JP6263875B2 - Common mode choke coil - Google Patents

Description

The present invention relates to a common mode choke coil configured by winding two or more conductor paths side by side.

  Conventionally, as this type of common mode choke coil, for example, there is a stacked common mode choke coil disclosed in Patent Document 1. In this laminated common mode choke coil, the two coils A and B formed by conductor lines on the surface of the magnetic material sheet are arranged in the laminated body block so as to face each other. Each of the coils A and B is configured by stacking conductor printed sheets on the upper and lower sides of a plurality of through-hole dummy sheets and electrically connecting the upper and lower conductor lines through the through-holes.

  Conventionally, as a coil formed by winding a conductor path, for example, there is a bending coil disclosed in Patent Document 2. 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.

  Conventionally, as a coil formed by winding a conductor path, for example, there is a bobbin coil disclosed in Patent Document 3. 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.

JP-A-3-219609 Japanese Patent Laid-Open No. 11-265813 JP 2002-93649 A

  However, since the laminated common mode choke coil disclosed in the above-mentioned conventional patent document 1 is configured by laminating a plurality of sheets, the conductor path forming the coil is wound in a spiral shape. The spiral coil is a vertically wound coil and has a problem that stray capacitance tends to occur. For this reason, it is necessary to configure a common mode choke coil using a horizontally wound structure coil such as a wound coil, but in the conventional technology, a common mode choke coil having a horizontally wound structure by a conductor path without using a winding. Is difficult to get.

  On the other hand, with any of the conventional coils disclosed in Patent Document 2 and Patent Document 3, a coil having a lateral winding structure such as a wound coil can be obtained by a conductor path. However, in any of these coils, a plurality of conductors are joined by a joining material to form a winding-like conductor path. For this reason, in any of the above conventional coils disclosed in Patent Document 2 and Patent Document 3, a process of joining a conductor with a 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 disclosed in Patent Document 2 and Patent Document 3 further requires a structure or manufacturing method for improving the connection reliability of each connection portion of each conductor, and the increase in product price is I can't escape.

The present invention has been made to solve such problems,
Two or more single conductor paths, each having a predetermined pattern in the width direction and periodically repeating the pattern in the length direction, are formed side by side on one or both sides of an electrically insulating sheet. In the thickness direction, the sheet is bent at a cycle in which the pattern is repeated, and each conductor path is wound ,
Provided with a base material having an uneven shape that fits into the bend of the sheet on one side,
Each conductor track comprises an electrode pad on at least one side of the sheet at the beginning and end of winding at both ends thereof,
A common mode choke that covers both side portions of the base material, both end portions are bent back to the bottom surface side of the base material, and electrode pads at both end portions folded back to the inside are exposed to the bottom surface of the base material A coil was constructed.

  According to this configuration, a sheet formed by arranging two or more single conductor paths is simply bent so that each conductor path formed on the sheet is wound to form a common mode choke coil. The Therefore, there is no need to connect a plurality of conductors to form a conductor path constituting the coil as in a conventional coil having a horizontal winding structure. For this reason, it is possible to form a common mode choke coil having a horizontal winding structure similar to a wound coil without providing a conductor connecting portion. As a result, a common mode choke coil with a side-winding structure similar to a wound-type coil that does not reduce the coil product price while eliminating the need to join the conductors and reducing the reliability of the connection part. Can be provided easily.

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 .

  According to this configuration, the electrode pads formed integrally with each conductor path at the start and end of winding of each conductor path are exposed on the bottom surface of the base material, and constitute the external electrode. For this reason, it is possible to provide each coil with an external electrode without having a conductor connecting portion at all, and to provide a laterally wound common mode choke coil including the external electrode at low cost and with high connection reliability. it can. In addition, since each conductor path is bent back on both sides of the base material, it is not necessary to take the dimension for forming the external electrode in the length direction of the coil, and the entire length direction of the coil is used for winding formation. be able to. For this reason, the inductance acquisition efficiency in the common mode choke coil having the same outer dimensions and the same constituent materials can be increased.

The present invention also provides:
Two or more single conductor paths, each having a predetermined pattern in the width direction and periodically repeating the pattern in the length direction, are formed side by side on one or both sides of an electrically insulating sheet. In the thickness direction, the sheet is bent at a cycle in which the pattern is repeated, and each conductor path is wound,
A base material that surrounds the periphery of the sheet, a base material that has a concave and convex shape that fits into the curvature of the sheet, or a lower base material and sheet that has a concave and convex shape that fits into the curvature of the sheet from below. A base material composed of an upper base material having a concave and convex shape that fits from above into a bend; and
Is electrically connected to the end winding start and the winding of the conductor paths exposed on the side surface of the substrate, and an external electrode formed on a side surface of the base material
A common mode choke coil was constructed.

According to this configuration, a sheet formed by arranging two or more single conductor paths is simply bent so that each conductor path formed on the sheet is wound to form a common mode choke coil. The Therefore, there is no need to connect a plurality of conductors to form a conductor path constituting the coil as in a conventional coil having a horizontal winding structure. For this reason, it is possible to form a common mode choke coil having a horizontal winding structure similar to a wound coil without providing a conductor connecting portion. As a result, a common mode choke coil with a side-winding structure similar to a wound-type coil that does not reduce the coil product price while eliminating the need to join the conductors and reducing the reliability of the connection part. Can be provided easily.
According to this configuration, by connecting the external electrode only at the start and end of winding of each conductor path exposed on the side surface of the base material, the horizontal mode common mode choke coil having the external electrode on the side surface of the base material is provided. Can be configured. For this reason, it is possible to provide a common mode choke coil having a laterally wound structure with an external electrode at a low cost and with high connection reliability, with few connection points of conductors and very little concern about a decrease in connection reliability. it can.
According to this configuration, the bending shape of the sheet is maintained by the base material surrounding the periphery of the sheet, and the strength is ensured, so that the product handling property of the coil is improved.
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.
According to the present configuration, the sheet is sandwiched between the lower base material and the upper base material each having a concavo-convex shape that fits from below and above to the bending of the sheet, so that the bent shape of the sheet is maintained and the strength is increased. This ensures the coil product handling.

  Further, the present invention is characterized in that the substrate is made of a nonmagnetic material or a magnetic material.

  According to this configuration, when the base material is made of a non-magnetic material, the magnetic permeability of the base material is reduced, and the inductance can be kept low. Therefore, a common mode choke coil having a horizontal winding structure for high frequency applications is provided. . In addition, since the magnetic permeability of the base material is increased when the base material is made of a magnetic material, a common mode choke coil having a lateral winding structure having an inductance of a desired size can be obtained by selecting the type of the magnetic material to be used. can get.

  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 common mode choke coil having a horizontal winding structure can be easily provided.

1 is an external perspective view of a common mode choke coil according to first and second embodiments of the present invention. FIG. It is an external appearance perspective view of the lower side base material and upper side base material which comprise the common mode choke coil shown in FIG. (A) is a top perspective view before the sheet | seat which comprises the common mode choke coil by 1st Embodiment is bent, (b) is the pattern period of the conductor path formed on the sheet | seat shown to (a). It is a top view for demonstrating. (A) is a perspective view of the state which the sheet | seat shown in FIG. 3 was bent, (b) is a perspective view of the state bent in another aspect. (A) is a top perspective view before the sheet | seat which comprises the common mode choke coil by 2nd Embodiment is bent, (b) is the pattern period of the conductor path formed on the sheet | seat shown to (a). It is a top view for demonstrating. (A) is a perspective view of the state which the sheet | seat shown in FIG. 5 was bent, (b) is a perspective view of the state bent in another aspect. It is an external appearance perspective view of the common mode choke coil by 3rd, 4th, 5th embodiment of this invention. It is an external appearance perspective view of the lower side base material and upper side base material which comprise the common mode choke coil shown in FIG. (A) is a top perspective view before the sheet | seat which comprises the common mode choke coil by 3rd Embodiment is bent, (b) is the pattern period of the conductor path formed on the sheet | seat shown to (a). It is a top view for demonstrating. (A) is a perspective view of the state which the sheet | seat shown in FIG. 9 was bent, (b) is a perspective view of the state bent in another aspect. (A) is a top perspective view before the sheet | seat which comprises the common mode choke coil by 4th Embodiment is bent, (b) is the pattern period of the conductor path formed on the sheet | seat shown to (a). It is a top view for demonstrating. (A) is a perspective view of the state which the sheet | seat shown in FIG. 11 was bent, (b) is a perspective view of the state bent in another aspect. (A) is a top perspective view before the sheet | seat which comprises the common mode choke coil by 5th Embodiment is bent, (b) is the pattern period of the conductor track formed on the sheet | seat shown to (a). It is a top view for demonstrating. (A) is a perspective view of a state where the sheet shown in FIG. 13 is bent, and (b) is a perspective view of a state where the sheet is bent in another mode. (A) is the external appearance perspective view of the common mode choke coil by the modification of 1st, 2nd each embodiment, (b) is the common mode by the modification of 3rd, 4th, 5th each embodiment. It is an external perspective view of chalk. (A) is the external appearance perspective view before providing the external electrode of the common mode choke coil by the other modification of each 1st, 2nd embodiment, (b) is the common mode choke coil shown to (a). It is an external appearance perspective view provided with the external electrode. (A) is an external appearance perspective view before providing the external electrode of the common mode choke coil by the other modification of each of 3rd, 4th, 5th embodiment, (b) is a common mode shown to (a). It is an external appearance perspective view provided with the external electrode of the choke coil. (A) is a side view of a mother substrate from which the common mode choke coil having the structure shown in FIG. 16 is obtained, and (b) is a side view of the mother substrate from which the common mode choke coil having the structure shown in FIG. 17 is obtained.

  Next, embodiments of the common mode choke coil and the manufacturing method thereof according to the present invention will be described.

  FIG. 1 is an external perspective view of a common mode choke coil 1A according to the first and second embodiments of the present invention.

  The common mode choke coil 1A includes a lower base material 2 and an upper base material 3 made of a non-magnetic material or a magnetic material, and a sheet 4 having electrical insulation, and has a width W, a length L, It has a rectangular parallelepiped shape with thickness t. The lower base material 2 has a rack gear shape whose external appearance is shown in FIG. 2 (b), and has an uneven shape that fits from below into a rectangular bend of the sheet 4 on one surface 2b facing the bottom surface 2a. For the number of turns of the coil 1A. The outer appearance of the upper base material 3 is shown in FIG. 2A, and the surface 3b facing the upper surface 3a has an uneven shape that fits from above into the rectangular bend of the sheet 4 for the number of turns of the coil 1A. . 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. . These convex parts 3d and 3d are larger than the convex part formed in the center part of the base material, and the height dimension thereof is the same as the thickness t of the coil 1A. 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.

  FIG. 3A is a plan perspective view before the sheet 4 used in the common mode choke coil 1A according to the first embodiment of the present invention is bent. In this figure, the thickness of the sheet 4 is exaggerated and thick for understanding. On one side of the sheet 4 shown in FIG. 3 (a), two single conductor paths 5a and 5b are formed by using a general internal electrode material such as copper or silver, using a printing method or a lithography technique. They are formed side by side by a general electrode forming method. These conductor paths 5a and 5b are oscillated in a predetermined trapezoidal wave pattern in the width W direction of the coil 1A, and the trapezoidal wave pattern in the length L direction of the coil 1A has a predetermined number of cycles corresponding to the number of turns of the coil 1A. Repeated to form a meander shape. As shown in FIG. 1, in the thickness t direction, the sheet 4 is bent as shown in the perspective view of FIG. 4 (a) at a period where one period in which the trapezoidal wave pattern is repeated is one period. Each of the conductor paths 5a and 5b has a winding shape. 4 that are the same as or correspond to those in FIG. 3 are assigned the same reference numerals, and descriptions thereof are omitted.

  The above-described folding of the sheet 4 is carried out with the line indicated by the alternate long and short dash line as the valley fold line v and the line indicated by the broken line as the mountain fold line m schematically shown in the plan view of FIG. In FIG. 5, the valley surface V and the mountain surface M appear alternately through the side surface S, and are bent at a period with one continuous period as one period. In this folding pattern, valley fold-mountain fold-mountain fold-valley fold is one cycle.

  Each of the conductor paths 5a and 5b formed in the sheet 4 is a valley surface of the first surface I divided by the first valley fold line v in the continuous four surfaces shown in FIG. In V, as it approaches the side surface S of the second surface II that is next continuous, the amplitude increases in the width W direction where the amplitude height increases, and crosses in the diagonal direction. Then, the side surface S of the next second surface II is traversed in parallel to the length L direction while maintaining or substantially changing the amplitude height. After that, the peak surface M of the next third surface III that is continuous with the second surface II swings in the width W direction in which the amplitude height decreases as it approaches the side surface S of the next continuous fourth surface IV, Cross diagonally. Then, the side surface S of the next fourth surface IV is traversed in parallel with the length L direction while maintaining the amplitude height.

  Accordingly, as each conductor path 5a, 5b advances in the length L direction, the bent sheet 4 descends to the valley surface V and rises to the mountain surface M in the thickness t direction of the coil 1A. Repeatedly through S, in the width W direction, the amplitude height is increased on the first surface I, kept on the second surface II or substantially unchanged, lowered on the third surface III, and maintained on the fourth surface IV. Amplifies and presents a wound structure. The inductance of the coil formed by each of the conductor paths 5a and 5b increases as the amplitude height changes sharply on the first surface I and the third surface III, and the trapezoidal wave pattern of each of the conductor paths 5a and 5b increases. However, it becomes difficult to manufacture the common mode choke coil 1A.

  As shown in FIG. 3A, each of the conductor paths 5a and 5b includes electrode pads 5c and 5c bent in a U-shape on both surfaces of the sheet 4 at the start and end of winding. The sheet 4 is bent with the electrode pads 5c and 5c exposed at the crest surfaces 3c and 3c (see FIG. 2) of the convex portions 3d and 3d provided at both ends of the upper base material 3, respectively. For this reason, each conductor path 5a, 5b on the side surface S in front of the electrode pads 5c, 5c is formed for electrode extraction.

  FIG. 5A is a plan perspective view before the sheet 4 used in the common mode choke coil 1A according to the second embodiment of the present invention is bent. This sheet 4 is different from the common mode choke coil 1A according to the first embodiment only in that one conductor path 5a is formed on the front surface and the other conductor path 5b is arranged on the back surface facing the conductor path 5a. . 5 that are the same as or correspond to those in FIG. 3 are given the same reference numerals, and descriptions thereof are omitted.

  The sheet 4 is bent in the same manner as in the first embodiment along the valley fold line v and the mountain fold line m schematically shown in the plan view of FIG. FIG. 6A is a perspective view of the sheet 4 in a state of being folded in this manner. 6 that are the same as or correspond to those in FIG. 4 and FIG. In the second embodiment, the conductor paths 5a and 5b are formed at the same positions on both surfaces of the sheet 4. Therefore, the folded sheet 4 is formed so as to be shifted to one side of the sheet 4 in the first embodiment. Unlike the embodiment, the conductor paths 5a and 5b overlap each other and appear as one.

  In each of the first and second embodiments, by pressing the sheet 4 between the lower base material 2 and the upper base material 3 and pressing the sheet 4, the sheet 4 becomes as shown in FIGS. 4 (a) and 6 (a). The common mode choke coil 1A is manufactured by bending as shown. 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.

  FIG. 7 is an external perspective view of a coil 1B according to the third, fourth, and fifth embodiments of the present invention.

  The coil 1B includes a lower base material 12 and an upper base material 13 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 12 is shown in FIG. 8B, and the surface 12b facing the bottom surface 12a has an uneven shape that fits from below into the serrated fold of the sheet 4, and the number of turns of the coil 1B. Have a minute. The outer appearance of the upper base material 13 is shown in FIG. 8 (a). On the one surface 13b facing the upper surface 13a, an uneven shape that fits from above into the serrated fold of the sheet 4 is provided for the number of turns of the coil 1B. Have. Further, the upper base material 13 includes convex portions 13d and 13d at both ends so as to cover both side portions 12c and 12c of the lower base material 12 and the crest surfaces 13c and 13c are aligned with the bottom surface 12a of the lower base material 12. . The thickness t of the coil 1B is the height dimension of the convex portions 13d and 13d. The length of the lower substrate 12 is shorter than the length of the upper substrate 13 by the amount of these convex portions 13d and 13d. The sheet 4 is provided by being sandwiched between the concave and convex portions of the lower base material 12 and the upper base material 13.

  FIG. 9A is a plan view before the sheet 4 used in the coil 1B according to the third embodiment of the present invention is bent. Two single conductor paths 5a and 5b are formed on one side of the sheet 4 by the same electrode forming method using the same internal electrode material as in the first and second embodiments. Each conductor path 5a, 5b is oscillated with a predetermined sine wave pattern in the width W direction of the coil 1B, and this sine wave pattern has a predetermined number of cycles corresponding to the number of turns of the coil 1B in the length L direction of the coil 1B. Repeated to form a meander shape. The sheet 4 is bent as shown in the perspective view of FIG. 10A with a period in which one cycle in which the sinusoidal pattern is repeated in the thickness t direction as one period, whereby the conductor paths 5a and 5b are Presents a winding shape. 10 that are the same as or correspond to those in FIG. 9 are assigned the same reference numerals, and descriptions thereof are omitted.

  The above-described folding of the sheet 4 is performed with the folding line indicated by the alternate long and short dash line in FIG. 9B as the valley folding line v, and the folding line indicated by the broken line as the mountain folding line m. Bending is performed with a period in which two continuous surfaces appearing alternately as slopes D are taken as one period. Each of the conductor paths 5a and 5b is formed on an ascending slope U and a descending slope D so as to intersect the folding line of the seat 4, and the maximum amplitude portion and the minimum amplitude portion of the sine wave amplitude are the ascending slope U and the descending slope. Each of the slopes D is formed at the center in the length L direction. Therefore, as each conductor path 5a, 5b advances in the length L direction, the rising of the sheet 4 on the rising slope U and the lowering on the falling slope D are alternately repeated in the thickness t direction of the coil 1B. In the width W direction, at the center of each of the ascending slope U and the descending slope D in the length L direction, the sine wave is amplified in a pattern that draws the maximum amplitude portion and the minimum amplitude portion, thereby exhibiting a winding structure.

  Each conductor path 5a, 5b is provided with electrode pads 5c, 5c on the sheet 4 at the start and end of winding. The sheet 4 is bent with the electrode pads 5c, 5c exposed at the crest surfaces 13c, 13c (see FIG. 8) of the convex portions 13d, 13d provided at both ends of the upper base material 13. For this reason, each conductor path 5a, 5b on the side surface S in front of the electrode pads 5c, 5c is formed for electrode extraction.

  FIG. 11A is a plan view before the sheet 4 used in the coil 1B according to the fourth embodiment of the present invention is folded, and FIG. 11B is a valley fold line v and a mountain when the sheet 4 is folded. It is a top view which shows the fold line m typically. In FIG. 11, parts that are the same as or correspond to those in FIG.

In the coil 1B according to the fourth embodiment, each of the conductor paths 5a and 5b is amplified in a predetermined rectangular wave pattern in the width W direction of the coil 1B, and the rectangular wave pattern is coiled in the length L direction of the coil 1B. A meander shape is formed by repeating a predetermined number of times corresponding to the number of turns of 1B. In this case, the conductor tracks 5a, 5b, in the width W direction, deflection from the lowest amplitude height h ₀ to the highest amplitude height h _1, then a 1 amplitude amplitude back to the lowest amplitude height h ₀ In this case, the predetermined ratio portions x and y having one amplitude are formed on either the up slope U or the down slope D. Further, the remaining ratio portions 1-x and 1-y having one amplitude are formed on the other of the ascending slope U and the descending slope D.

  Also in the coil 1B according to the fourth embodiment, the sheet 4 is bent in the same manner as the coil 1B according to the third embodiment as shown in the perspective view of FIG. In FIG. 12, parts that are the same as or correspond to those in FIG. As each conductor path 5a, 5b travels in the length L direction, in the thickness t direction of the coil 1B, the rising of the sheet 4 on the rising slope U and the lowering on the falling slope D are alternately repeated, In the W direction, a predetermined proportion of one amplitude is oscillated on the ascending slope U, and the remaining proportion of one amplitude is oscillated on the descending slope D to present a winding structure.

  FIG. 13 (a) is a plan view before the sheet 4 used in the coil 1B according to the fifth embodiment of the present invention is folded, and FIG. 13 (b) is a valley fold line v and a peak when the sheet 4 is folded. It is a top view which shows the fold line m typically. In FIG. 13, parts that are the same as or correspond to those in FIG.

  In the coil 1B according to the fifth embodiment, each of the conductor paths 5a and 5b has portions of a predetermined length formed along the valley fold line v and the mountain fold line m of the sheet 4 on both sides. It is formed side by side facing both sides. In this coil 1B, each conductor path 5a, 5b is made to swing in a predetermined rectangular wave pattern in the width W direction of the coil 1B on both surfaces of the sheet 4, and this rectangular wave pattern is moved in the length L direction of the coil 1B. A meander shape is formed by periodically repeating a predetermined number of times corresponding to the number of turns of the coil 1B.

  Also in the coil 1B according to the fifth embodiment, the sheet 4 is bent in the same manner as the coil 1B according to the third embodiment as shown in the perspective view of FIG. As each conductor path 5a, 5b travels in the length L direction, in the thickness t direction of the coil 1B, the rising of the sheet 4 on the rising slope U and the lowering on the falling slope D are alternately repeated, In the W direction, it swings along the valley fold line v and horizontally traverses the ascending slope U in the length L direction, and then swings along the mountain fold line m and the descending slope D in the length L direction. Crosses horizontally and presents a wound structure.

  In each of the third, fourth, and fifth embodiments, the sheet 4 is pressed between the lower base material 12 and the upper base material 13 so that the sheet 4 is shown in FIGS. a) As shown in FIG. 14A, the coil 1B is manufactured by bending. At this time, an adhesive is applied to both surfaces of the sheet 4 and press working is performed.

  According to the common mode choke coils 1A and 1B of the first to fifth embodiments, the sheet 4 on which the two single conductor paths 5a and 5b are formed is simply bent, thereby Each of the conductor paths 5a and 5b formed on 4 is wound to form common mode choke coils 1A and 1B. 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 the common mode choke coils 1A and 1B having a lateral winding structure similar to a wound coil without providing a conductor connecting portion. As a result, a common mode choke coil with a side-winding structure similar to a wound-type coil that does not reduce the coil product price while eliminating the need to join the conductors and reducing the reliability of the connection part. 1A and 1B can be provided easily.

  Further, in the common mode choke coil 1A of the first and second embodiments, the lower base material 2 and the upper base material each having the concave and convex shapes that fit into the bend of the sheet 4 from below and above on one surface 2b and 3b, respectively. In the common mode choke coil 1B of each of the third, fourth, and fifth embodiments, the concave and convex shapes that are fitted from below and above to the bend of the sheet 4 are formed on one surface 12b and 13b, respectively. Since the sheet 4 is sandwiched between the lower substrate 12 and the upper substrate 13 included in the sheet 4, the folded shape of the sheet 4 is maintained and the strength is ensured, so that the product handling of the common mode choke coils 1A and 1B is improved. To do.

  In the common mode choke coil 1A of each of the first and second embodiments, electrode pads 5c and 5c integrally formed on the conductor paths 5a and 5b at the start and end of winding of the conductor paths 5a and 5b are provided. The protrusions 3d and 3d provided at both ends of the upper base material 3 are exposed on the crest surfaces 3c and 3c to constitute external electrodes. In the common mode choke coil 1B of the third, fourth, and fifth embodiments, the electrode pads 5c, 5c integrally formed on the conductor paths 5a, 5b at the start and end of winding of the conductor paths 5a, 5b. However, it is exposed to the crest surfaces 13c and 13c of the convex portions 13d and 13d provided at both ends of the upper base material 13 and constitutes an external electrode. For this reason, an external electrode can be provided in the coil comprised by each conductor path 5a, 5b, without having any connection part of an electric conductor, and the common mode choke coil 1A, 1B of the horizontal winding structure provided with the external electrode Can be provided at low cost and with high connection reliability.

  In the common mode choke coils 1A and 1B of the first to fifth embodiments, when the lower base materials 2 and 12 and the upper base materials 3 and 13 are made of a nonmagnetic material such as alumina, The magnetic permeability of the side base materials 2 and 12 and the upper base materials 3 and 13 is reduced. For this reason, since the inductance of the coil comprised by each conductor path 5a, 5b can be suppressed low, the common mode choke coils 1A, 1B having a lateral winding structure for high frequency applications are provided. Further, when the lower base materials 2 and 12 and the upper base materials 3 and 13 are made of a magnetic material such as ferrite, the magnetic permeability of the lower base materials 2 and 12 and the upper base materials 3 and 13 is increased. For this reason, by selecting the type of magnetic material to be used, the common mode choke coils 1A and 1B having a lateral winding structure having an inductance having a desired size can be obtained.

  Moreover, according to the manufacturing method of the common mode choke coils 1A and 1B of the first to fifth embodiments, the step of bending the sheet 4 to process the conductor paths 5a and 5b into a wound structure, and the lower base material 2, 12 and the upper base materials 3, 13 are processed to a strength that keeps the bent shape of the sheet 4, and the sheet is interposed between the lower base materials 2, 12 and the upper base materials 3, 13. 4 is performed in one step of pressing with 4 in between. For this reason, a manufacturing process decreases and the product cost of the common mode choke coils 1A and 1B of a horizontal winding structure can further be reduced.

  Moreover, according to the manufacturing method of the common mode choke coils 1A and 1B of each of the first to fifth embodiments, the adhesive is applied to both surfaces of the sheet 4 and the above pressing is performed. A step of processing each of the conductor paths 5a and 5b into a wound structure, a step of processing the lower base materials 2 and 12 and the upper base materials 3 and 13 into a strength to keep the bent shape of the sheet 4, and The step of joining the sheet 4 between the lower base materials 2 and 12 and the upper base materials 3 and 13 sandwiches the sheet 4 between the lower base materials 2 and 12 and the upper base materials 3 and 13. This is done in one step of pressing. For this reason, the number of manufacturing steps is further reduced, and the product cost of the common mode choke coils 1A and 1B having the lateral winding structure can be further reduced.

  Moreover, in the coil 1B of each of the third, fourth, and fifth embodiments, the sheet 4 includes two continuous pieces as shown in FIGS. 10 (a), 12 (a), and 14 (a). The ascending slope U and the descending slope D are bent in a sawtooth shape with a period of one period. For this reason, as shown in FIGS. 4 (a) and 6 (a), the sheet 4A is less in number of times than the case where the sheet 4A is bent into a rectangular wave shape with a period of four consecutive surfaces as one period. Can be bent per turn. For this reason, according to the coils 1B of the third, fourth and fifth embodiments, the common mode choke coil having the same outer dimensions can earn a larger number of turns, so that the horizontal winding having a large inductance can be obtained. A common mode choke coil 1B having a structure can be provided. In addition, in the common mode choke coil having the same number of turns, the number of times the sheet 4 is bent can be reduced, so that an improvement in the reliability of the sheet 4 can be expected. If the number of times the sheet 4 is bent per unit length is increased to make the sheet 4 bend sharply, the inductance of the coil 1B increases, but the coil 1B becomes difficult to manufacture.

  Further, in the coils 1B of the third and fourth embodiments using the sheet 4 shown in FIGS. 10A and 12A, the portions where the conductor paths 5a and 5b are bent by bending the sheet 4 are as follows. , Only the portions where the respective conductor paths 5a and 5b intersect the valley fold line v and the mountain fold line m of the sheet 4 are provided. For this reason, since the part by which the conductor paths 5a and 5b are bent decreases, the improvement of the reliability of the conductor paths 5a and 5b can be expected.

  In addition, according to the coil 1B of the fifth embodiment using the sheet 4 shown in FIG. 14A, the portions of the conductor paths 5a and 5b having a predetermined length formed along the folding line of the sheet 4 are bent. It is located on the outermost side of each surface of the sheet 4. Therefore, in the common mode choke coil having the same outer dimensions, the coil winding diameter can be formed largest. Therefore, a large cross-sectional area of the coil inner diameter portion can be secured, the magnetic flux can easily pass through the coil inner diameter portion, and the Q value of the common mode choke coil 1B can be increased.

  In each of the first and second embodiments, the width of the amplitude increases as the conductor paths 5a and 5b approach the second surface II in the first surface I of the continuous surfaces. A case has been described in which the amplitude is in the W direction and the amplitude in the width W direction in which the amplitude height decreases as the third surface III approaches the fourth surface IV. However, each of the conductor paths 5a and 5b has an amplitude in the width W direction in which the amplitude height decreases as it approaches the second surface II in the first surface I of the continuous surfaces, and the fourth surface in the third surface III. You may comprise so that it may amplitude in the width W direction where an amplitude height becomes high as it approaches the surface IV. The conductor paths 5a and 5b may be configured to cross the second surface II and the third surface III, for example, in an arc shape without changing the amplitude height.

  Further, in each of the first and second embodiments, the conductor paths 5a and 5b have the amplitude height increased on the first surface I, kept on the second surface II or substantially unchanged, and decreased on the third surface III. The case where the amplitude is maintained on the fourth surface IV has been described. However, each conductor path 5a, 5b maintains the amplitude height on the first surface I or does not substantially change, increases or decreases on the second surface II, maintains or does not substantially change on the third surface III, and changes the fourth surface IV. The amplitude may be lowered or increased.

  In the coil 1B according to the third and fourth embodiments, the case where the respective conductor paths 5a and 5b are formed on one side of the sheet 4 has been described as shown in FIGS. However, similarly to the coil 1A according to the second embodiment using the sheet 4 shown in FIG. 5, it is also possible to form the third and fourth conductor paths 5a and 5b so as to face both surfaces of the sheet 4 side by side. A common mode choke coil having a horizontal winding structure similar to that of the coil 1B according to each embodiment is obtained.

  In the first to fifth embodiments, the case where two single conductor paths 5a and 5b are formed on one side or both sides of the sheet 4 has been described. However, three or more single conductor paths may be formed on one or both sides of the sheet 4 to constitute a common mode choke coil such as a trifilar structure.

  In the first to fifth embodiments, the case where the electrode pads 5c and 5c at the start and end of winding of the conductor paths 5a and 5b are formed on both surfaces of the sheet 4 has been described. However, the electrode pads 5c and 5c are not necessarily formed on both surfaces, and may be configured to be formed only on one surface exposed at least to the outside.

  In the first to fifth embodiments, the case where the sheet 4 is folded along the valley fold line v and the mountain fold line m has been described. However, it is not always necessary to bend the sheet 4 along the fold line, and the conductor paths 5a and 5b formed on the sheet 4 may be formed into a winding structure by being bent in a wavy shape or the like. In this case, the concavo-convex shape provided on the lower base materials 2 and 12 and the upper base materials 3 and 13 is also a curved shape such as a wave shape.

  Further, in each of the first to fifth embodiments, the lower base materials 2 and 12 and the upper base materials 3 and 13 that are fitted from below and above to the bend of the sheet 4 constitute a structure that maintains the strength of the sheet 4. I explained the case. However, the electrode pads 5c and 5c are exposed, the resin around the sheet 4 is filled with resin, and a structure that maintains the strength of the sheet 4 is provided by including a resin base material that surrounds the sheet 4 with resin 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 handling property of the coils 1A and 1B is improved also by this configuration. .

  Moreover, the strength of the sheet 4 is maintained by providing only the lower base materials 2 and 12 having the concave and convex shapes fitted on the curved surface of the sheet 4 from below without providing the upper base materials 3 and 13 on one surface 2b and 12b. You may make it comprise a structure. According to the present configuration, the bent shape of the sheet 4 is maintained only by the lower base materials 2 and 12, and the strength is ensured. Therefore, the product handleability of the coils 1A and 1B is also improved by this configuration.

  At this time, unlike the first and second embodiments, the sheet 4 is folded in front of the electrode pads 5c and 5c in a mountain fold, so that the sheet 4 is formed as shown in FIGS. As shown in the perspective view of b), both ends are folded into a shape folded back inward. For this reason, the external appearance of the coil 1 </ b> C obtained by providing only the lower base material 2 is shown in the perspective view of FIG. In the figure, the same or corresponding parts as those in FIGS. 2 and 4 are denoted by the same reference numerals, and the description thereof is omitted. In this coil 1 </ b> C, the sheet 4 covers both side portions 2 c and 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 5c and 5c are exposed and bent. In FIG. 15A, the sheet 4 of FIG. 4B is illustrated, but the same coil 1C can also be obtained by the sheet 4 of FIG. 6B.

  In addition, unlike the third, fourth, and fifth embodiments, the sheet 4 is folded in front of the electrode pads 5c, 5c in a mountain fold, so that the sheet 4 is formed as shown in FIGS. As shown in the perspective views of FIGS. 12B and 14B, both ends are folded into a shape folded back inside. For this reason, the outer appearance of the coil 1D obtained by providing only the lower base 12 is shown in the perspective view of FIG. In the figure, the same or corresponding parts as those in FIGS. 8 and 10 are denoted by the same reference numerals and description thereof is omitted. In this coil 1 </ b> D, the sheet 4 covers both side portions 12 c and 12 c of the lower substrate 12, and both end portions are bent back to the bottom surface 12 a side of the lower substrate 12, so that the sheet 4 is formed on the bottom surface 12 a of the lower substrate 12. The electrode pads 5c and 5c are exposed and bent. In FIG. 15B, the sheet 4 of FIG. 10B is shown, but the same coil 1D can be obtained by the sheet 4 of FIGS. 12B and 14B.

  According to the coils 1C and 1D having these configurations, the electrode pads 5c and 5c formed integrally with the conductor paths 5a and 5b at the start and end of winding of the conductor paths 5a and 5b are formed on the lower base members 2 and 12, respectively. It is exposed to the bottom surfaces 2a and 12a to constitute an external electrode. For this reason, even with the coils 1C and 1D of the present configuration, the coils 1C and 1D can be provided with external electrodes without having any conductor connection portions, and a laterally wound common mode choke coil having external electrodes. 1C and 1D can be provided at low cost and with high connection reliability. Further, the conductor paths 5a and 5b are bent back on both side portions of the lower base materials 2 and 12, and the dimensions for forming the external electrodes in the length L direction of the coils 1C and 1D are shown in FIGS. The coils 1A and 1B shown need not be taken, and the length L direction of the coils 1C and 1D can be used for the 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.

  Such effects obtained by the coils 1C and 1D shown in FIGS. 15A and 15B are obtained by not providing the convex portions 3d, 3d, 13d, and 13d. 13A, and the sheet 4 is sandwiched between the lower base materials 2 and 12 and the upper base materials 3A and 13A.

  Moreover, in each of the first and second embodiments, the upper base material 3 is provided with convex portions 3d and 3d larger than the convex portions formed at the central portion of the upper base material 3, and peaks of the convex portions 3d and 3d. The case where the electrode pads 5c and 5c are exposed on the surfaces 3c and 3c to configure the external electrode has been described. However, the upper base material 3A may be configured, for example, as shown in the external perspective view of FIG. 16A without providing the convex portions 3d and 3d. In the figure, the same or corresponding parts as in FIG. In this case, at the start and end of winding of the respective conductor paths 5a and 5b 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 electrodes 7a and 7b are electrically connected. The external electrodes 7a and 7b are formed by a dip coating method, for example.

  Further, in each of the third, fourth, and fifth embodiments, the upper base 13 is provided with convex portions 13d and 13d at both ends, and the electrode pads 5c and 5c are provided on the crest surfaces 13c and 13c of the convex portions 13d and 13d. The case where the external electrode is configured by being exposed has been described. However, the upper base material 13A may be configured as shown in the external perspective view of FIG. 17A, for example, without providing the convex portions 13d and 13d. In FIG. 17, parts that are the same as or correspond to those in FIG. In this case, at the start and end of winding of the conductor paths 5a and 5b exposed on the side surface 16a of the base material 16 constituted by the lower base material 12 and the upper base material 13A, as shown in FIG. The external electrodes 17a and 17b are electrically connected. The external electrodes 17a and 17b are also formed by a dip coating method, for example.

  According to each of these configurations, by connecting the external electrodes 7a, 7b, 17a, 17b only at the start and end of winding of the conductor paths 5a, 5b exposed on the side surfaces 6a, 16a of the base members 6, 16, Common mode choke coils 1E and 1F having a lateral winding structure including external electrodes 7a, 7b, 17a and 17b on the side surfaces 6a and 16a of the substrates 6 and 16 can be configured. Further, unlike the above-described embodiments, it is not necessary to form the convex portions 3d, 3d, 13d, and 13d at both ends of the upper base materials 3 and 13, and the winding start and winding of the conductor paths 5a and 5b are not required. It is not necessary to form the electrode pads 5c and 5c at the end. For this reason, the common mode choke coil 1E having a laterally wound structure including the external electrodes 7a, 7b, 17a, and 17b, in which the number of connection portions of the conductors is small in four and there is very little concern that the connection reliability is lowered. 1F can be provided at low cost and with high connection reliability.

  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 with resin in the shape of a rectangular parallelepiped, and the uneven | corrugated shape fitted from the downward | lower direction to the curve of the sheet | seat 4 are provided in one surface 2b, 12b. In the coil 1C, 1D having the above-described winding structure configured by including only the lower base materials 2, 12, the electrode pads 5c, 5c are not provided at both ends of the conductor paths 5a, 5b, and the resin base material or the lower side is provided. By exposing the start and end of winding of the conductor paths 5a and 5b to the side surfaces of the base materials 2 and 12, external electrodes such as the external electrodes 7a, 7b, 17a, and 17b are formed on the side surfaces of the base material. I can. For this reason, even with such a coil having a winding structure, there are only four conductors connected, and there is very little concern about a decrease in connection reliability. The coil can be provided at low cost and with high connection reliability.

  Further, in the above-described common mode choke coil having the lateral winding structure in which the external electrode is formed separately from each of the conductor paths 5a and 5b as described above, the concave and convex shape that fits the bend of the sheet 4 is continuously formed on one surface. Using the mother substrate made of the material of the base material, the sheet 4 in which the conductor paths 5a, 5b not provided with the electrode pads 5c, 5c are continuously formed on the mother substrate is fitted, It can be divided into individual products by dicing or the like. In addition, a resin base material surrounding the periphery of the sheet 4 on which the respective conductor paths 5a and 5b not provided with the electrode pads 5c and 5c are continuously formed is used as a mother substrate, and the mother substrate is divided by dicing or the like. You can get a product. For this reason, the coil of each said structure can be manufactured by the wafer processing which takes many products from one mother board | substrate.

  18A, the lower mother substrate 22A and the upper mother substrate 33A made of the material of the base material are used, and the sheet 4 is sandwiched between the lower mother substrate 22A and the upper mother substrate 33A. The common mode choke coil 1E having the structure shown in FIG. 16 is manufactured by wafer processing in which a large number of products are taken from the mother boards 22A and 33A by dicing along the dotted line and dividing into individual products. Can do. In this case, the lower mother board 22A and the upper mother board 33A are each formed with a concave and convex shape that fits from below and above the rectangular wave-like curve of the sheet 4 on one surface.

  18B, the lower mother substrate 22B and the upper mother substrate 33B made of the material of the base material are used, and the sheet 4 is sandwiched between the lower mother substrate 22B and the upper mother substrate 33B. The common mode choke coil 1F having the structure shown in FIG. 17 is manufactured by wafer processing that takes a large number of products from the mother substrates 22B and 33B by dicing along the dotted line and dividing the product into individual products. Can do. In this case, the lower mother board 22B and the upper mother board 33B are formed with concavities and convexities that are fitted from the lower side and the upper side to the serrated curve of the sheet 4 on one surface.

  Further, in the common mode choke coils 1E and 1F having the laterally wound structure shown in FIGS. 16 and 17, the uneven pitches and the unevenness of the uneven shape of the lower base materials 2 and 12 and the uneven shape of the upper base materials 3A and 13A. When the depth is uniform and the structure is the same, one of the lower bases 2 and 12 or the upper bases 3A and 13A is shifted by one pitch with respect to the other and inverted, thereby lowering the lower bases 2 and 12. Alternatively, one of the upper base materials 3A and 13A can be used as both the lower base materials 2 and 12 and the upper base materials 3A and 13A. Accordingly, compatibility occurs between the lower base materials 2 and 12 and the upper base materials 3A and 13A, and when the molding of the lower base materials 2 and 12 and the upper base materials 3A and 13A is performed by a press, the same Press molding of the lower base materials 2 and 12 and the upper base materials 3A and 13A can be performed with a press die. For this reason, it is possible to halve the cost of the mold required for each coil 1E, 1F product, and to further reduce the manufacturing cost of the common mode choke coils 1E, 1F having a lateral winding structure. Become.

1A, 1B, 1C, 1D, 1E, 1F ... common mode choke coil 2, 12 ... lower substrate 2a, 12a ... bottom surface 2b, 12b ... one surface 2c, 12c ... side surface 3, 3A, 13, 13A ... upper substrate 3a, 13a ... Upper surface 3b, 13b ... One side 3c, 13c ... Mountain surface 3d, 13d ... Projection 4 ... Sheet 5a, 5b ... Conductor path 5c ... Electrode pad W ... Width L ... Length t ... Thickness v ... Valley folding line V ... Valley surface m ... Mountain fold line M ... Mountain surface S ... Side surface U ... Uphill slope D ... Downhill slope

Claims (3)

Two or more single conductor paths, each having a predetermined pattern in the width direction and periodically repeating the pattern in the length direction, are formed side by side on one or both sides of an electrically insulating sheet. In the thickness direction, the sheet is bent at a cycle in which the pattern is repeated, and each of the conductor paths is wound ,
A substrate having an uneven shape that fits into the bend of the sheet on one side,
Each of the conductor paths includes an electrode pad on at least one surface of the sheet at the start and end of winding at both ends thereof,
The sheet covers both side portions of the base material, both end portions thereof are bent back to the bottom surface side of the base material, and the electrode pads at both end portions folded back to the inside are exposed to the bottom surface of the base material. coil. Two or more single conductor paths, each having a predetermined pattern in the width direction and periodically repeating the pattern in the length direction, are formed side by side on one or both sides of an electrically insulating sheet. In the thickness direction, the sheet is bent at a cycle in which the pattern is repeated, and each of the conductor paths is wound ,
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, or a lower base material that has a concave and convex shape that fits to the bend of the sheet from below. And the base material which consists of an upper base material which has the uneven shape which fits from above into the curvature of the sheet,
A common mode choke coil comprising an external electrode electrically connected to a winding start and a winding end of each conductor path exposed on the side surface of the base material and formed on the side surface of the base material . The common mode choke coil according to claim 1 , wherein the base material is made of a nonmagnetic material or a magnetic material.

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