Patent Publication Number: US-2023140077-A1

Title: Method for manufacturing coil component

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of priority to Korean Patent Application No. 10-2021-0146407 filed on Oct. 29, 2021 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety. 
     TECHNICAL FIELD 
     The present disclosure relates to a method for manufacturing a coil component. 
     BACKGROUND 
     There has been continuous demand for a wire-wound power inductor including a wound coil, which may implement higher efficiency characteristics in low-current and high-current environments. Accordingly, there is a trend to develop a power inductor implementing higher efficiency in low-current and high-current environments by having reduced direct current resistance (Rdc) and increased inductance (Ls). It is expected that continuous demand for improved efficiency characteristics of power conductors will be made in the future. Accordingly, there is a growing need to develop a method of implementing the power inductor achieving improved efficiency in the low-current and high-current environments by having reduced Rdc and increased Ls. 
     SUMMARY 
     An aspect of the present disclosure may provide a method for manufacturing a coil component, which may be used for manufacturing a coil component with easy mass production and excellent price competitiveness. 
     Another aspect of the present disclosure may provide a method for manufacturing a coil component, which may reduce a size of a coil component. 
     Another aspect of the present disclosure may provide a method for manufacturing a coil component, which may secure a cut margin of a coil component. 
     Another aspect of the present disclosure may provide a method for manufacturing a coil component, which may prevent a defective coil exposure of the coil component. 
     Another aspect of the present disclosure may provide a method for manufacturing a coil component, which may increase a volume of a magnetic material of a coil component. 
     According to an aspect of the present disclosure, a method for manufacturing a coil component may include: preparing a wound coil, a first jig and a second jig; disposing the wound coil on the first jig; and pressing the wound coil, wherein the pressing the wound coil includes bringing the first jig and the second jig into contact with each other by a first rotation of the first jig. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The above and other aspects, features and advantages of the present disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which: 
         FIG.  1    is a cross-sectional view illustrating that wound coils are arranged on a tray; 
         FIG.  2    is a cross-sectional view of a wound coil before being processed in processes of manufacturing a coil component according to an exemplary embodiment; 
         FIG.  3    is a perspective view of a portion of a coil alignment device used in the processes of manufacturing a coil component according to an exemplary embodiment; 
         FIGS.  4  through  6    are process views sequentially illustrating some of the processes of manufacturing a coil component according to an exemplary embodiment; 
         FIG.  7    is a cross-sectional view illustrating a wound coil manufactured by the processes of manufacturing a coil component according to an exemplary embodiment; 
         FIGS.  8  through  10    are process views sequentially illustrating the remainder of the processes of manufacturing a coil component according to an exemplary embodiment; 
         FIG.  11    is a top plan view of a portion of a coil alignment device used in processes of manufacturing a coil component according to another exemplary embodiment; 
         FIG.  12    is a cross-sectional view illustrating a wound coil manufactured by processes of manufacturing a coil component according to yet another exemplary embodiment; and 
         FIG.  13    is a flowchart illustrating a method for manufacturing a coil component according to an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Hereinafter, exemplary embodiments in the present disclosure will now be described in detail with reference to the accompanying drawings. 
     Meanwhile, in the present disclosure, an X-direction refers to an L direction or a length direction, a Y-direction refers to a W direction or a width direction, and a Z-direction refers to a T direction or a thickness direction. 
     Method for Manufacturing Coil Component 
     Hereinafter, the description describes a method for manufacturing a coil component according to an exemplary embodiment of the present disclosure, and in particular, exemplarily describes a method for manufacturing a wound-type coil component, and the present disclosure is not necessarily limited thereto. 
     Input Process 
       FIG.  1    is a cross-sectional view illustrating that wound coils are arranged on a tray. 
       FIG.  2    is a cross-sectional view of a wound coil before being processed in processes of manufacturing a coil component according to an exemplary embodiment. 
     A method for manufacturing a coil component according to an exemplary embodiment may include: preparing a wound coil  10 , a first jig  100 A and a second jig  200 ; disposing the wound coil  10  on the first jig  100 A; and pressing the wound coil  10 , wherein the pressing the wound coil  10  includes bringing the first jig  100 A and the second jig  200  into contact with each other by a first rotation of the first jig  100 A. 
     In the preparing the wound coil  10 , the wound coil  10  maybe formed by a winding method, and may include a wound portion  11  and a lead-out portion  12 . The wound coil  10  may include, for example, a metal wire such as copper (Cu) or silver (Ag), and is not necessarily limited thereto. 
     The wound coil  10  may not be limited to a single wire, and may include a stranded wire or two or more wires. In addition, the wound coil  10  may not be limited to having a circular cross-sectional shape, and may have any of various known cross-sectional shapes such as a square. 
     In addition, the wound coil  10  maybe wound while having a plurality of layers, and may form at least one or more turns in each layer. 
     The wound coil  10  may include the wound portion  11  and a pair of lead-out portions  12  each led out from ends of the coil of the wound portion  11 . In this case, the pair of lead-out portions  12  may be led out in opposite directions. 
       FIG.  1    is a cross-sectional view illustrating that the plurality of wound coils  10  are arranged on a tray  310 . That is, the wound coils  10  may be prepared, and then be arranged in a plurality of recesses  311  formed in the tray  310 , while having a plurality of rows and columns. An alignment mark  312  may be formed in the tray  310  to easily identify each of the plurality of recesses  311  and the wound coil  10  disposed in the recess  311 . 
     Referring to  FIG.  2   , the wound coil  10  before deformation may have an outer diameter of WA 1  and an inner diameter of WB 1  in the width (W) direction. Here, the outer diameter may refer to a longest distance between two points of the wound coil  10  are connected to each other in the W direction defined as the width (W) direction. 
     In addition, the inner diameter may refer to a distance having a longest distance between two points of the innermost layer of the wound coil  10  are connected to each other in the width (W) direction. 
       FIG.  3    is a perspective view of a portion of a coil alignment device used in the processes of manufacturing a coil component according to an exemplary embodiment. 
     In the method for manufacturing a coil component according to an exemplary embodiment, the first and second jigs  100 A and  200  may be prepared together with the wound coil  10 . The coil alignment device in the present disclosure may include the first and second jigs  100 A and  200 . 
       FIG.  3    shows a configuration of the first jig  100 A of the coil alignment device. The first jig  100 A may include an operation portion  110 , a support portion  120  disposed on the operation portion  110 . First and second pressing portions  131  and  132  respectively connected to two opposite sides of the support portion  120  and opposing each other in the W direction. First and second contact portions  141  and  142  each attaches to the outer surface of each of the first and second pressing portions  131  and  132 , which is opposite to the side that are connected to the support portion. First and second springs  151  and  152  respectively are disposed in grooves  131   h  and  132   h  formed in the first and second pressing portions  131  and  132 , and the first and second springs  151  and  152  respectively connect the first and second pressing portions  131  and  132  and the first and second contact portions  141  and  142 . 
     The following description describes each component in detail based on a sequence of the method for manufacturing a coil component using the wound coil  10  according to an exemplary embodiment of the present disclosure. 
     In the method for manufacturing a coil component according to an exemplary embodiment, the wound coil  10  may be disposed on the first jig  100 A. In detail, the wound coil  10  disposed on the tray  310  (not illustrated) may be disposed on the support portion  120  of the first jig  100 A by using a first robot arm (not illustrated). 
     Meanwhile, the support portion  120  may have a core pin  121  and a suction portion  122 . The core pin  121  may have a shape such as a circular shape, an elliptical shape, or a rectangular shape to correspond to a core portion of the wound coil  10 .  FIG.  3    shows an elliptical core pin  121 . 
     The suction portion  122  of the support portion  120  may be formed in one surface of the support portion  120  and formed in a region where the wound coil  10  is to be disposed along a circumference of the core pin  121 . In the disposing the wound coil  10  on one surface of the support portion  120  of the first jig  100 A, the suction portion  122  may be formed in the support portion  120  to prevent the wound coil  10  from being misaligned or falling off by impact. The suction portion  122  may be connected to an exhaust portion  160  of the first jig  100 A to suck air away from the suction portion  122  toward the outside, thereby generating a vacuum state. Accordingly, the wound coil  10  disposed on one surface of the support portion  120  may be stably fixed during the pressing process. 
     Alignment Process 
       FIGS.  4  through  6    are process views sequentially illustrating some of the processes of manufacturing a coil component according to an exemplary embodiment. 
     Referring to  FIG.  4   , as described above, the wound coil  10  may be disposed on one surface of the support portion  120  of the first jig  100 A, and may be fixed to the core pin  121  and the suction portion  122 . 
     Meanwhile, the second jig  200  may be disposed on each of two sides of the first jig  100 A. The second jig  200  may include a pair of a second-1 st  jig  210  and a second-2 nd  jig  220 . The second-1 st  jig  210  may include a holder  211 , a rotation portion  212 , a fix portion  213 , a bearing  214 , a support portion  215  and a spring  216 . In addition, the second-2 nd  jig  220  may include a holder  221 , a rotation portion  222 , a fix portion  223 , a bearing  224 , a support portion  225  and a spring  226 . 
     Hereinafter, the description collectively describes each component of the second jig  200  including the second-1 st  and the second-2 nd  jigs  210  and  220 . 
     The holder  211  or  221  may support the second jig  200 , and the rotation portion  212  or  222  may be fixed to the holder  211  or  221  by using the fix portion  213  or  223 . The rotation portion  212  or  222  may be rotated by a predetermined distance, based on the fix portion  213  or  223 , and when the rotation portion  212  or  222  is rotated, pressure may be applied to the spring  216  or  226 , and rotation of the rotation portion  212  or  222  may be suppressed by the support portion  215  or  225 . The bearing  214  or  224  may be disposed at one end of the rotation portion  212  or  222 . The bearing  214  or  224  may be one machine element reducing friction between moving portions, and may be a mechanical device supporting the rotational or reciprocating axis at a fixed position to freely move the moving portion. The bearing  214  or  224  in the present disclosure may correspond to a region where the first or second contact portion  141  or  142  is in contact with the second jig  200  in processes described below, and may reduce friction during their contacts, thereby preventing damage to a surface of the first or second contact portion  141  or  142 . The bearing  214  or  224  may be one of a ball bearing, a roller bearing, a plain bearing, a fluid bearing, a magnetic bearing, a sleeve bearing and a covering bearing, and is not limited thereto. 
       FIG.  5    shows the pressing the wound coil  10 . When the wound coil  10  is disposed on the support portion  120  of the first jig  100 A, the first jig  100 A may be rotated in a first direction by command and operation of the operation portion  110  including a power motor, and this rotation maybe referred to as the first rotation. Here, the first jig  100 A may be rotated in position, based on a central axis of the first jig  100 A when viewed from above, and may be rotated in the first direction, a rotation direction of the first rotation. In an exemplary embodiment, the first direction may be a clockwise direction. 
     As illustrated in  FIG.  5   , the first jig  100 A may be rotated in the first direction, and the first or second contact portion  141  or  142  of the first jig  100 A may thus be in contact with the bearing  214  or  224  of the second jig  210  or  220 . 
     The first or second contact portion  141  or  142  may be formed on the other surface of the first or second pressing portion  131  or  132 , and have a triangular prism shape having a triangular cross section when viewed from above. The first or second contact portion  141  or  142  having the triangular prism shape may have a horizontal cross section formed in a triangular shape, and here, the triangular shape, a shape of the horizontal cross section of each of the first and second contact portions  141  and  142 , may be the triangular shape symmetrical in the W direction. The first and second contact portions  141  and  142  may respectively be connected to the first and second pressing portions  131  and  132 , and may respectively be attached to or integrally formed with the other surface of each of the first and second pressing portions  131  and  132 . 
     The first and second pressing portions  131  and  132  may be disposed on the support portion  120  of the first jig  100 A so that one surface of the first pressing portion  131  and one surface of the second pressing portion  132  oppose each other in the W direction, and may be designed to be moved in the W direction. Meanwhile, the movement of the first or second pressing portion  131  or  132  may be controlled by the first or second spring  151  or  152  disposed in the first or second groove  131   h  or  132   h  such that the first and second pressing portions  131  and  132  may be kept as far as possible from each other by elasticity of the first and second springs  151  and  152  before the first rotation of the first jig  100 A. 
     When the first or second contact portion  141  or  142  comes into contact with the bearing  214  or  224  by the rotation of the first jig  100 A, pressure may be applied to the first or second contact portion  141  or  142 . Accordingly, the first or second pressing portion  131  or  132  connected to the first or second contact portion  141  or  142  may be moved toward the core pin  121  of the support portion  120 . When the first rotation is continued, the first and second pressing portions  131  and  132  may be moved to bring the inner surface of each of the first and second pressing portions  131  and  132  into contact with the wound portion  11  of the wound coil  10  fixed to the core pin  121 , and as a result, pressure may be applied from the outside of the wound portion  11  of the wound coil  10 . Here, the width (W) direction, the direction in which one surface of the first pressing portion  131  and one surface of the second pressing portion  132  oppose each other, may be the width (W) direction of the wound coil  10 . 
     Here, the first or second contact portion  141  or  142  and the first or second pressing portion  131  or  132  may be connected to each other, and the first or second spring  151  or  152  disposed in the first or second groove  131   h  or  132   h  may use the elasticity to apply force in an opposite direction to the direction in which the first or second contact portion  141  or  142  is moved toward the wound coil  10  or the core pin  121 . Therefore, when the first jig  100 A is rotated to a maximum angle by the first rotation, the first or second pressing portion  131  or  132  may maintain a shortest distance with the core pin  121 , while being in contact with the wound coil  10 , and the first or second spring  151  or  152  may here be in a maximum retraction. 
     As a result, pressure applied to the first or second contact portion  141  or  142  by the first rotation of the first jig  100 A may be transmitted to the first or second pressing portion  131  or  132 , the first or second pressing portion  131  or  132  may thus be moved toward the wound coil  10 . Accordingly, the wound coil  10  may receive pressure again in the width (W) direction, and thus have a deformed shape. The deformed shape of the wound coil  10  by pressure applied in the width (W) direction is described below. 
     An enlarged view of  FIG.  5    shows that one surface of the first or second pressing portion  131  or  132  is in contact with the wound coil  10  by the first rotation of the first jig  100 A, and the wound coil  10  is pressed by the first or second pressing portion  131  or  132  and the core pin  121  to have the deformed shape. 
     Meanwhile, when the first or second contact portion  141  or  142  comes into contact with the bearing  214  or  224  by the rotation of the first jig  100 A, the bearing  214  or  224  may also be under pressure. The bearing  214  or  224  may be disposed at one end of the rotation portion  212  or  222  of the second-1-th jig  210  or the second-2-th jig  220 , and the rotation portion  212  or  222  may be rotated based on the fix portion  213  or  223 . 
     That is, when the bearing  214  receives pressure from the first contact portion  141  by the first rotation of the first jig  100 A, the rotation portion  212  of the second-1 st  jig  210  may receive counterclockwise pressure, and thus be rotated counterclockwise based on the fix portion  213 . Pressure may be applied to the support portion  215  by the rotation of the rotation portion  212 , and this pressure may be relieved by the spring  216  disposed between the rotation portion  212  and the support portion  215 . Here, the rotation of the rotation portion  212  may be limited only by the predetermined distance by the support portion  215 . 
     Similarly, when the bearing  224  receives pressure from the second contact portion  142  by the first rotation of the first jig  100 A, the rotation portion  222  of the second-2 nd  jig  220  may receive counterclockwise pressure, and thus be rotated counterclockwise based on the fix portion  223 . Pressure may be applied to the support portion  225  by the rotation of the rotation portion  222 , and this pressure may be relieved by the spring  226  disposed between the rotation portion  222  and the support portion  225 . Here, the rotation of the rotation portion  222  may be limited only by the predetermined distance by the support portion  225 . 
     As a result, the rotation portion  212  or  222  of the second-1 st  jig  210  or the second-2 nd  jig  220  may be rotated by the first rotation of the first jig  100 A, thereby causing the bearing  214  of the second-1 st  jig  210  and the bearing  224  of the second-2 nd  jig  220  to be temporarily moved away from each other. 
     Referring to  FIG.  6   , the wound coil  10  before deformation may be pressed to a desired strength and pressure, and the first jig  100 A may then perform a second rotation by the command and operation of the operation portion  110  of the first jig  100 A again. The second rotation may be performed in a second direction opposite to the first direction, based on a center of the support portion  120  as a rotation axis. In an exemplary embodiment, the second direction may be a counterclockwise direction. 
     Pressure between the first or second contact portion  141  or  142  and the bearing  214  or  224  may be reduced by the second rotation of the first jig  100 A illustrated in  FIG.  6   . 
     Accordingly, pressure applied to the first or second pressing portion  131  or  132  by the first or second contact portion  141  or  142  may also be reduced, thereby also reducing pressure applied to the wound coil  10  by the first or second pressing portion  131  or  132 . In this case, the elasticity of the first or second spring  151  or  152  which may return the spring retracted to the maximum to its original state before the retraction may be applied to the first or second contact portion  141  or  142  and the first or second pressing portion  131  or  132 . Accordingly, one surface of the first pressing portion  131  and one surface of the second pressing portion  132  may thus be moved away from each other again in the W direction. 
     The first and second pressing portions  131  and  132  may be moved away from each other by the second rotation of  FIG.  6   , thereby completing a shape of a deformed wound coil  20  described below with reference to  FIG.  7   . 
     In addition, the bearings  214  and  224 , temporarily moved away from each other by the first rotation, may also be close to each other again by the second rotation of the first jig  100 A illustrated in  FIG.  6    and return to the original states. When the first rotation is performed to the maximum angle, the rotation portion  212  or  222  may also be rotated to the maximum angle, and the spring  216  or  226  may also be in the maximum retraction. When the second rotation is performed as illustrated in  FIG.  6   , pressure applied to the spring  216  or  226  may be reduced, and the elasticity of the spring  216  or  226  applied to the rotation portion  212  or  222  may be greater than pressure applied to the rotation portion  212  or  212  from the first jig  100 A, thereby rotating the rotation portion  212  or  222  to its original state. Therefore, the bearings  214  and  224 , temporarily moved away from each other may be close to each other again in their original states. 
     The enlarged view of  FIG.  6    shows the direction in which one surface of the first pressing portion  131  and one surface of the second pressing portion  132  are moved away from the wound coil  20  again by the second rotation of the first jig  100 A. 
       FIG.  7    is a cross-sectional view illustrating a wound coil manufactured by the processes of manufacturing a coil component according to an exemplary embodiment. 
     The wound coil  20  of  FIG.  7    may be manufactured by the series of manufacturing processes of  FIGS.  4  through  6    described above. 
     The deformed wound coil  20  of  FIG.  7    may have the shape having the outer diameter of W A2  and the inner diameter of W B2 , deformed by pressure applied in the width (W) direction, to the wound coil  10  before the deformation illustrated in  FIG.  2   . That is, W A1 , the outer diameter of the wound coil  10  before the deformation illustrated in  FIG.  2    in the width (W) direction, may be reduced, and the outer diameter W A2  of the deformed wound coil  20  in the width (W) direction may thus be smaller than W A1 . 
     In addition, W B1 , the inner diameter of the wound coil  10  before the deformation illustrated in  FIG.  2    in the width (W) direction, may be reduced after deformation, and the inner diameter W B2  of the deformed wound coil  20  in the width (W) direction may thus be smaller than W B1 . 
     As such, the outer and inner diameters of the wound coil  10  may be effectively reduced, and the wound coil  20  may easily have a reduced overall size by using the manufacturing method of  FIGS.  4  through  6    according to an exemplary embodiment. 
     In a case of a conventional coil before the deformation, a width of an outermost turn of a wound coil  10  may be reduced by tensile stress of a wound portion  11  due to a radius of curvature of the wound coil  10 , and here, a spring back phenomenon may occur in which a width of an innermost turn of the wound coil  10  returns to its original state by compression stress. Due to this phenomenon, a shape of the finally-wound wound coil  10  may not have a size designed by a simulation, and wound in a larger shape than a target shape. 
     In the case of the wound coil  20  of  FIG.  7    pressed and deformed by using a method for manufacturing a coil component according to an exemplary embodiment of the present disclosure, it is possible to effectively suppress an increase in the size of the wound coil  20  in response to the above-described tensile stress/compression stress. In addition, the outer diameter of the wound coil  20  may have the reduced size in the width (W) direction. Accordingly, when the wound coil  20  has an inductor structure in the future, a margin of the body in the width (W) direction may be secured to increase capacity of a magnetic material in the body while preventing a defective exposure, thereby increasing its inductance. 
     Production process 
       FIGS.  8  through  10    are process views sequentially illustrating the remainder of the processes of manufacturing a coil component according to an exemplary embodiment. 
       FIG.  8    shows a process in which the deformed wound coil  20  of  FIG.  7    is disposed in a recess  321  of a frame  320  by a second robot arm (not illustrated). 
     The frame  320  may form a portion of an appearance of a wound coil assembly  10 - 1  in which the plurality of wound coils  20  are disposed. The frame  320  may include magnetic powder particles, and may be made of the magnetic powder particles and a thermosetting resin such as epoxy or polyimide interposed between the magnetic powder particles. 
     As a specific example, the magnetic powder particles may be ferrite or metal magnetic powder particles exhibiting a magnetic characteristic. In addition, the ferrite powder particles may include, at least one selected from the group consisting of Mn-Zn-based ferrite powder particles, Ni-Zn-based ferrite powder particles, Ni-Zn-Cu-based ferrite powder particles, Mn-Mg-based ferrite powder particles, Ba-based ferrite powder particles and Li-based ferrite powder particles, and the metal magnetic powder particles may include at least one selected from the group consisting of iron (Fe), silicon (Si), chromium (Cr), aluminum (Al), niobium (Nb), phosphorus (P), boron (B), carbon (C), cobalt (Co) and nickel (Ni). However, the present disclosure is not limited thereto. 
     Referring to  FIG.  8   , the frame  320  may have the plurality of recesses  321  open upward, and the deformed wound coil  20  may be disposed in each of the plurality of recesses  321 . In addition, an alignment mark  322  may be formed to easily identify each of the plurality of recesses  321  and the wound coil  20  disposed in the recess  321 . As described above, the wound coil  20  may be disposed on the frame  320  having the plurality of recesses  321  each open upwardly. Accordingly, compared to a conventional molding method in which a wound coil is disposed on a mold, a sealing material is then filled and then cured, it is possible to significantly reduce a cost of replacing a mold, and thus be advantageous in not only excellent price competitiveness but also easy mass production. 
     The plurality of recesses  321  maybe regularly arranged based on a plane of the frame  320 , in the W direction and the L direction inclined by 90 degrees from the W direction. In this case, a dicing key may be engraved on a boundary line between the plurality of recesses  321 . It may thus significantly improve positional accuracy of the coil, thus making the mass production easy. 
     The recess  321  may have a size large enough compared to the size of the wound coil  10  to accommodate the wound coil  20 . A region of the recess  321 , around the wound coil  20 , may be filled with a magnetic sheet  330  described below. 
     The recess  321  may not be particularly limited to a planar shape, and for example, may have a polygonal shape such as a square shape or may have a protrusion passing through a core of the wound coil  20 . However, the recess  321  is not limited thereto, and may be variously modified to have another shape. In addition, it is possible to also form a space accommodating at least a portion of a lead-out portion  22  of the wound coil  20  as well as the wound coil  20 . 
     The wound coil  20  may be disposed in each of the plurality of recesses  321 , and interposed between the frame  320  and the magnetic sheet  330  so that at least a portion thereof is embedded therein. 
     Referring to  FIG.  9   , the magnetic sheet  330  may be formed on an upper surface of the frame  320 . 
     The magnetic sheet  330  may form a portion of the appearance of the wound coil assembly  10 - 1  together with the frame  320 . 
     Like the frame  320 , the magnetic sheet  330  may include the magnetic powder particles, and may be made of the magnetic powder particles and the thermosetting resin such as epoxy or polyimide interposed between the magnetic powder particles. 
     Referring to  FIG.  9   , the magnetic sheet  330  obtained by molding a magnetic powder-resin composite into a sheet shape may be pressed and cured on the frame  320 . The magnetic sheet  330  may cover the upper surface of the frame  320  and fill the recess  321  around the wound coil  20 . In this case, a filling rate of the magnetic material maybe increased, thereby further improving performance of a coil component. 
     The frame  320  and the magnetic sheet  330  may be made of the same material, or may be made of different materials. In the present disclosure, the frame  320  and the magnetic sheet  330  forming a space including a magnetic path may be separately formed, and it is thus possible to easily use two types of magnetic materials, and easily implement a desired product characteristic. 
     The present disclosure does not particularly limit a specific method of forming the magnetic sheet on the upper surface of the magnetic mold. For example, the magnetic sheet obtained by forming the magnetic powder-resin composite in the sheet shape may be stacked on the upper surface of the frame  320 , and then heated and pressed to be cured at a temperature equal to or higher than a temperature in which the resin is cured. Here, the region of the recess  321 , around the wound coil  20 , may be filled with the magnetic sheet by pressure applied thereto. 
     Meanwhile, as described above,  FIGS.  8  and  9    illustrate that the recess  321  of the frame  320  does not completely pass through the frame  320  and is open upward. However, the method for manufacturing a coil component of the present disclosure is not limited thereto, and may use a frame completely passed through by the recess  321  and open both upward and downward. In this case, the wound coil  20  may be fixed in the recess  321  by using a tape T, the magnetic sheet  330  may be pressed on the upper surface of the frame  320 , the tape T may then be peeled off, and the magnetic sheet  330  may be additionally pressed on a lower surface of the frame  320  again. In this manner, the magnetic sheet  330  may be pressed on both the upper and lower surfaces of the frame  320 , and then be cured to manufacture the coil component. 
     Next, referring to  FIG.  10   , a body  10 A of the coil component may be manufactured by dicing the frame  320  and the magnetic sheet  330  along the boundary between the plurality of processed spaces. Here, it is possible to dice the frame  320  and the magnetic sheet  330  into individual coil components by using a dicing facility, or by using another cutting method such as a blade or a laser. 
     An external electrode (not illustrated) may be formed on the outside of the body  10 A, and an insulating layer preventing a short circuit between the external electrodes may be formed, thereby completing the coil component. In an exemplary embodiment, the external electrode may be disposed on each of two opposite surfaces of the body  10 A in the length (L) direction perpendicular to the width (W) direction of the wound coil  20 . The external electrode disposed on a surface of the body  10 A may be electrically connected to the wound coil  20  embedded in the body. The external electrode maybe disposed on each of the two opposite surfaces of the body  10 A. However, this disposition is only an example, and the disposition of the external electrode may be variously modified based on the type, design and process need of the coil component. 
     The external electrode may include a metal such as silver (Ag), silver-palladium (Ag—Pd), nickel (Ni), copper (Cu) or an alloy thereof, and a nickel (Ni) plating layer and a tin (Sn) plating layer may be selectively formed on a surface of the external electrode. 
       FIG.  11    is a top plan view of a portion of a coil alignment device used in processes of manufacturing a coil component according to another exemplary embodiment. 
       FIG.  11    shows a first jig  100 B of the coil alignment device used in the processes of manufacturing a coil component according to another exemplary embodiment. 
     The first jig  100 B of the coil component used in the processes of manufacturing a coil component according to another exemplary embodiment may be different from the first jig  100 A of the coil component used in the processes of manufacturing a coil component according to an exemplary embodiment in that the first and second pressing portions  131  and  132  respectively include first and second protrusions  131   a  and  132   a . Accordingly, the description of the processes of manufacturing a coil component according to an exemplary embodiment and the coil alignment device used therein may be equally applied to the rest overlapping components. 
     Referring to  FIG.  11   , the first jig  100 B used in the processes of manufacturing a coil component according to another exemplary embodiment may include the first or second protrusion  131   a  or  132   a  protruding from each of two ends of the first or second pressing portion  131  or  132 . 
     The first protrusion  131   a  may be formed at each of the two ends of the first pressing portion  131 , in a direction perpendicular to the above-described W direction, and the second protrusion  132   a  may be formed at each of the two ends of the second pressing portion  132  in the direction perpendicular to the above-described W direction. Here, the first and second protrusions  131   a  and  132   a  may oppose each other in the W direction, the direction in which the first and second pressing portions  131  and  132  oppose each other. 
     It is possible not only press the wound portion  11  of the wound coil  10  but also press the lead-out portion  12  of the wound coil  10  when the first and second pressing portions  131  and  132  respectively include the first and second protrusions  131   a  and  132   a . That is, both surfaces of the first and second protrusions  131   a  and  132   a , opposing each other, may press the lead-out portion  12 , thereby deforming a shape of the lead-out portion  12  as well as that of the wound portion  11 . 
       FIG.  12    is a cross-sectional view illustrating a wound coil manufactured by processes of manufacturing a coil component according to yet another exemplary embodiment. 
     Referring to  FIG.  12   , a deformed wound coil  30  may have a lead-out portion  32  whose shape is different from that of the lead-out portion of the deformed wound coil  20  of  FIG.  7   . That is, the deformed wound coil  30  may have the lead-out portion  32  bent in the length (L) direction perpendicular to the width (W) direction. 
     Accordingly, the lead-out portion  32  may be easily exposed to each of cross-sections of the later-completed coil component, opposing each other, in the length (L) direction of the body, thereby preventing the defective exposure of the lead-out portion  32 . 
     As set forth above, according to the present disclosure, it is possible to provide the method for manufacturing a coil component, which may be used for manufacturing the coil component with easy mass production and excellent price competitiveness. 
     According to the present disclosure, it is possible to provide the method for manufacturing a coil component, which may reduce the size of the coil component. 
     According to the present disclosure, it is possible to provide the method for manufacturing a coil component, which may secure the cut margin of the coil component. 
     According to the present disclosure, it is possible to provide the method for manufacturing a coil component, which may prevent the defective coil exposure of the coil component. 
     According to the present disclosure, it is possible to provide the method for manufacturing a coil component, which may increase the volume of the magnetic material of the coil component. 
     While exemplary embodiments have been shown and described above, it will be apparent to those skilled in the art that modifications and variations could be made without departing from the scope of the present disclosure as defined by the appended claims.