JP2013042021A - Coil component and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To decrease the number of manufacturing steps, reduce a manufacturing cost, and promote reduction in size of a coil component, while overall heat radiation characteristic is improved.SOLUTION: A coil component includes a coil body part which uses a square wire Wf and a coil part which has a coil terminal part integral with both ends of the square wire Wf derived from the coil body part. The coil component includes a coil part 2 which is manufactured by bending a coil base material Pc provided by integrally punching out a portion corresponding to coil terminal parts 4p and 4q and a coil body part 3 from a plate base material Pr having a predetermined thickness which is formed from a conductive material E, and separator members 5p and 5q where one or more insulating members 5pa, 5pb..., 5qa, 5qb... are provided with a predetermined interval which are formed from an insulating material D to perform electrical insulation among turn parts 3 t... by inserting the insulating members in the turn parts 3 t... of the coil body part 3.

Description

  The present invention relates to a coil component including a coil portion having a coil terminal portion integrated with a coil main body portion using a flat wire, and a manufacturing method thereof.

  2. Description of the Related Art Conventionally, a coil component having a coil portion using a rectangular wire, particularly, a coil portion having a coil body portion using a rectangular wire and coil terminal portions integrally formed at both ends of a rectangular wire derived from the coil body portion. As the coil parts, the coil parts disclosed in Patent Documents 1 to 4 are known.

  Patent Document 1 discloses a magnetic core mounting terminal block having a surface mounting terminal and a terminal processing terminal for mounting a substrate and having an engaging groove for positioning a magnetic core, and a terminal block for magnetic core mounting in the engaging groove. A pair of E-shaped cores positioned and fixed on the inside, and a coil that is provided around the cylindrical portion of the pair of E-shaped cores and is formed by winding a rectangular wire in an annular shape, and is formed at the leading end of the coil An inductance element having a configuration in which a terminal processing terminal is inserted and connected to the formed hole and a coil for the element are disclosed. Patent Document 2 discloses a coil formed by winding an insulating flat wire conductor having a flat band shape in an edgewise manner so that the plane intersects the direction of the coil center line. Inductance element parts mounted on an iron core forming the same are disclosed. In Patent Document 3, a rectangular hole is provided in a rectangular recess on the back side of the base, and a notch is provided on one edge of the base so as to face the short recess, and for fixing to the bottom surface of the terminal. Ribs are provided, and the terminals are fitted into the notches and short recesses provided in the base, and the terminals are fixed to the base by bending the fixing ribs of both terminals into the holes provided in the rectangular recesses. An inductor is disclosed in which both ends of the edgewise coil are in contact with the terminals separately, and both ends of the edgewise coil are fixed to the terminals with solder. Patent Document 4 includes a coil in which a rectangular wire is wound edgewise, an upper cover and a lower cover made of insulating resin provided on end faces in the axial direction of the coil, and these upper cover and lower cover. The coil includes an upper core and a lower core that form a closed magnetic circuit in between, and the coil is pulled out from the edgewise winding portion, and the tip portion that becomes a pair of terminals is bent in an out-of-plane direction, respectively. A choke coil that is inserted into a through hole formed in a cover is disclosed.

JP-A-7-245217 Japanese Patent Laid-Open No. 10-308315 JP 2001-155932 A JP 2010-219473 A

  However, the conventional coil component including the coil portion using the rectangular wire described above has the following problems.

  First, when manufacturing the coil part, prepare a material roll in which a flat wire material coated with insulating paint (polyimide resin, etc.) is wound on the surface, and bend the flat wire material drawn out from this material roll. Then, when the coil main body is manufactured, the coil main body is manufactured. Then, the coil main body is cut from the material roll, and then both ends of the rectangular wire led out from the coil main body are formed as the coil terminal. At this time, the insulating paint is removed from the portion where the coil terminal portion is formed, and if necessary, a bent portion or a circular hole is formed, and if the circular hole is large, the coil terminal portion is crushed. Increase the area. As described above, in the conventional coil component, the process of forming the coil terminal portion is indispensable after the coil main body portion is manufactured, which increases the number of manufacturing steps and further increases the manufacturing cost.

  Secondly, since the coil terminal portion is formed by directly using a flat wire, the shape and the like that can be manufactured are limited. That is, when the coil terminal portion is formed in a complicated shape or a larger shape, there are not a few cases where it cannot be handled depending on the rectangular wire. In this case, it is necessary to connect (couple) a separately manufactured coil terminal part to the tip of the flat wire, which causes the complication and size increase of the coil parts due to an increase in the number of parts, and further manufacturing. Increases man-hours and costs.

  Third, since the coil portion is wound with a flat wire in close contact, it is not easy to ensure heat dissipation. In particular, this type of coil component is often used by passing a large current, and the amount of heat generation increases, so it is important to improve the overall heat dissipation, but a rectangular wire coated with insulating paint is important. The conventional coil component having the coil portion having the laminated structure cannot be said to have good heat dissipation.

  An object of the present invention is to provide a coil component and a method for manufacturing the same that solve the problems existing in the background art.

  In order to solve the above-described problem, the coil component 1 according to the present invention includes a coil main body portion using a flat wire Wf and a coil portion having integral coil terminal portions at both ends of the flat wire Wf derived from the coil main body portion. A coil base obtained by integrally punching portions corresponding to the coil main body portion 3 and the coil terminal portions 4p and 4q from a plate base material Pr formed of a conductive material E and having a predetermined thickness when the coil component is provided. One or two formed by an insulating material D that electrically insulates between each of the turn parts 3t by inserting the coil part 2 manufactured by bending the material Pc and each turn part 3t in the coil main body 3. The above-mentioned insulating pieces 5pa, 5pb, 5qa, 5qb ... are provided with separator members 5p, 5q provided with predetermined intervals.

  On the other hand, the method of manufacturing a coil component according to the present invention includes a coil main body portion using a flat wire Wf and a coil portion having a coil portion having integral coil terminal portions at both ends of the flat wire Wf derived from the coil main body portion. When manufacturing a part, a portion corresponding to the coil main body 3 and the coil terminal portions 4p and 4q is integrally punched from the plate base Pr having a predetermined thickness formed of the conductive material E to produce the coil base Pc. A coil base material manufacturing step (S2), a coil main body portion manufacturing step (S4) for manufacturing the coil main body portion 3 by bending the coil base material Pc, and one or two formed on the coil portion 2 by the insulating material D. Separator members 5p, 5q in which the insulating pieces 5pa, 5pb,..., 5qa, 5qb, etc. are provided at predetermined intervals are assembled, and the insulating pieces 5pa, 5pb,. Are inserted between the turn portions 3t in the coil main body 3, and the separator member assembling step (S5, S6) for electrically insulating the turn portions 3t is provided. .

  Further, according to a preferred aspect of the present invention, the core 11 formed of the magnetic material M to be assembled to the coil portion 2 via the coil bobbin 12 formed of the insulating material D can be provided. In this case, the core 11 can be configured by a combination of a pair of core halves 11u and 11d formed in an E shape (or a combination of an E-shaped first core divided portion and an I-shaped second core divided portion). On the other hand, the separator members 5p can be integrally formed by a support base 5pm, and insulating pieces 5pa, 5pb, which are projected from the support base 5pm at a predetermined interval in a perpendicular direction. Note that two separator members 5p and 5q can be used that are assembled to the coil portion 2 from a position facing substantially 180 [°] in the radial direction. Further, the position of the separator members 5p and 5q can be regulated by bringing the separator members 5p and 5q into contact with the core 11. Therefore, when manufacturing, after the separator member assembling step (S5, S6), the core 11 is assembled to the coil portion 2 via the coil bobbin 12, and the separator members 5p, 5q and the core 11 are brought into contact with each other. Thus, a core assembling step (S7, S8) for restricting the position of the separator members 5p, 5q can be provided. In addition, when manufacturing, if necessary, an additional processing step (S3) for performing additional processing on the coil terminal portions 4p and 4q is provided after the coil base material manufacturing step (S2) or the coil body portion manufacturing step (S4). be able to.

  According to the coil component 1 and the manufacturing method thereof according to the present invention as described above, the following remarkable effects can be obtained.

  (1) Since the coil base material Pc formed by integrally punching the portions corresponding to the coil main body portion 3 and the coil terminal portions 4p and 4q from the plate base material Pr having a predetermined thickness formed of the conductive material E is used. The process of forming the coil terminal portions 4p and 4q after the main body portion 3 is manufactured becomes unnecessary, and the number of manufacturing steps can be reduced, and further the manufacturing cost can be reduced. In addition, since such a plate base material Pr is used, it is optimal for the manufacture of the coil component 1 having a small number of turns.

  (2) Even if the coil terminal portions 4p and 4q have a complicated shape or a large shape, the coil terminal portions 4p and 4q can be integrally formed at both ends of the flat wire Wf, so that separate coil terminal portions to be connected (coupled) are not necessary. Therefore, complication of the coil terminal portions 4p and 4q can be avoided, the size of the entire coil component 1 can be reduced, and the manufacturing steps can be further reduced and the cost can be reduced.

  (3) One or two or more insulating piece portions 5pa, 5pb,... Formed by an insulating material D that electrically insulates the respective turn portions 3t by inserting between the turn portions 3t in the coil main body 3. Since the separator members 5p, 5q are provided with predetermined intervals, 5qa, 5qb,... Are not required to be applied to the surface of the coil body 3, and the insulating pieces 5pa inserted between the turn portions 3t. , 5 pb... Therefore, even if it is the coil component 1 which flows and uses a large current, the whole heat dissipation can be improved more.

  (4) According to a preferred embodiment, if the separator member 5p is integrally formed by the support base 5pm, and the insulating pieces 5pa, 5pb ... projected from the support base 5pm at predetermined intervals in the direction perpendicular to the support base 5pm Can be manufactured at low cost by using an insulating material D such as a plastic material, and the ease of assembly and the stability of assembly can be improved, and the peripheral surface of the coil body 3 can be formed by the support base 5pm. And other parts (core etc.) can be insulated.

  (5) If two separator members 5p and 5q are provided to the coil portion 2 from a position facing substantially 180 [°] in the radial direction, a gap between the turn portions 3t. Uniformity and stability can be ensured, and each separator member 5p can be reduced in size. Moreover, since the heat radiation space can be made wider, it is possible to contribute to further improvement in heat radiation.

  (6) If the separator members 5p, 5q and the core 11 are brought into contact with each other and the position of the separator members 5p, 5q is regulated according to a preferred embodiment, the separator members 5p, 5q are used with separate fixing means. Since it can also be fixed to the coil part 2, it can contribute to further reduction in the number of parts and manufacturing man-hours.

  (7) According to a preferred embodiment, an additional processing step (S3) for performing additional processing on the coil terminal portions 4p and 4q after the coil base material manufacturing step (S2) or the coil main body portion manufacturing step (S4) is provided at the time of manufacture. Then, it is possible to perform additional processing on the coil terminal portions 4p and 4q as necessary. That is, since the substantial formation of the coil terminal portions 4p and 4q is performed in the coil base material manufacturing step (S2), for example, a step that is insufficient in the coil base material manufacturing step (S2) such as forming a stepped portion is performed. It can be supplemented by an additional processing step (S3).

Manufacturing process drawing for demonstrating the manufacturing method of the coil components which concern on suitable embodiment of this invention, Exploded view of the coil parts, The perspective view of the coil part used for the coil component, A plan view of a separator member used for the coil component, Explanatory drawing of the manufacturing method of the coil component, Cross-sectional front view of the coil component,

  Next, preferred embodiments according to the present invention will be given and described in detail with reference to the drawings.

  First, main components constituting the coil component 1 according to the present embodiment will be described with reference to FIGS.

  2 is a coil part. As shown in FIGS. 2 and 3, the coil unit 2 includes a coil main body 3 using a flat wire Wf, and integrated coil terminal portions 4 p and 4 q at both ends of the flat wire Wf derived from the coil main body 3. . The number of turns of the exemplified coil body 3 is 3.5, and one turn is indicated by the turn 3t. One coil terminal portion 4p is formed wider than the flat wire Wf, has a circular hole 4ph for connection, and has a step portion 4ps bent in a crank shape from the tip (one end) of the flat wire Wf. . The other coil terminal portion 4q is also formed wider than the flat wire Wf, has a circular hole 4qh for connection, and has an extended portion 4qv that extends in a direction perpendicular to the tip (other end) of the flat wire Wf. Have.

  5p and 5q are separator members. As shown in FIGS. 2 and 4, one separator member 5p has a support base portion 5pm and three insulating pieces 5pa, 5pb, 5pc protruding from the support base portion 5pm at a predetermined interval in a perpendicular direction. It integrally molds with the plastic material etc. which are the insulating materials D. The separator member 5p can electrically insulate the turn parts 3t by inserting the insulation pieces 5pa ... between the turn parts 3t in the coil body 3. As shown in FIG. 4, each insulating piece portion 5pa has a shape along a flat wire Wf, and the length thereof is approximately ¼ of the entire circumference of the coil main body portion 3 in the example. About 1/3 was selected. Further, the support base 5pm is formed so as to be able to contact an inner surface of the core 11 described later. In the illustrated example, since the inner surface of the abutting core 11 is a flat surface, the abutting portion of the support base 5pm is also formed as a flat surface, and the position of the separator member 5p is regulated (fixed) by the inner surface of the core 11. To do.

  In this way, if the separator member 5p is integrally formed by the support base 5pm and the insulating pieces 5pa, 5pb.. It can be manufactured at low cost by using the insulating material D, etc., and the ease of assembly and the stability of assembly can be improved, and the peripheral surface of the coil main body 3 and other parts, concretely, by the support base 5 pm. Has an advantage that insulation against the inner surface of the core 11 can be achieved. The other separator member 5q is formed in the same manner as the one separator member 5p. Therefore, in this case, the two separator members 5p and 5p are prepared, and one is used as the separator member 5p and the other is used as the separator member 5q. In the other separator member 5q, 5qa, 5qb.

  Reference numeral 12 denotes a coil bobbin. The coil bobbin 12 is configured by a combination of a first bobbin dividing unit 12m and a second bobbin dividing unit 12s. The first bobbin divided portion 12m and the second bobbin divided portion 12s are integrally formed of a plastic material or the like that is an insulating material D, respectively. In this case, the first bobbin dividing portion 12m covers the one end face side of the coil main body 3 by integrally forming the bobbin cylindrical portion 12mc to be inserted into the internal space of the coil main body 3 and one end of the bobbin cylindrical portion 12mc. It has a ring-shaped bobbin barrier portion 12mb. The second bobbin dividing portion 12 s is formed as a ring-shaped bobbin barrier portion that covers the other end face side of the coil main body portion 3.

  11 is a core. The core 11 is configured by combining a pair of core halves 11u and 11d. The core halves 11u and 11d are integrally formed with the magnetic material M, respectively. One core half portion 11u is formed in an E shape as a whole, and has an inner core portion 11ui protruding in a cylindrical shape to be inserted into the inner space of the bobbin cylinder portion 12mc (coil body portion 3), and a coil body portion. 3 has a U-shaped outer core portion 11 uo positioned outside the 3. The other core half 11d is formed in the same manner as the one core half 11u. Therefore, in this case, two core halves 11u and 11u are prepared, and one is used as the core half 11u and the other is used as the core half 11d. In the other core half portion 11d, 11di indicates an inner core portion, and 11do indicates an outer core portion 11uo.

  Next, a method for manufacturing a coil component according to the present embodiment will be described according to the manufacturing process diagram shown in FIG. 1 with reference to FIGS.

  The pair of core halves 11u and 11d constituting the core 11 are prepared and prepared in advance by a separate firing process or the like, and the first bobbin dividing portion 12m and the second bobbin dividing portion 12s constituting the coil bobbin 12 are , And prepared in advance by a separate molding process or the like.

  Hereinafter, the manufacturing procedure of the coil component 1 will be described. First, a plate base material Pr is prepared (step S1). FIG. 5A shows a rectangular plate base material Pr as an imaginary line as an example. The plate base material Pr is formed with the same thickness as the above-described rectangular wire Wf, for example, with a conductive material E such as a copper material. First, a coil base material manufacturing process is performed in which the portions corresponding to the coil main body portion 3 and the coil terminal portions 4p and 4q are integrally punched from the plate base material Pr (step S2). In this case, the plate base material Pr is set in a press machine or the like, and a plurality of coil base materials Pc... Shown in FIG. The coil base material Pc has a straight rectangular wire Wf, and has coil terminal portions 4p and 4q at both ends of the rectangular wire Wf. In the example, one coil terminal portion 4p is formed wider than the flat wire Wf, has a connecting circular hole 4ph, and the other coil terminal portion 4p is formed wider than the flat wire Wf. It has a circular hole 4qh for connection, and has an extended portion 4qv extending in the direction perpendicular to the tip (other end) of the flat wire Wf, and the coil terminal portions 4p and 4q are formed at this time.

  Next, an additional process is performed on the coil base material Pc obtained in the coil base material manufacturing process (step S3). As shown in FIG. 3, the illustrated coil part 2 has a step part 4 ps. Therefore, the coil base material Pc is set in a press or the like, and the step part 4 ps is formed with respect to the coil terminal part 4 p. FIG. 5B shows a coil substrate Pc having a stepped portion 4 ps. The example shows the case where the stepped portion 4ps is formed only for one coil terminal portion 4p, but the other coil terminal portion 4q can be similarly provided. Thus, if the additional process process which performs the additional process with respect to coil terminal part 4p, 4q is provided after a coil base-material manufacturing process, the additional process with respect to coil terminal part 4p, 4q can be performed as needed. That is, since the substantial formation of the coil terminal portions 4p and 4q is performed in the coil base material manufacturing process, as shown in the example, a process that is insufficient in the coil base material manufacturing process, such as forming a stepped portion 4ps, is additionally processed. It can be complemented by the process.

  Thereafter, the process proceeds to a coil body part manufacturing process, and the coil body part 3 is manufactured by a bending process (curving formation) on the coil base material Pc (step S4). In this case, since the space between the coil terminal portions 4p and 4q in the coil substrate Pc is formed as a flat wire Wf, the portion of the flat wire Wf is bent through a bending roller or the like, and the coil main body 3 shown in FIG. To manufacture. The coil part 2 shown in FIG. 3 can be obtained through the above steps.

  Next, the separator member 5p... Is assembled to the coil portion 2, and the separator member assembling step is performed in which the insulating piece portions 5pa, 5pb... Are inserted between the turn portions 3t in the coil main body portion 3 (steps S5 and S6). . In this case, as shown in FIG. 2, two separator members 5p, 5q are prepared, and the insulating piece portions 5pa, 5pb, 5pc of one separator member 5p are arranged around the coil body portion 3 as shown in FIG. It inserts between each turn part 3t ... from the surface side, and electrically insulates between each turn part 3t .... This state is shown in FIG. The other separator member 5q is also assembled in the same manner from a position facing substantially 180 [°] in the radial direction of the coil main body 3. As described above, if two separator members 5p and 5q are provided to the coil portion 2 from a position facing substantially 180 ° in the radial direction, the uniformity and stability of the gap between the turn portions 3t. Can be ensured, and can contribute to miniaturization of each separator member 5p. Moreover, since the heat radiation space can be made wider, there is an advantage that it can contribute to further improvement of heat dissipation.

  Thereafter, as shown in FIG. 2, a core assembling step for assembling the core 11 through the coil bobbin 12 is performed (steps S7 and S8). In this case, the coil bobbin 12 is constituted by the first bobbin dividing portion 12m and the second bobbin dividing portion 12s, and the core 11 is constituted by the pair of core half portions 11u and 11d, so that the assembling order thereof is not limited. It can be assembled in an arbitrary order in consideration of assembly. For example, when arranged as shown in FIG. 2, after the second bobbin split part 12s is mounted on the inner core part 11di of one core half part 11d, the coil part 2 assembled with the separator members 5p and 5q is used as the inner core part. 11di can be installed. Next, after the first bobbin dividing portion 12m is attached to the inner core portion 11di, the other core half portion 11u can be attached to the first bobbin dividing portion 12m.

  Thereby, it can be set to the assembly | attachment state of FIG. In this case, since the separator member 5p has a support base portion 5pm formed on the flat surface at a portion that contacts the inner surface of the core 11, when the core 11 is assembled, the support base portion 5pm of the separator member 5p. Are in contact with the inner surface of the core 11 and the separator members 5p and 5q are regulated (fixed), and the peripheral surface of the coil body 3 and the inner surface of the core 11 are insulated. In this way, if the separator member 5p and the core 11 are brought into contact with each other and the position of the separator member 5p is regulated, the separator member 5p is attached to the coil portion 2 without using a separate fixing means. Therefore, there is an advantage that it can contribute to further reduction in the number of parts and manufacturing man-hours. Further, when the coil bobbin 12 and the core 11 are assembled, the outer surface of the core 11 is taped and fixed in the assembled state (step S9). Then, while performing necessary finishing processing such as removing dirt and performing necessary inspections (performance inspection, appearance inspection, etc.), the target coil component 1 shown in FIG. 6 can be obtained (steps S10 and S11). ).

  Therefore, according to the coil component 1 and the manufacturing method thereof according to the present embodiment, the coil main body 3 and the coil terminal portions 4p and 4q are formed from the plate base Pr having a predetermined thickness formed of the conductive material E. Since the coil base material Pc in which the part corresponding to 1 is integrally punched is used, the process of forming the coil terminal parts 4p and 4q after the coil body part 3 is manufactured becomes unnecessary, reducing the manufacturing man-hours and further reducing the manufacturing cost. Can be achieved. In addition, since such a plate base material Pr is used, it is optimal for the manufacture of the coil component 1 having a small number of turns. Moreover, even if the coil terminal portions 4p and 4q have a complicated shape or a large shape, the coil terminal portions 4p and 4q can be integrally formed at both ends of the flat wire Wf. Therefore, complication of the coil terminal portions 4p and 4q can be avoided, the size of the entire coil component 1 can be reduced, and the manufacturing steps can be further reduced and the cost can be reduced. Further, one or two or more insulating pieces 5pa, 5pb,..., 5qa formed by an insulating material D that electrically insulates between the respective turns 3t. , 5qb... Are provided at predetermined intervals, so that an insulating coating applied to the surface of the coil body 3 is not necessary, and the insulating pieces 5pa inserted between the turn portions 3t. A heat radiation space can be provided by 5 pb. Therefore, even if it is the coil component 1 which flows and uses a large current, the whole heat dissipation can be improved more.

  Although the preferred embodiment has been described in detail above, the present invention is not limited to such an embodiment, and the detailed configuration, shape, material, quantity, technique, and the like do not depart from the gist of the present invention. It can be changed, added, or deleted arbitrarily.

  For example, the case where the core 11 is configured by a combination of a pair of core halves 11u and 11d formed in an E shape has been shown, but a set of an E-shaped first core divided portion and an I-shaped second core divided portion. You may comprise by combining. Moreover, although the case where the additional process process was performed after the coil base-material manufacturing process was shown, while it may be performed after a coil main-body part manufacturing process, this additional process process can be provided as needed. Therefore, for example, when the stepped portion 4 ps or the like like the illustrated coil portion 2 is not formed, it is not always necessary to provide it. Furthermore, although the case where the core 11 and the coil bobbin 12 were assembled | attached was shown, it comprises as an inductor which does not provide the core 11 and the coil bobbin 12, ie, a simple inductor which only assembled | attached the separator members 5p and 5q to the coil part 2. May be. In this case, a separate fixing means such as a taping means for fixing the separator members 5p and 5q to the coil portion 2 is required.

  The coil component and the manufacturing method thereof according to the present invention can be used for various coil components such as an inductor and a transformer having a coil terminal portion integrated with a coil body portion using a rectangular wire.

  DESCRIPTION OF SYMBOLS 1: Coil components, 2: Coil part, 3: Coil main-body part, 3t ...: Turn part, 4p: Coil terminal part, 4q: Coil terminal part, 5p, 5q: Separator member, 5pa, 5pb ...: Insulation piece part, 5qa, 5qb ...: insulation piece, 5pm ...: support base, 11: core, 11u, 11d: core half, 12: coil bobbin, Wf: rectangular wire, E: conductive material, D: insulation material, M: magnetism Material, Pr: Plate base material, Pc: Coil base material, (S2): Coil base material manufacturing process, (S3): Additional processing process, (S4): Coil body part manufacturing process, (S5, S6): Separator member Assembly process, (S7, S8): Core assembly process

Claims (9)

  In a coil component comprising a coil body portion using a rectangular wire and a coil portion having integral coil terminal portions at both ends of the rectangular wire derived from the coil body portion, a predetermined thickness formed by a conductive material is used. A coil portion manufactured by bending a coil base material obtained by integrally punching a portion corresponding to the coil main body portion and the coil terminal portion from a plate base material, and inserting between each turn portion in the coil main body portion A coil component comprising: a separator member provided with one or two or more insulating pieces formed at an interval from each other by an insulating material that performs electrical insulation between the turn portions.   The coil component according to claim 1, further comprising: a core formed of a magnetic material that is assembled to the coil portion via a coil bobbin formed of an insulating material.   The core is constituted by a combination of a pair of half-cores formed in an E shape, or a combination of an E-shaped first core divided portion and an I-shaped second core divided portion. The coil component described.   4. The coil component according to claim 1, wherein the separator member is integrally formed by a support base and the insulating pieces protruded from the support base at a predetermined interval in a direction perpendicular to the support base.   5. The coil component according to claim 4, comprising two separator members assembled from a position opposed to the coil portion at approximately 180 degrees in the radial direction.   The coil component according to claim 4 or 5, wherein the separator member and the core are brought into contact with each other to restrict the position of the separator member.   A coil body manufacturing method comprising a coil body portion using a rectangular wire and a coil portion having integral coil terminal portions at both ends of the rectangular wire led out from the coil body portion, which is formed of a conductive material. A coil base material manufacturing process for manufacturing a coil base material by integrally punching portions corresponding to the coil main body portion and the coil terminal portion from a plate base material having a predetermined thickness, and a coil by bending the coil base material A coil body part manufacturing process for manufacturing a body part, and a separator member provided with one or two or more insulating piece parts formed of an insulating material at predetermined intervals are assembled to the coil part, and the insulating piece part is attached to the coil A separator member assembling step that is inserted between the turn portions of the main body portion and electrically insulates between the turn portions. Method.   8. The method of manufacturing a coil component according to claim 7, further comprising an additional processing step of performing additional processing on the coil terminal portion after the coil base material manufacturing step or the coil body portion manufacturing step.   After the separator member assembling step, a core formed of a magnetic material is assembled to the coil portion via a coil bobbin formed of an insulating material, and the separator member and the core are brought into contact with each other to restrict the position of the separator member. 9. The method of manufacturing a coil component according to claim 7, further comprising a core assembling step.

Images