Pot-core components for planar mounting and method of manufacturing the same

A method for manufacturing a composite coil component comprising an inner coil wire and an outer coil wire, the method comprising the steps of:

• preparing a block having recesses at four corners of the block and a winding shaft integrally formed on the upper surface of the block, two retainer paws disposed in two of the recesses respectively, said block and the shaft being adapted to be driven together, a gap-former cylinder having inner and outer diameters capable of forming a predetermined gap between the inner and outer coil wires, said gap-former cylinder being formed from two separate pieces so as to form a slot which allows passage of a terminal of the inner coil, the method further comprising the steps of:
• (a) retaining one terminal in one of the recesses by one of the paws, positioning the inner coil wire tangentially of the shaft and rotating the shaft in one direction until a given number of turns of the inner coil is reached;
• (b) fitting the gap-former cylinder, having an inner diameter substantially the same as the outer diameter of the inner coil wire, on an outer periphery of the inner coil (6a) to cover the inner coil wire;
• (c) retaining one terminal end of the outer coil wire in another recess by the other paw, positioning the outer coil wire tangentially of the cylinder, and rotating the shaft in one direction until the outer coil obtains a necessary number of turns around the cylinder;
• and
• (d) bending the other terminals and of the inner and outer coils and onto the remaining different recesses, respectively and cutting the ends to a predetermined length.