび３ｂに有する下側基材２および上側基材３によってシート４が挟まれることで、シート４の図３（ｂ），図４（ｂ），図５（ｂ）に示す折り曲げ形状が保たれ、強度が確保されるので、コイル１の製品取り扱い性が向上する。 Moreover, according to the coil 1 of each of the first, second, and third embodiments, the lower base material 2 and the upper side that have the concave and convex shapes that fit into the bend of the sheet 4 from the lower side and the upper side on the one surface 2b and 3b, respectively. Since the sheet 4 is sandwiched by the base material 3, the bent shape shown in FIGS. 3B, 4 B, and 5 B of the sheet 4 is maintained and the strength is ensured. Product handling is improved.

また、第１，第２，第３の各実施形態のコイル１においては、導体路５Ａ，５Ｂ，５Ｃの巻き始めおよび巻き終わりに導体路５Ａ，５Ｂ，５Ｃに一体に形成された電極パット５ａ，５ａが、上側基材３の両端部に備えられた凸部３ｄ，３ｄの山面３ｃ，３ｃに露出し、外部電極を構成する。このため、導電体の接続部を全く有すること無く、コイル１に外部電極を備えることができ、外部電極を備えた巻き構造のコイル１を安価にかつ接続信頼性高く提供することができる。 In the coil 1 of each of the first, second, and third embodiments, the electrode pads 5a formed integrally with the conductor paths 5A, 5B, and 5C at the start and end of winding of the conductor paths 5A, 5B, and 5C. , 5a are exposed on the crest surfaces 3c, 3c of the convex portions 3d, 3d provided at both ends of the upper base material 3 to constitute external electrodes. For this reason, it is possible to provide the coil 1 with an external electrode without having any connection portion of the conductor, and to provide the coil 1 having a winding structure including the external electrode at low cost and with high connection reliability.

また、第１，第２，第３の各実施形態のコイル１においては、シート４は、上記のように、連続する２つの上り斜面Ｕおよび下り斜面Ｄを１周期とする周期で鋸歯状に折り曲げられる。このため、図６（ａ）に示すシート４Ａが、同図（ｂ）に示すように、長さＬ方向において谷面Ｖと山面Ｍとが側面Ｓを介して交互に現れる、連続する４つの面を１周期とする周期で矩形波状に折り曲げられ、１折り曲げ周期で導体路５Ｄが１周期の振幅を行う場合に比較して、少ない回数で１巻き当たりの折り曲げを行える。なお、図６において図３と同一または相当する部分には同一符号を付してその説明は省略する。このため、第１，第２，第３の各実施形態のコイル１によれば、同外形寸法のコイルにおいて、より多くの巻き数を稼ぐことができるので、大きなインダクタンスを有する巻き構造コイル１を提供することができる。また、同じ巻き数のコイルにおいて、シート４の折り曲げ回数を少なくすることができるので、シート４の信頼性の向上を期待することができる。なお、単位長さ当たりのシート４の折り曲げ回数を多くして、シート４の折り曲げ角度を急峻にすると、コイル１のインダクタンス分は大きくなるが、コイル１を製造し難くなる。 Moreover, in the coil 1 of each of the first, second, and third embodiments, as described above, the sheet 4 has a sawtooth shape with a period in which the two consecutive uphill slopes U and downhill slopes D are one cycle. It can be bent. For this reason, in the sheet 4A shown in FIG. 6A, the valley surface V and the mountain surface M appear alternately via the side surface S in the length L direction as shown in FIG. Compared with the case where one surface is bent in a rectangular wave shape with a period of one cycle and the conductor path 5D has an amplitude of one cycle with one cycle, the number of times can be bent per turn. 6 that are the same as or correspond to those in FIG. 3 are assigned the same reference numerals, and descriptions thereof are omitted. For this reason, according to the coil 1 of each of the first, second, and third embodiments, it is possible to earn a larger number of turns in a coil having the same outer dimensions. Can be provided. In addition, since the number of times the sheet 4 is bent can be reduced in the coil having the same number of turns, an improvement in the reliability of the sheet 4 can be expected. If the number of times of folding the sheet 4 per unit length is increased and the folding angle of the sheet 4 is made steep, the inductance of the coil 1 increases, but the coil 1 becomes difficult to manufacture.

また、第１，第２，第３の各実施形態のコイル１においては、導体路５Ａ，５Ｂ，５Ｃの幅ｂ（図３（ａ），図４（ａ），図５（ａ）参照）の大きさや、シート４における導体路５Ａ，５Ｂ，５Ｃの形成位置を適宜選択することで、様々な特性を備えるコイル１を簡易に製作することができる。 Further, in the coil 1 of each of the first, second, and third embodiments, the width b of the conductor paths 5A, 5B, and 5C (see FIGS. 3A, 4A, and 5A). The coil 1 having various characteristics can be easily manufactured by appropriately selecting the size of the conductors 5 and the formation positions of the conductor paths 5A, 5B, and 5C in the sheet 4.

例えば、導体路５Ａ，５Ｂ，５Ｃの幅ｂを広くすることで、上り斜面Ｕおよび下り斜面Ｄ上に形成された導体路５Ａ，５Ｂ，５Ｃがコイル１の厚みｔ方向に占める高さは大きくなる。このため、巻き構造コイル１の巻き内径が小さくなってコイル内径部の断面積が小さくなり、コイル内径部を磁束が通り難くなるので、コイル１のＱ値は低くなる。しかし、コイル１の直流抵抗値Ｒ_ＤＣは低くなるので、大電流を流せる巻き構造コイル１が提供され、大電流対応のフェライトビーズの商品化が可能になる。他方、導体路５Ａ，５Ｂ，５Ｃの幅ｂを狭くすることで、上り斜面Ｕおよび下り斜面Ｄ上に形成された導体路５Ａ，５Ｂ，５Ｃがコイル１の厚みｔ方向に占める高さは小さくなる。このため、巻き構造コイル１の内径および内径部断面積の大きさを確保することができ、コイル内径部を磁束が通り易くなるので、高周波でも高いインピーダンスを有する、高いＱ値を持つ巻き構造コイル１が提供される。また、コイル１の幅Ｗ方向における導体路５Ａ，５Ｂ，５Ｃの振幅高さを大きくすることで、巻き構造コイル１の内径部の断面積をさらに大きくすることができる。このため、コイル内径部を磁束がさらに通り易くなるので、より高いＱ値を持つ巻き構造コイル１が提供される。 For example, by increasing the width b of the conductor paths 5A, 5B, 5C, the height of the conductor paths 5A, 5B, 5C formed on the ascending slope U and the descending slope D in the thickness t direction of the coil 1 is large. Become. For this reason, the winding inner diameter of the winding structure coil 1 is reduced, the cross-sectional area of the coil inner diameter portion is reduced, and the magnetic flux does not easily pass through the coil inner diameter portion, so the Q value of the coil 1 is reduced. However, since the direct-current resistance value R _DC of the coil 1 is low, the winding structure coil 1 capable of flowing a large current is provided, and commercialization of a ferrite bead capable of large current is possible. On the other hand, by reducing the width b of the conductor paths 5A, 5B, 5C, the height of the conductor paths 5A, 5B, 5C formed on the ascending slope U and the descending slope D in the thickness t direction of the coil 1 is small. Become. For this reason, since the magnitude | size of the internal diameter and internal-diameter part cross-sectional area of the winding structure coil 1 can be ensured and a magnetic flux passes easily through a coil internal-diameter part, the winding structure coil with a high Q value which has a high impedance also in high frequency 1 is provided. Further, by increasing the amplitude height of the conductor paths 5A, 5B, 5C in the width W direction of the coil 1, the cross-sectional area of the inner diameter portion of the wound structure coil 1 can be further increased. For this reason, since it becomes easier for the magnetic flux to pass through the inner diameter portion of the coil, the wound structure coil 1 having a higher Q value is provided.

また、図５に示すシート４を用いる第３の実施形態のコイル１によれば、シート４の折り曲げ線に沿って形成された所定長の導体路５Ｃ部分は、折り曲げられたシート４の最も外側に位置する。従って、同じ外形寸法で同じ導体路５Ｃの幅ｂのコイルにおいて、コイルの巻き径を最も大きく形成することができる。このため、コイル内径部の断面積を大きく確保でき、コイル内径部を磁束が通り易くなって、コイル１のＱ値を高くすることができる。 Further, according to the coil 1 of the third embodiment using the sheet 4 shown in FIG. 5, the portion of the conductor path 5 C having a predetermined length formed along the folding line of the sheet 4 is the outermost side of the folded sheet 4. Located in. Therefore, in the coil having the same outer dimensions and the same width b of the conductor path 5C, the winding diameter of the coil can be maximized. For this reason, the cross-sectional area of a coil inner diameter part can be ensured large, a magnetic flux can pass easily through a coil inner diameter part, and Q value of the coil 1 can be made high.

また、図３，図４に示すシート４を用いる第１，第２の各実施形態のコイル１においては、シート４の折り曲げによって導体路５Ａ，５Ｂが曲げられる部分は、シート４の谷折り線ｖおよび山折り線ｍに導体路５Ａ，５Ｂが交差する部分だけになる。このため、導体路５Ａ，５Ｂが曲げられる部分が少なくなるので、導体路５Ａ，５Ｂの信頼性の向上を期待することができる。また、導体路５Ａ，５Ｂの大部分が上り斜面Ｕおよび下り斜面Ｄの面部に位置するので、第３の実施形態のコイル１のように、シート４の折り曲げ部に沿って導体路５Ｃを形成する場合に比較して、シート４の折り曲げの影響を受けずに任意の幅ｂの導体路５Ａ，５Ｂを形成し易くなる。このため、シート４の折り曲げ線に沿って導体路５Ｃを形成する場合に比較して、導体路５Ａ，５Ｂの幅ｂを広くすることが可能になり、コイル１の直流抵抗値Ｒ_ＤＣを容易に低減化することができる。 Further, in the coils 1 of the first and second embodiments using the sheet 4 shown in FIGS. 3 and 4, the portions where the conductor paths 5 A and 5 B are bent by bending the sheet 4 are the valley fold lines of the sheet 4. Only the portions where the conductor paths 5A and 5B intersect v and the mountain fold line m are present. For this reason, since the part by which conductor track 5A, 5B is bent decreases, the improvement of the reliability of conductor track 5A, 5B can be anticipated. In addition, since most of the conductor paths 5A and 5B are located on the surfaces of the ascending slope U and the descending slope D, the conductor path 5C is formed along the bent portion of the sheet 4 as in the coil 1 of the third embodiment. Compared with the case where it does, it becomes easy to form the conductor paths 5A and 5B of arbitrary width b, without being influenced by the bending of the sheet 4. For this reason, compared with the case where the conductor path 5C is formed along the folding line of the sheet 4, the width b of the conductor paths 5A and 5B can be increased, and the DC resistance value R _DC of the coil 1 can be easily achieved. Can be reduced.

また、第１，第２，第３の各実施形態のコイル１においては、下側基材２および上側基材３がアルミナ等の非磁性体からなる場合には、下側基材２および上側基材３の透磁率が小さくなる。このため、コイル１のインダクタンスを低く抑えることができるので、高周波用途の巻き構造コイル１が提供される。また、下側基材２および上側基材３がフェライト等の磁性体からなる場合には、下側基材２および上側基材３の透磁率が大きくなる。このため、用いる磁性体の種類を選択することで、所望の大きさのインダクタンスを有する巻き構造コイル１が得られる。 In the coils 1 of the first, second, and third embodiments, when the lower base material 2 and the upper base material 3 are made of a nonmagnetic material such as alumina, the lower base material 2 and the upper base material 2 are used. The magnetic permeability of the substrate 3 is reduced. For this reason, since the inductance of the coil 1 can be kept low, the wound structure coil 1 for high frequency applications is provided. Further, when the lower base material 2 and the upper base material 3 are made of a magnetic material such as ferrite, the magnetic permeability of the lower base material 2 and the upper base material 3 is increased. For this reason, the winding structure coil 1 which has the inductance of a desired magnitude | size is obtained by selecting the kind of magnetic body to be used.

また、第１，第２，第３の各実施形態のコイル１の製造方法によれば、シート４を曲げて導体路５Ａ，５Ｂ，５Ｃを巻き構造に加工する工程と、下側基材２と上側基材３とを嵌合させてシート４の曲げ形状を保つ強度に加工する工程とが、下側基材２と上側基材３との間にシート４を挟んでプレスする１つの工程で行われる。このため、製造工程が少なくなり、巻き構造コイル１の製品コストをさらに低減することができる。 Moreover, according to the manufacturing method of the coil 1 of each of the first, second, and third embodiments, the step of bending the sheet 4 to process the conductor paths 5A, 5B, and 5C into the winding structure, and the lower substrate 2 And the step of fitting the upper base material 3 to the strength to keep the bent shape of the sheet 4 is one step of pressing the sheet 4 between the lower base material 2 and the upper base material 3 Done in For this reason, a manufacturing process decreases and the product cost of the winding structure coil 1 can further be reduced.

また、第１，第２，第３の各実施形態のコイル１の製造方法によれば、シート４の両面に接着剤が付けられて上記のプレス加工が行われるので、シート４を曲げて導体路５Ａ，５Ｂ，５Ｃを巻き構造に加工する工程と、下側基材２と上側基材３とを嵌合させてシート４の曲げ形状を保つ強度に加工する工程と、下側基材２と上側基材３との間にシート４を接合する工程とが、下側基材２と上側基材３との間にシート４を挟んでプレスする１つの工程で行われる。このため、製造工程がさらに少なくなり、巻き構造コイル１の製品コストをさらに低減することができる。 Moreover, according to the manufacturing method of the coil 1 of each of the first, second, and third embodiments, the adhesive is applied to both surfaces of the sheet 4 and the above pressing is performed. A step of processing the paths 5A, 5B, and 5C into a winding structure, a step of fitting the lower base material 2 and the upper base material 3 to a strength that maintains the bent shape of the sheet 4, and the lower base material 2 And the step of bonding the sheet 4 between the upper substrate 3 and the upper substrate 3 are performed in one step of pressing the sheet 4 between the lower substrate 2 and the upper substrate 3. For this reason, the number of manufacturing steps is further reduced, and the product cost of the wound structure coil 1 can be further reduced.

なお、上記の第１，第２，第３の各実施形態では、シート４の曲がりに下方および上方から嵌合する下側基材２および上側基材３により、シート４の強度を保つ構造を構成した場合について、説明した。しかし、電極パット５ａ，５ａを露出させてシート４の周囲に樹脂を充填し、シート４の周囲を樹脂で直方体状に囲む樹脂基材などを備えることで、シート４の強度を保つ構造を構成するようにしてもよい。本構成によれば、シート４の曲げ形状がシート４の周囲を囲む樹脂などの基材によって保たれ、強度が確保されるので、本構成によっても、コイル１の製品取り扱い性が向上する。 In each of the first, second, and third embodiments described above, the structure in which the strength of the sheet 4 is maintained by the lower base material 2 and the upper base material 3 that are fitted to the bend of the sheet 4 from below and above. The configuration has been described. However, the structure which maintains the intensity | strength of the sheet | seat 4 is comprised by exposing the electrode pad 5a, 5a, filling the circumference | surroundings of the sheet | seat 4 with resin, and providing the resin base material etc. which enclose the circumference | surroundings of the sheet | seat 4 in a rectangular parallelepiped shape. You may make it do. According to this configuration, the bent shape of the sheet 4 is maintained by the base material such as a resin surrounding the periphery of the sheet 4 and the strength is ensured, so that the product handleability of the coil 1 is also improved by this configuration.

また、上側基材３を備えず、シート４の曲がりに下方から嵌合する凹凸形状を一面２ｂに有する下側基材２だけを備えることで、シート４の強度を保つ構造を構成するようにしてもよい。本構成によれば、シート４の曲げ形状が下側基材２だけによって保たれ、強度が確保されるので、本構成によっても、コイル１の製品取り扱い性が向上する。 Moreover, the structure which maintains the intensity | strength of the sheet | seat 4 is comprised by not providing the upper side base material 3 but providing only the lower base material 2 which has the uneven | corrugated shape which fits in the curvature of the sheet | seat 4 from below on the one surface 2b. May be. According to the present configuration, the bent shape of the sheet 4 is maintained only by the lower base material 2 and the strength is ensured, so that the product handleability of the coil 1 is also improved by this configuration.

この際、シート４の電極パット５ａ，５ａ前の折り方を、上記の各実施形態と異なり山折りとすることで、シート４は、図３（ｃ），図４（ｃ），図５（ｃ）の斜視図に示すように、両端部が内側に折り返された形状に折られる。このため、下側基材２だけを備えることで得られるコイル１Ａは、図７の斜視図に外観が示されるようになる。なお、図７において図２および図３と同一または相当する部分には同一符号を付してその説明は省略する。このコイル１Ａにおいては、シート４は、下側基材２の両側部２ｃ，２ｃを覆って下側基材２の底面２ａ側に両端部が曲げ返され、下側基材２の底面２ａに電極パット５ａ，５ａを露出させて、曲げられている。図７においては導体路５Ａが形成されたシート４を図示しているが、導体路５Ｂ，５Ｃが形成されたシート４によっても、同様なコイル１Ａが得られる。 At this time, unlike the above embodiments, the sheet 4 is folded in front of the electrode pads 5a, 5a in a mountain fold, so that the sheet 4 is formed as shown in FIG. 3 (c), FIG. 4 (c), FIG. As shown in the perspective view of c), both ends are folded into a shape folded back inward. For this reason, the external appearance of the coil 1 A obtained by providing only the lower substrate 2 is shown in the perspective view of FIG. 7. 7 that are the same as or correspond to those in FIG. 2 and FIG. In this coil 1 A, the sheet 4 covers both side portions 2 c, 2 c of the lower substrate 2, and both end portions are bent back to the bottom surface 2 a side of the lower substrate 2, so that the sheet 4 is formed on the bottom surface 2 a of the lower substrate 2. The electrode pads 5a and 5a are exposed and bent. In FIG. 7, the sheet 4 on which the conductor path 5A is formed is illustrated, but a similar coil 1A can also be obtained by the sheet 4 on which the conductor paths 5B and 5C are formed.

本構成のコイル１Ａによれば、導体路５Ａ，５Ｂ，５Ｃの巻き始めおよび巻き終わりに導体路５Ａ，５Ｂ，５Ｃに一体に形成された電極パット５ａ，５ａが下側基材２の底面２ａに露出し、外部電極を構成する。このため、本構成のコイル１Ａによっても、導電体の接続部を全く有すること無く、コイル１Ａに外部電極を備えることができ、外部電極を備えた巻き構造のコイル１Ａを安価にかつ接続信頼性高く提供することができる。また、下側基材２の両側部で導体路５Ａ，５Ｂ，５Ｃが曲げ返されることで、コイル１Ａの長さＬ方向に外部電極形成のための寸法を図１に示すコイル１のように取る必要がなくなり、コイル１Ａの長さＬ方向を全て巻線形成に使用することができる。このため、同外形寸法および同構成材料のコイルにおけるインダクタンス取得効率を上げることができる。図７に示すコイル１Ａが奏するこのような作用効果は、凸部３ｄ，３ｄを備えない次述する図８に示す上側基材３Ａを用い、シート４を下側基材２と上側基材３Ａとの間に挟んだ構成においても、得られる。 According to the coil 1A of this configuration, the electrode pads 5a, 5a integrally formed on the conductor paths 5A, 5B, 5C at the start and end of winding of the conductor paths 5A, 5B, 5C are the bottom surface 2a of the lower substrate 2. To constitute an external electrode. For this reason, even with the coil 1A of this configuration, the coil 1A can be provided with an external electrode without having a conductor connecting portion at all, and the coil 1A having a wound structure including the external electrode can be inexpensively connected. Can be offered high. Further, the conductor paths 5A, 5B, 5C are bent back on both sides of the lower base material 2, so that the dimensions for forming the external electrodes in the length L direction of the coil 1A are as in the coil 1 shown in FIG. It is not necessary to take this, and the entire length L direction of the coil 1A can be used for forming the winding. For this reason, the inductance acquisition efficiency in the coil of the same outer dimension and the same constituent material can be increased. Such an effect produced by the coil 1A shown in FIG. 7 is obtained by using the upper base material 3A shown in FIG. 8 described below, which does not include the convex portions 3d and 3d, and the sheet 4 is made of the lower base material 2 and the upper base material 3A. It can also be obtained in a configuration sandwiched between the two.

また、上記の第１，第２，第３の各実施形態では、上側基材３の両端部に凸部３ｄ，３ｄを備え、凸部３ｄ，３ｄの山面３ｃ，３ｃに電極パット５ａ，５ａを露出させて外部電極を構成した場合について、説明した。しかし、このような凸部３ｄ，３ｄを備えずに、例えば図８（ａ）の外観斜視図に示すように、上側基材３Ａを構成するようにしてもよい。なお、図８において図１と同一または相当する部分には同一符号を付してその説明は省略する。この場合、下側基材２と上側基材３Ａとによって構成される基材６の側面６ａに露出する導体路５Ａ，５Ｂ，５Ｃの巻き始めおよび巻き終わりに、同図（ｂ）に示すように外部電極７を電気的に接続する。この外部電極７の形成は例えばディップ塗布法などで行われる。 In each of the first, second, and third embodiments, the upper base material 3 is provided with convex portions 3d and 3d at both ends, and the electrode pads 5a and 3d are formed on the crest surfaces 3c and 3c of the convex portions 3d and 3d. The case where the external electrode is configured by exposing 5a has been described. However, the upper base material 3A may be configured, for example, as shown in the external perspective view of FIG. 8A without providing the convex portions 3d and 3d. 8 that are the same as or correspond to those in FIG. 1 are assigned the same reference numerals, and descriptions thereof are omitted. In this case, at the start and end of winding of the conductor paths 5A, 5B, 5C exposed on the side surface 6a of the base 6 constituted by the lower base 2 and the upper base 3A, as shown in FIG. The external electrode 7 is electrically connected to. The external electrode 7 is formed by, for example, a dip coating method.

本構成によれば、基材６の側面６ａに露出する導体路５Ａ，５Ｂ，５Ｃの巻き始めおよび巻き終わりにだけ外部電極７を接続することで、基材６の側面６ａに外部電極７を備える巻き構造のコイル１Ｂを構成することができる。また、上記の各実施形態のように、上側基材３の両端部に凸部３ｄ，３ｄを形成する必要が無く、また、導体路５Ａ，５Ｂ，５Ｃの巻き始めおよび巻き終わりに電極パット５ａ，５ａを形成する必要も無い。このため、導電体の接続箇所が２箇所で、接続信頼性の低下を招くことの懸念が極めて少ない、外部電極７を備えた巻き構造のコイル１Ｂを安価にかつ接続信頼性高く提供することができる。 According to this configuration, the external electrode 7 is connected to the side surface 6a of the base material 6 by connecting the external electrode 7 only at the start and end of winding of the conductor paths 5A, 5B, 5C exposed on the side surface 6a of the base material 6. The coil 1B of the winding structure provided can be comprised. Further, unlike the above-described embodiments, it is not necessary to form the convex portions 3d and 3d at both end portions of the upper base material 3, and the electrode pads 5a at the start and end of winding of the conductor paths 5A, 5B and 5C. , 5a need not be formed. For this reason, it is possible to provide the coil 1B having a wound structure including the external electrode 7 at a low cost and with high connection reliability, with two conductor connection points and very little concern about a decrease in connection reliability. it can.

また、シート４の周囲を樹脂で直方体状に囲む樹脂基材などを備えて構成される上述した巻き構造のコイルや、シート４の曲がりに下方から嵌合する凹凸形状を一面２ｂに有する下側基材２だけを備えて構成される上述した巻き構造のコイル１Ａにおいて、導体路５Ａ，５Ｂ，５Ｃの両端部に電極パット５ａ，５ａを備えず、樹脂基材または下側基材２の側面に導体路５Ａ，５Ｂ，５Ｃの巻き始めおよび巻き終わりを露出させることで、上記の外部電極７のような外部電極を基材の側面に構成することできる。このため、このような巻き構造のコイルによっても、導電体の接続箇所が２箇所で、接続信頼性の低下を招くことの懸念が極めて少ない、外部電極を備えた巻き構造のコイルを安価にかつ接続信頼性高く提供することができる。 Moreover, the coil | winding structure coil | winding structure comprised by providing the resin base material etc. which enclose the circumference | surroundings of the sheet | seat 4 in a rectangular parallelepiped shape with resin, or the lower side which has the uneven | corrugated shape fitted from the downward | lower direction to the bending of the sheet | seat 4 In the coil 1A having the above-described winding structure configured to include only the base material 2, the electrode pads 5a and 5a are not provided at both ends of the conductor paths 5A, 5B, and 5C, and the side surface of the resin base material or the lower base material 2 is provided. By exposing the winding start and the winding end of the conductor paths 5A, 5B, 5C, an external electrode such as the external electrode 7 can be formed on the side surface of the base material. For this reason, even with such a coil having a wound structure, there are only two conductor connection points, and there is very little concern that the connection reliability will be lowered. Connection reliability can be provided with high reliability.

また、このように外部電極を導体路５Ａ，５Ｂ，５Ｃとは別に形成する上記の巻き構造コイルにおいては、シート４の曲がりに嵌合する凹凸形状が連続して１面に形成された、基材の材質からなるマザー基板を用いて、マザー基板の上に、電極パット５ａ，５ａを備えない導体路５Ａ，５Ｂ，５Ｃが連続して形成されたシート４を嵌合させて、ダイシング等によって個々の製品に分割することができる。また、電極パット５ａ，５ａを備えない導体路５Ａ，５Ｂ，５Ｃが連続して形成されたシート４の周囲を囲む樹脂基材をマザー基板とし、このマザー基板をダイシング等によって分割することで、個々の製品を得ることができる。このため、１枚のマザー基板から多数個の製品を取るウエハ加工により、外部電極を導体路５Ａ，５Ｂ，５Ｃとは別に形成する上記各構造のコイルを製造することができる。 Further, in the above-described wound structure coil in which the external electrode is formed separately from the conductor paths 5A, 5B, and 5C in this way, a concavo-convex shape that fits to the bend of the sheet 4 is continuously formed on one surface. Using a mother substrate made of a material, a sheet 4 in which conductor paths 5A, 5B, 5C not provided with electrode pads 5a, 5a are continuously formed is fitted on the mother substrate, and then dicing or the like. Can be divided into individual products. In addition, a resin base material surrounding the periphery of the sheet 4 on which the conductor paths 5A, 5B, 5C not including the electrode pads 5a, 5a are continuously formed is a mother substrate, and the mother substrate is divided by dicing or the like. Individual products can be obtained. For this reason, the coil of each said structure which forms an external electrode separately from conductor path 5A, 5B, 5C by the wafer processing which takes many products from one mother board | substrate can be manufactured.

また、図９に示す、基材の材質からなる下側マザー基板２２および上側マザー基板３３を用いて、これら下側マザー基板２２および上側マザー基板２３の間にシート４を挟んで図の点線に沿う箇所でダイシングをし、個々の製品に分割することによっても、マザー基板２２，３３から多数個の製品を取るウエハ加工によって図８に示す構造のコイル１Ｂを製造することができる。この場合、下側マザー基板２２および上側マザー基板３３には、シート４の曲がりに下方および上方から嵌合する凹凸形状が連続してそれぞれの１面に形成されている。 Further, the lower mother substrate 22 and the upper mother substrate 33 made of the material of the base material shown in FIG. 9 are used, and the sheet 4 is sandwiched between the lower mother substrate 22 and the upper mother substrate 23, and the dotted line in the figure. 8 can be manufactured by wafer processing in which a large number of products are taken from the mother substrates 22 and 33 by dicing along a portion along the line and dividing the product into individual products. In this case, the lower mother board 22 and the upper mother board 33 are each formed with a concave-convex shape that fits from below and above the bend of the sheet 4 on one surface.

また、図８に示す巻き構造のコイル１Ｂにおいて、下側基材２の凹凸形状と上側基材３Ａの凹凸形状との各凹凸ピッチおよび各凹凸深さが均一でかつ同一の構造にすると、下側基材２または上側基材３Ａの一方を他方に対して１ピッチずらし、かつ反転させることで、下側基材２または上側基材３Ａの一方を下側基材２および上側基材３Ａの双方として用いることができる。従って、下側基材２と上側基材３Ａとの間に互換性が生じ、下側基材２および上側基材３Ａの成形加工をプレスによって行う場合、同一のプレス金型で下側基材２および上側基材３Ａのプレス成形加工を行うことができる。このため、コイル１Ｂの製品１個当たりに必要とされる金型のコストを半減することができ、巻き構造コイル１Ｂの製造コストをさらに低減することが可能になる。 Further, in the coil 1B having a winding structure shown in FIG. 8, when the unevenness pitch and the unevenness depth of the uneven shape of the lower substrate 2 and the uneven shape of the upper substrate 3A are uniform and the same structure, By shifting one of the side substrate 2 or the upper substrate 3A by one pitch with respect to the other and inverting it, one of the lower substrate 2 or the upper substrate 3A is changed between the lower substrate 2 and the upper substrate 3A. It can be used as both. Therefore, compatibility occurs between the lower base material 2 and the upper base material 3A, and when forming the lower base material 2 and the upper base material 3A by pressing, the lower base material is used with the same press mold. 2 and the upper substrate 3A can be press-molded. For this reason, the cost of the metal mold | die required per product of the coil 1B can be halved, and it becomes possible to further reduce the manufacturing cost of the winding structure coil 1B.

１，１Ａ，１Ｂ…コイル
２…下側基材
２ａ…底面
２ｂ…一面
２ｃ…側面
３，３Ａ…上側基材
３ａ…上面
３ｂ…一面
３ｃ…山面
３ｄ…凸部
４…シート
５Ａ，５Ｂ，５Ｃ…導体路
５ａ…電極パット
Ｗ…幅
Ｌ…長さ
ｔ…厚み
ｖ…谷折り線
ｍ…山折り線
Ｕ…上り斜面
Ｄ…下り斜面
Ｓ…側面 DESCRIPTION OF SYMBOLS 1,1A, 1B ... Coil 2 ... Lower side base material 2a ... Bottom surface 2b ... One side 2c ... Side surface 3, 3A ... Upper side base material 3a ... Upper side 3b ... One side 3c ... Mountain surface 3d ... Convex part 4 ... Sheet 5A, 5B, 5C ... Conductor path 5a ... Electrode pad W ... Width L ... Length t ... Thickness v ... Valley fold line m ... Mountain fold line U ... Uphill slope D ... Downhill slope S ... Side

Claims

A single conductor path having a predetermined pattern in the width direction and periodically repeating the pattern a predetermined number of times in the length direction is formed on the sheet having electrical insulation, and the pattern is repeated in the thickness direction. A coil in which the sheet is bent at a period and the conductor path is wound;
A substrate having a concave and convex shape that fits into the bent sheet is provided on one side,
The conductor paths, the pattern to repeat a portion formed on two consecutive surfaces of the sheet as one cycle, an electrode pad on said sheet opposite ends of its winding start and winding end,
The sheet is bent in a cycle with two continuous surfaces as one cycle in which ascending slopes and descending slopes appear alternately in the length direction, covers both sides of the substrate, and covers the bottom surface of the substrate A coil , wherein both ends are bent back to the side, and the electrode pads on both ends folded back to the inside are exposed on the bottom surface of the substrate .

A single conductor path having a predetermined pattern in the width direction and periodically repeating the pattern a predetermined number of times in the length direction is formed on the sheet having electrical insulation, and the pattern is repeated in the thickness direction. A coil in which the sheet is bent at a period and the conductor path is wound;
The sheet is bent in a cycle with two continuous surfaces as one cycle, in which an upward slope and a downward slope appear alternately in the length direction,
The conductor path repeats the pattern with a portion formed on two continuous surfaces as one cycle,
A base material that surrounds the periphery of the sheet, a base material that has a concave and convex shape that fits to the bend of the sheet on one side, or a lower base that has a concave and convex shape that fits to the bend of the sheet from below. A base material consisting of an upper base material having a concave and convex shape that fits from above into the bending of the material and the sheet;
The conductor paths are winding start and winding end electrically connected, features and to Turkey yl further comprising an external electrode formed on one surface side of the substrate to be exposed in the side face of the substrate.

The coil according to claim 1 , wherein the base material is made of a non-magnetic material or a magnetic material.