JP6673247B2 - Manufacturing method of wound coil - Google Patents

Description

  The present invention relates to a method of manufacturing a wound coil, and more particularly, to a method of manufacturing a wound coil in which a coating resin is disposed so as to cover a coil wound around a core.

  As a typical wound type coil element, a wire is wound around a core portion of a core including a core portion, and a pair of flange portions provided at both ends of the core portion, and a start end and an end of the wire are wound. And those connected to terminal electrodes provided on the flange portion. Further, in such a wound coil, there is a wound coil in which a coating resin is disposed so as to cover a wire wound around a core portion.

  As shown in FIG. 13, in Patent Document 1, a core 113 having a core 111, a pair of flanges 112 provided at both ends of the core 111, and a core 113 wound around the core 111. And a wire 115 wound around the core portion 111 and a covering resin 117 disposed to cover the entire periphery of the wire 115.

In the method of manufacturing a wound coil according to Patent Literature 1, as shown in FIG. 14, a coating resin 117 is applied around the wire 115, and then is dried by touching (the center of the applied surface is touched with a finger). In a case where the paint does not adhere to the fingertips), the coiled coil element 110 is pressed into the component storage portion 124 made of a heat-resistant rubber elastic body and heated, so that the coating resin 117 is removed from the component storage portion. It is shaped into a shape corresponding to the shape 124.
The flange 112 is provided with four escape portions 118 so as to allow the escape of the coating resin 117 protruding from the periphery of the core 111 when shaping the coating resin 117. The shaping is performed by storing the coating resin 117 in the 118.

JP 2000-286140 A

However, in the method of Patent Document 1, the coiled coil element 110 is press-fitted into the component storage portion 124 in a state where the coating resin 17 is dry to the touch. There is a problem that the shape of the coating resin 117 collapses due to the elastic force, and it cannot be formed into a desired shape.
Further, the shape of the coating resin 117 accumulated in the escape portion 118 of the flange portion 112 may be different depending on each of the plurality of escape portions 118, and there is a problem that the external shape is not stable.

  The present invention is to solve the above-mentioned problem, and is formed by winding a wire around a core portion, and is covered with a coating resin at least from an upper portion to both side portions of the core portion, and has a stable external shape. It is an object of the present invention to provide a method of manufacturing a wound coil capable of efficiently manufacturing a wound coil having the following.

In order to solve the above-described problems, a method of manufacturing a wound coil of the present invention includes:
A core including a core, a pair of flanges provided on both ends of the core, a terminal electrode provided on the pair of flanges, and a wire wound around the core. Manufacture of a wound coil having a wound coil element formed by turning and having a coil having a start end and an end connected to the terminal electrode, and a coating resin disposed to cover the coil The method
(A) press-fitting the wire-wound coil element into the holding hole of the holding jig provided with a holding hole whose inner peripheral surface is made of an elastic material so that the pair of flanges face in the horizontal direction ;
The upper end of the coil is lower than the upper end of the holding hole,
A gap exists between the inner peripheral surface of the holding hole and the coil,
The lower end of the core portion is equal to or higher than the lower end of the holding hole, and
As the lower end of the terminal electrode is lower than the lower end of the holding hole,
Holding the winding type coil element on the holding jig,
(B) supplying the coating resin having fluidity to the holding hole from the upper surface side of the holding jig, and coating the coating resin with the coating resin from at least the upper portion of the core portion to both side portions;
(C) curing the supplied coating resin in a state where the coil-type coil element is held by the holding jig .

Further, in the step (a), when the wire-wound coil element is press-fitted into the holding hole of the holding jig , the lower end of the core of the wire-wound coil element is positioned at the lower end of the holding hole. It is preferable to hold the wire-wound coil element so as to be higher.
By setting the height of the lower surface of the holding jig (lower end of the holding hole) lower than the lower end (lower portion) of the core, the coating resin also wraps around the lower end (lower) of the coil, and The entire outer peripheral surface is covered, and the entire coil formed by winding the wire around the core, that is, the upper end (upper), lower end (lower), and side end (side) of the coil are covered. Coated with resin.

  In the present invention, in the step (b), the coating resin is supplied to a position higher than the upper end of the holding hole, and the coating resin existing at a position higher than the upper end of the holding hole is removed. Thereafter, it is preferable that the step (c) of curing the coating resin is performed.

  The coating covering the upper end of the coil by supplying the coating resin to a position higher than the upper end of the holding hole and removing the coating resin present at a position higher than the holding hole by a blade-like jig such as a scraper. When the upper surface of the resin is flattened, it is possible to provide a winding type coil having a flat upper surface and high pickup reliability by vacuum suction during mounting.

  Preferably, the method further comprises a step of cleaning the surface of the holding jig with a brush after the coating resin is cured in the step (c).

  After the coating resin is cured, by cleaning the surface of the holding jig with a brush, the holding jig can be easily cleaned, and by repeatedly using the holding jig, as described above. Thus, it is possible to provide a coil type coil having excellent shape accuracy and high reliability.

  Further, in supplying the coating resin in the step (b), the coating resin is removed while the mask having an opening corresponding to the planar shape of the holding hole is arranged so as to cover the holding jig. It is preferable to be configured to supply from an opening.

  With the above configuration, it is possible to suppress the adhesion of the coating resin to the upper surface of the holding jig and reduce the load required for cleaning the holding jig.

  Further, it is preferable that the planar shape of the holding hole is rectangular.

  In the case where the planar shape of the holding hole is rectangular, the flange of the wire-wound coil element can be securely held by the holding hole, and productivity can be improved.

  Further, as the holding jig, a holding hole such that a gap is formed between an inner peripheral surface of the holding hole and a side surface of the flange when the wire-wound coil element is press-fitted into the holding hole. It is also possible to use a holding jig provided with.

  By using the holding jig having the holding holes as described above, it is possible to form a wound coil having a structure in which not only the coil but also a part of the side surface of the flange is covered with the coating resin.

Further, in the step (a), when the wire-wound coil element is press-fitted into the holding hole of the holding jig , the upper end of the flange of the wire-wound coil element is higher than the upper end of the holding hole. It is preferable to hold the coil-type coil element in such a manner that the coil element becomes lower.

  With the above configuration, it is possible to obtain a wound coil in which both the core and the flange are covered with the covering resin and the entire upper surface is formed of the covering resin.

In the step (b), a sealing member for sealing a part of the holding hole is provided on a lower surface of the holding jig so as not to contact a lower end of the coil. It is preferable to supply the coating resin having fluidity to the holes.

  With the above configuration, the opening area on the lower surface side of the holding hole can be reduced, and it is possible to suppress and prevent the coating resin from flowing downward from the holding hole. Can be closed. This configuration is particularly significant when the dimensions of the wound coil element are large.

  In addition, since the sealing member is disposed so as not to contact the lower end of the coil, the coil may be damaged by contact with the sealing member, or the portion of the coil in contact with the sealing member may be covered with resin. Can be prevented from being uncovered.

The method of manufacturing a wound coil according to the present invention is configured as described above, and press-fits a wound coil element into a holding hole of a holding jig provided with a holding hole whose inner peripheral surface is made of an elastic material. Is lower than the upper end of the holding hole, there is a gap between the inner peripheral surface of the holding hole and the coil, the lower end of the core is equal to or higher than the lower end of the holding hole, and the terminal As the lower end of the electrode is lower than the lower end of the holding hole, the winding type coil element is held by the holding jig, and a coating resin having fluidity is supplied to the holding hole from the upper surface side of the holding jig, at least. Since the supplied coating resin is cured after coating with the coating resin from the upper portion of the core portion to both sides, the winding having a structure in which at least both sides from the upper portion of the core portion are buried in the coating resin. A linear coil can be manufactured efficiently.

  That is, when the wire-wound coil element is press-fitted, the upper end of the coil is lower than the upper end of the holding hole, there is a gap between the inner peripheral surface of the holding hole and the coil, and the lower end of the core part is The coating resin supplied to the holding hole is held by holding the wire-wound coil element on the holding jig so that the lower end of the terminal electrode is lower than the lower end of the holding hole. Moves downward along the gap between the inner peripheral surface of the holding hole and the coil due to its own weight and capillary action. At this time, the moved coating resin is held in the gap between the inner peripheral surface of the holding hole and the coil due to surface tension, and does not flow downward from the gap.

  Further, according to the present invention, it becomes possible to obtain a wound-type coil provided with a covering resin corresponding to the shape of the holding hole. It becomes possible to manufacture efficiently.

  In addition, when a resin material containing magnetic powder is used as a material of the coating resin, for example, a wire-wound coil having excellent electric characteristics such as a magnetic flux shielding property and an inductance obtaining efficiency and having a small variation in the electric characteristics is manufactured. It becomes possible to do.

  Further, according to the method of manufacturing a wound coil of the present invention, it is not necessary to provide an escape portion of the coating resin on the flange portion as in the related art, and the shape (core shape) of the wound coil element can be simplified. It becomes possible to do.

It is a perspective view for explaining a wound type coil, (a) is a wound type coil (winding type coil element) before coating with a coating resin, (b) is a winding core part and a coil of the winding type coil element are coated. It is a figure showing a coil of a coil type covered with resin. 2A and 2B are diagrams illustrating the wound-type coil illustrated in FIG. 1B, wherein FIG. 1A is a plan view, FIG. 1B is a cross-sectional view taken along line A <b> 1-A <b> 1, and FIG. It is. FIG. 4 is a perspective view of a holding jig for holding the wound coil element. FIGS. 4A and 4B are diagrams showing a state in which the winding coil element is held by a holding jig, wherein FIG. 3A is a plan view of a portion C in FIG. 3, FIG. It is a line sectional view by B2-B2. A state immediately after the coating resin is supplied to the holding hole for holding the wound coil element, (b) a state in which the gap between the inner peripheral surface of the holding hole and the coil is filled with the coating resin, and (c) a holding hole. FIG. 5 is a diagram showing a state in which a coating resin existing at a position higher than the upper end of the resin is removed. It is a figure which shows the state which removed the hardened coating resin which exists in the position higher than the holding hole of a holding jig. (A), (b), (c) is a figure which shows the other method of supplying coating resin to a coiled coil element. It is a figure which shows the other method of supplying a coating resin to a coil type coil element. It is a figure (top view) showing other manufacturing methods of a coil of a coil. It is a figure (top view) showing still another manufacturing method of a winding type coil. It is a figure (sectional view by the A2-A2 line) showing still another manufacturing method of a coil of a winding type. It is a figure which shows another manufacturing method of a winding type coil, (a) is a top view, (b) is sectional drawing by A2-A2, (c) is sectional drawing by B2-B2 line. It is a figure showing the conventional winding type coil. It is a figure for explaining the manufacturing method of the conventional winding type coil. It is a figure which shows a winding type coil, (a) is a top view, (b) is sectional drawing by A1-A1 line, (c) is sectional drawing by B1-B1 line.

  Hereinafter, the features of the present invention will be described in more detail by showing embodiments of the present invention.

  First, a wound coil manufactured by the method of manufacturing a wound coil according to the present invention will be described with reference to FIGS. FIGS. 1A and 1B show the wound coil element 10 and the wound coil 1 with the lower surface 12b of the flange portion 12 on which the terminal electrode 14 is disposed facing upward.

As shown in FIG. 1A, the wound coil element 10 includes a core part 11 having a rectangular cross section in a direction perpendicular to an axis (core axis) 11x of the core part 11, The core 13 has a pair of flanges 12 disposed at both ends and having a rectangular shape as viewed from the axial direction of the core shaft 11x. A terminal electrode 14 is formed on a lower surface 12b of the flange portion 12 which is a surface facing a mounting target (such as a circuit board) of the wound coil 1. A wire 15 is wound around the core 11 to form a coil 16, and the start and end of the wire 15 are connected to different terminal electrodes of the pair of terminal electrodes 14, respectively.
As shown in FIGS. 1B and 2, the wound coil 1 covers the entire outer peripheral surface (upper surface 11 a, lower surface 11 b, and both side surfaces 11 c) of the core 11, and A coating resin 17 is provided to cover the entire coil 16 formed by winding the wire 15.
In other words, the coating resin 17 covers the entire coil 16 including the wire 15 wound around the core 11 (an upper portion (upper end) 16 a corresponding to the upper surface 11 a of the core 11, a lower surface of the core 11). The lower portion (lower end) 16b which is a region corresponding to 11b and the pair of side portions (side ends) 16c which are regions corresponding to a pair of side portions (side surfaces) 11c of the core 11 facing each other (all). They are arranged in such a way as to be covered.

  Next, a method of manufacturing the wound coil according to the embodiment of the present invention will be described.

(1) First, a holding jig 21 as shown in FIGS. The holding jig 21 has a jig main body 22 made of a material having rigidity, and an inner peripheral surface 24c made of an elastic material for elastically holding the wound coil element 1. The axial direction X is the upper surface 21a of the holding jig 21, A plurality of holding holes 24 orthogonal to the lower surface 21b are provided.
The holding hole 24 is provided so as to penetrate each of the plurality of elastic members 23 fitted into the jig body 22 in a matrix, and has a planar shape (a shape when viewed from the axial direction X of the holding hole 24). Is a square.
As the elastic material forming the inner peripheral surface 24c of the holding hole 24, silicon rubber having heat resistance is used.

(2) Next, the wire-wound coil element 10 is pressed into the holding hole 24 of the holding jig 21. The press-fit wound coil element 10 has the outer end surface 12d and both side surfaces 12c of the flange portion 12 abutting against the inner peripheral surface 24c of the holding hole 24, and is elastically retained by the elastic force of the elastic material forming the inner peripheral surface 24c. (See FIG. 4A).
Here, the holding hole 24 is formed such that the axial direction X thereof is oriented in the vertical direction, and the press-fitted coiled coil element 10 is configured such that the surface of the flange 12 on which the terminal electrode 14 is formed is the lower surface. Is held so that

In the wound coil element 1, the upper end (upper portion) 16 a of the coil 16 is lower than the upper end of the holding hole 24, and the gap between the side end (side portion) 16 c of the coil 16 and the inner peripheral surface 24 c of the holding hole 24. A lower end (lower portion) 16b of the core part 11 is higher than a lower end 24b of the holding hole 16 and a lower end of the terminal electrode 14 is lower than the lower end 24b of the holding hole 24. In this manner, the holding jig 21 is held in the holding hole 24 (FIGS. 4B and 4C).
It is preferable that the gap G is usually in a range of 0.05 mm or more and 0.2 mm or less. It is desirable that the size of the gap G be appropriately adjusted depending on the viscosity of the coating resin or the like.

  In this embodiment, the upper end 16a of the coil 16 is lower than the upper end 24a of the holding hole 24 by, for example, 0 mm or more and 0.1 mm or less. The height difference between the upper end 16a of the coil 16 and the upper end 24a of the holding hole 24 is appropriately adjusted according to the target thickness of the coating resin 17 that covers the coil 16.

  By adjusting the height difference between the lower end 16 b of the core 11 and the lower end 24 b of the holding hole 16, the thickness of the coating resin 17 that covers the lower end 16 b of the coil 16 can be controlled.

(3) Next, as shown in FIG. 5 (a), using a resin supply means (for example, a dispenser) 31, a coating having fluidity is formed on the holding hole 24 holding the wound coil element 10. The resin 17 is supplied. At this time, the coating resin 17 is supplied to a position higher than the upper end 24a of the holding hole 24.
In this embodiment, a magnetic powder-containing resin in which Fe powder (60 to 80% by weight) is dispersed in an epoxy resin which is a thermosetting resin is used as the coating resin 17.
The viscosity of the magnetic powder-containing resin is, for example, 10 Pa · s or more and 90 Pa · s or less.

  As shown in FIG. 5B, the coating resin 17 supplied onto the holding hole 24 is lowered along the gap G between the inner peripheral surface 24c of the holding hole 24 and the coil 16 due to its own weight and capillary action. Moving. The moved coating resin 17 is held in the gap G by the surface tension and does not flow downward from the gap G.

  On the other hand, by setting the height of the lower surface 21b (the lower end 24b of the holding hole 24) of the holding jig 21 lower than the lower end (the lower portion) 16b of the core 11, the lower end (the lower) of the core 11 is formed. The coating resin 17 also wraps around the core 16b to cover the entire outer peripheral surface (the upper surface 11a, the lower surface 11b, and both side surfaces 11c) of the winding core 11, and the entire coil 16, that is, the upper end (upper) 16a and the lower end of the coil 16. The (lower) portion 16b and the side end (side portion) 16c are covered with the covering resin 17.

  (4) Then, as shown in FIG. 5C, the coating resin 17 existing at a position higher than the upper end 24a of the holding hole 24 of the holding jig 21 is removed by an elastic squeegee 32.

  (5) Next, the coiled coil element 10 is placed in an oven (not shown) at 100 ° C. to 150 ° C. together with the holding jig 21 to thermally cure the coating resin 17.

  After that, by taking out the coil-type coil element 10 from the holding jig 21, as shown in FIG. 1B and FIG. 2, the coating resin 17 also wraps around the lower end (lower part) 16 b of the coil 16, The entire outer peripheral surface (upper surface 11 a, lower surface 11 b and both side surfaces 11 c) of the portion 11 is covered, and a wire 15 is wound around the core portion 11, thereby forming a coil 16 formed on the outer peripheral portion of the core portion 11. , That is, a winding type coil 1 having a structure in which all of an upper end (upper) 16a, a lower end (lower) 16b, and a side end (side) 16c of the coil 16 are securely covered with the coating resin 17 (see FIG. 1 (b), FIG. 2) can be obtained.

As shown in FIG. 6, if the coating resin (excess cured resin) 17 remains at a position higher than the surface of the holding jig 21 (the upper end 24a of the holding hole 24) after the heat curing, It is also possible to remove the coating resin 17 using a cured resin removing means (for example, a cleaning brush) 35.
With this configuration, it is possible to obtain an effect that burrs of the cured resin formed near the upper end of the holding hole 24 can be removed at the same time.

In addition, when supplying the coating resin 17, as shown in FIG. 7A, after supplying an amount of the coating resin 17 including an excess on the upper surface of the holding jig 21, the coating resin 17 is provided above the holding jig 21. A scraper (blade-shaped jig) 36 is used to scrape off the surplus so that the required amount remains on the holding jig 21 so that the coating resin 17 is efficiently supplied to the holding holes 24. It is also possible to configure.
The supplied coating resin 17 fills the gap G between the inner peripheral surface 24c of the holding hole 24 and the coil 16 by its own weight and capillary action as shown in FIG. The height of the lower surface 21b (lower end 24b of the holding hole 24) is set lower than the lower end (lower end) 16b of the core part 11, so that the coating resin 17 also wraps around the lower end (lower end) 16b of the coil 16. The entire coil 16 including the lower end (lower) 16b as well as the upper end (upper) 16a and the side end (side) 16C of the coil 16 formed by winding the wire 15 around the core 11 is covered. It is covered with the resin 17.
Thereafter, as shown in FIG. 7C, the coating resin 17 existing at a position higher than the upper end 24a of the holding hole 24 is scraped off by the squeegee 32.

When supplying the coating resin of the above embodiment, a mask (a metal mask in this embodiment) 37 having an opening 37a corresponding to the holding hole 24 is covered with the holding jig 21 as shown in FIG. It is also possible to supply the coating resin 17 from the opening 37a using the squeegee 32.
By using the mask 37 as described above, adhesion of the coating resin 17 to the upper surface 21a of the holding jig 21 can be suppressed, and the load required for cleaning the holding jig 21 can be reduced.

Further, according to the present invention, it is possible to form the wound coil 1A while holding the wound coil element 10 in the mode as shown in FIG.
That is, using the holding jig 21 in which the holding hole 24 elastically holds the outer end surfaces 12 d of the pair of flanges 12 of the core 13 facing each other, the inner peripheral surface 24 c of the holding hole 24 and the side surface 12 c of the flange 12 are connected. By holding the coiled coil element 10 and supplying the coating resin 17 to the holding holes 24 in such a manner that a gap is formed between the coils, not only the coil 16 but also the side surface 12c of the flange 12 is coated with the coating resin 17. The coiled coil 1A having the structure covered by the above can be formed.

Further, according to the present invention, it is possible to form the wound coil 1B while holding the wound coil element 10 in a manner as shown in FIG.
That is, as the holding jig 21, the holding hole 24 elastically holds the outer end surface 12 d of the flange portion 12, and elastically holds a region that is a part of the side surface 12 c of the flange portion 12 and close to the outer end surface 12 d. The tool 21 is used to hold the wound coil element 10 in such a manner that a gap is formed between the inner peripheral surface 24c of the holding hole 24 and a part of the side surface 12c of the flange portion 12, and the holding hole By supplying the coating resin 17 to the coil 24, it is possible to form the winding type coil 1 </ b> B having a structure in which not only the coil 16 but also a part of the side surface 12 c of the flange portion 12 is coated with the coating resin 17.

Further, according to the present invention, it is possible to form the wound coil 1C while holding the wound coil element 10 in the mode as shown in FIG.
That is, in the step of supplying the coating resin 17, the winding type coil element 10 is held in the holding hole 24 in such a manner that the upper end (upper surface) 12 a of the flange 12 is lower than the upper end 24 a of the holding hole 24. By supplying the coating resin 17 to a position higher than the upper end 12a of the flange portion 12, the entire upper surface is formed of the coating resin 17, and the upper (upper end) 16a of the coil 16 is thickly covered with the coating resin 17. The linear coil 1C can be formed.

  Further, according to the present invention, it is also possible to supply the coating resin 17 by holding the flange portion 12 in the holding hole 24 such that the upper end (upper surface) 12 a of the flange portion 12 is higher than the upper end 24 a of the holding hole 24. is there. The covering resin 17 existing on the upper end (upper surface) 12a of the flange portion 12 can be removed by the squeegee 32 having elasticity. When the coating resin 17 is formed on the upper end (upper surface) 12a of the flange portion 12, if the thickness of the coating resin 17 varies, the height of the coiled coil 1C (the length from the upper end to the lower end of the coiled coil 1C) is reduced. Variation increases. On the other hand, by removing the coating resin 17 present on the upper end (upper surface) 12a of the flange 12, it is possible to suppress variations in the height of the coil 1C.

  In addition, in the method of manufacturing the wire-wound inductor according to the present invention, as shown in FIGS. 12A, 12B and 12C, the wire-wound coil element 10 is held in the holding hole 24 of the holding jig 21. A sealing member 50 for sealing a part of the holding hole 24 is provided on the lower surface 21b of the holding jig 21 so as not to be in contact with the lower end of the coil 16 formed by winding the wire 15 around the core 11. It is also possible to supply the coating resin 17 having fluidity to the holding holes 24 in a state where the resin is provided.

Thus, by disposing the sealing member 50 on the lower surface 21b of the holding jig 21 and reducing the opening area on the lower surface 21b side of the holding hole 24, the coating resin 17 flows downward from the holding hole 24. This can be suppressed and prevented from occurring.
This configuration is particularly significant when the dimensions of the coil element 10 are large.

  Further, in the method of manufacturing the wound coil of the present invention, not only when the entire outer peripheral surface of the core portion is coated with the coating resin, but also at least over the both sides from the upper portion of the core portion, the coating may be performed with the coating resin. It is possible. In this case, the step (2) is different from the method of manufacturing the wound coil according to the embodiment. Specifically, when the coiled coil element 10 is press-fitted into the holding hole 24 of the holding jig 21, the height of the lower surface 21 b (the lower end 24 b of the holding hole 24) of the holding jig 21 is changed to the height of the core. Keep it equal to the lower end. Thereby, the coating resin 17 can be covered with the coating resin from at least the upper part of the core part 11 to both side parts without the coating resin 17 wrapping around the entire lower end (lower part) 16b of the core part 11.

  As shown in FIG. 15, the wound coil element 10 has a core part 11 having a rectangular cross section in a direction orthogonal to the core axis 11 a, and a core axis provided at both ends of the core part 11. A core 13 having a pair of flanges 12 having a rectangular shape as viewed from the axial direction of 11a is provided. A terminal electrode 14 is formed on a lower surface 12b of the flange portion 12 which is a surface facing a mounting target (such as a circuit board) of the wound coil 1. A wire 15 is wound around the core 11 to form a coil 16, and the start and end of the wire 15 are connected to different terminal electrodes of the pair of terminal electrodes 14, respectively.

  As shown in FIG. 15, the wound coil 1 includes a coating resin 17 that covers a main part of the coil 16 (a region excluding a region facing a mounting target of the coil 16). In other words, the coating resin 17 is provided on the upper (upper end) 16 a of the coil 16 made of the wire 15 wound around the core 11, which is a region corresponding to the upper surface of the core 11, and on both sides ( The pair of side portions (side ends) 16c, which are regions corresponding to both side surfaces, are covered, while the lower portions (bottom ends) 16b, which are regions corresponding to the lower surface of the core 11, are not covered. ing.

  In addition, the coating resin 17 includes an upper portion (upper end) 16 a which is a region corresponding to the upper surface of the core portion 11 of the coil 16 including the wire 15 wound around the core portion 11, and both side portions ( A pair of side portions (side ends) 16c which are regions corresponding to the both side surfaces) are covered, and a lower portion (lower end) which is a region corresponding to the lower surface of the core 11 from each of the pair of side portions (side ends) 16c. The coating resin may be provided so as to extend to the portion 16b and cover a part of the lower portion (lower end) 16b.

  Further, since the sealing member 50 is disposed so as not to contact the lower end (lower portion) 16 b of the coil 16, the coil 16 may be damaged by contact with the sealing member 50, or may be damaged by the sealing member 50 of the coil 16. It can be avoided that the contacting part is not covered with the coating resin 17.

  In the present invention, the posture of the holding jig when supplying the coating resin is not limited to the case where the main surface is horizontal and the axial direction of the holding hole is vertical, for example, When the coating resin is supplied in a posture where the main surface of the holding jig has some inclination with respect to the horizontal direction (a posture where the axial direction of the holding hole has some angle with respect to the vertical direction) Does not exclude.

  In the present invention, the coating resin is not limited to the magnetic powder-containing resin, and may be, for example, a thermosetting resin or a UV-curable resin containing no magnetic powder.

Further, the coiled coil element 10 is placed in an oven together with the holding jig 21 and the coating resin 17 is thermally cured. When a UV curable resin is used instead of the thermosetting resin, the coiled coil element 10 is held and cured. The coating resin may be cured by irradiating the UV curable resin with UV light from one or both sides of the holding hole of the holding jig in the state of being held by the tool 21.

  Further, when a portion of the wire 15 that is extended to the terminal electrode is floating from the core, the portion may be disconnected. If the viscosity of the coating resin is appropriate, the portion can be filled with the coating resin to prevent disconnection.

  The present invention is not limited to the above-described embodiment in other respects, and various applications and modifications can be made within the scope of the present invention.

1, 1A, 1B, 1C Winding coil 10 Winding coil element 11 Core 11a Upper surface of core 11b Lower surface of core 11c Side of core 11x Core shaft 12 Flange 12a Upper end of flange ( Top)
12b Lower edge of flange (lower surface)
12c Side surface of flange 12d Outer end surface of flange 13 Core 14 Terminal electrode 15 Wire 16 Coil 16a Upper end (upper) of coil
16b Lower end of coil (lower)
16c Side end of coil (side part)
17 Coating resin 21 Holding jig 21a Upper surface of holding jig 21b Lower surface of holding jig 22 Jig body 23 Elastic member 24 Holding hole of holding jig 24a Upper end of holding hole 24b Lower end of holding hole 24c Inner peripheral surface of holding hole 31 resin supply means 32 squeegee 35 cured resin removal means (cleaning brush)
36 Scraper (blade-shaped jig)
37 Mask 37a Opening of mask 50 Sealing member G Gap between inner peripheral surface of holding hole and coil X Axial direction of holding hole

Claims (9)

A core including a core, a pair of flanges provided on both ends of the core, a terminal electrode provided on the pair of flanges, and a wire wound around the core. Manufacture of a wound coil having a wound coil element formed by turning and having a coil having a start end and an end connected to the terminal electrode, and a coating resin disposed to cover the coil The method
(A) press-fitting the wire-wound coil element into the holding hole of the holding jig provided with a holding hole whose inner peripheral surface is made of an elastic material so that the pair of flanges face in the horizontal direction ;
The upper end of the coil is lower than the upper end of the holding hole,
A gap exists between the inner peripheral surface of the holding hole and the coil,
The lower end of the core portion is equal to or higher than the lower end of the holding hole, and
As the lower end of the terminal electrode is lower than the lower end of the holding hole,
Holding the winding type coil element on the holding jig,
(B) supplying the coating resin having fluidity to the holding hole from the upper surface side of the holding jig, and coating the coating resin with the coating resin from at least the upper portion of the core portion to both side portions;
(C) curing the supplied coating resin in a state where the coil type coil element is held by the holding jig . In the step (a), when the wire-wound coil element is pressed into the holding hole of the holding jig , the lower end of the core of the wire-wound coil element is smaller than the lower end of the holding hole. The method for manufacturing a wound coil according to claim 1, wherein the wound coil element is held so as to be higher.   In the step (b), the coating resin is supplied to a position higher than the upper end of the holding hole, and the coating resin present at a position higher than the upper end of the holding hole is removed. 3. The method according to claim 1, wherein the step of curing the coating resin is performed.   The wound coil according to any one of claims 1 to 3, further comprising a step of cleaning the surface of the holding jig with a brush after the coating resin is cured in the step (c). Manufacturing method.   In supplying the coating resin in the step (b), in a state where a mask having an opening corresponding to the planar shape of the holding hole is arranged so as to cover the holding jig, the coating resin is removed from the opening. The method for manufacturing a wire-wound coil according to any one of claims 1 to 4, wherein the coil is configured to be supplied.   The method for manufacturing a wire-wound coil according to any one of claims 1 to 5, wherein a planar shape of the holding hole is rectangular.   The holding jig includes a holding hole such that a gap is formed between an inner peripheral surface of the holding hole and a side surface of the flange when the wire-wound coil element is pressed into the holding hole. The method for manufacturing a wire-wound coil according to claim 1, wherein a holding jig is used. In the step (a), when the wire-wound coil element is pressed into the holding hole of the holding jig , the upper end of the flange of the wire-wound coil element is lower than the upper end of the holding hole. The method for manufacturing a wire-wound coil according to any one of claims 1 to 7, wherein the wire-wound coil element is held in such a manner. In the step (b), a sealing member for sealing a part of the holding hole is disposed on the lower surface of the holding jig so as not to contact the lower end of the coil. The method for manufacturing a wire-wound coil according to any one of claims 1 to 8, wherein the method is configured to supply the coating resin having fluidity.

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