JPH0226769B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to electric winding components such as small transformers and chiyoke coils, and methods for producing the same.

Electrical winding parts include those that are wound directly on a ferrite core and those that are wound using a bobbin, but most of the winding parts are wound by automated winding machines. It is lined.

There are two types of winding machines: those that rotate a ferrite core or bobbin to wind the wire, and flyer-type machines that attach wire to a fixed ferrite core or bobbin. Since the flange is held by a chuck, the ferrite core or bobbin often swings, rotates, or tilts during winding, which causes various problems as described below. do.

(1) If the ferrite core or bobbin oscillates or shifts during winding,
Not only is the wire not wound evenly, but the winding force is uneven, which may damage the core or the bobbin clamping portion.

(2) In an attempt to securely hold the ferrite core or bobbin in the correct position, the clamping force of the chuck becomes too strong, which may crush and destroy the core or bobbin.

(3) As the winding portion becomes smaller, the portion held by the chuck becomes narrower, and the adverse effects of (1) and (2) above increase.

(4) As ferrite cores or bobbins become smaller, chucks become a nuisance, making it difficult to automate coil terminal processing.

(5) If the thickness of the ferrite core flange or bobbin flange is 0.5 mm or less, the flange will break due to the clamping force of the chuck.
It is no longer possible to wind the wire by holding the flange.

(6) When winding a relatively thick wire, the strong tensile force of the wire being wound is applied to the ferrite core or bobbin, which may cause the core or bobbin to come off the chuck.

The first object of the present invention is to solve the above-mentioned drawbacks and to propose an electrical winding component suitable for mechanical winding. In addition, many of these types of electrical winding parts are constructed by inserting a ferrite core that has been pre-wound and then sintered into a cylindrical part of the bobbin. Since there is a wall thickness interval of the bobbin between the coil and the iron core, from the viewpoint of improving accuracy, it is preferable to make the wall thickness of the bobbin corresponding to the winding portion as thin as possible. However, there is a limit to how thin the wall thickness of the bobbin formed by the mold can be made, and if this wall thickness is thin, distortion may occur during the winding process, making it difficult to insert the core. On the other hand, there are electrical winding components that use a highly insulating nickel-based ferrite core and wind the coil directly around the core, but this winder has only a few terminal pins installed at both ends of the core. An insulating flange body is fixed to the flange body, and a terminal pin is implanted in this flange body. However, the winding parts themselves are becoming smaller. For example, in winding parts where the core length is 10 mm or less, the planar size of the flange body is about 4 mm, so the flange body is attached to the core. The fixing work becomes troublesome and work efficiency becomes extremely low.

A second object of the present invention is to solve the above-mentioned drawbacks.

Therefore, in the present invention, the support member for mechanical winding, which is removed after winding, is formed integrally with the bobbin or insulating collar body fixed to the ferrite core, and protrudes in the direction in which the winding portion of the core or bobbin extends. constitute an electrical winding component, and wind the support member by holding it on a fixed part such as a chuck of a winding machine,
After winding, the support member is cut or broken off from the bobbin or the insulating collar.

Further, in the present invention, after the ferrite core is inserted into the mold for forming the bobbin or the insulating flange body, the melted resin material is filled and solidified, and these are fixed to the ferrite core at the same time as the bobbin or the flange body is formed. At the same time, the bobbin part corresponding to the winding part of the bobbin is formed into a thin film shape, and furthermore, the forming mold is provided with a forming hole for a support member for mechanical winding, and the bobbin part corresponding to the winding part of the bobbin is formed into a thin film shape. The support member is formed integrally with the bobbin or the collar.

Examples of the present invention will be described below.

FIG. 1 is a simplified cross-sectional view of a mold for forming a flange body, and this mold 1 includes a mold hole in which a ferrite core 2 is placed, a mold hole for forming flanges 3a and 3b, and a mechanical winding mold. A mold hole is provided in which the supporting member 4 is formed.

The ferrite iron core 2 is placed in the mold 1 in advance before being filled with a resin melting material that forms the collar body and the support member, and then the mold 1 is filled with a resin melting material such as phenol resin.

If the mold is cut out after the melted resin material has solidified, the second
As shown in the figure, a winding component is completed in which the flanges 3a and 3b are fixed to the ferrite core 2, and the support member 4 is integrated with the flanges 3a. In addition, in the figure, 3a' and 3b' are the terminal pull-out grooves of the coil wound on the ferrite core 2, and these grooves 3
a' and 3b' are molded together with the collar bodies 3a and 3b.

FIG. 4 shows a state in which a wire is wound around the winding component configured as described above, in which the support member 4 is held between the chuck 5 of the winding machine, and the wire is wound around the ferrite core 2 by a known method. do.

As shown in the figure, the prismatic support member 4 has a large contact area with the chuck 5 and is securely held.
The ferrite core 2 hardly tilts, displaces or swings due to the winding force, and the chuck 5 clamps and holds it at a position away from the collar body 3a, so the coil end is automatically attached to the terminal pin 6. It does not get in the way when raised from the ground, and since the flange body is not clamped, the thickness of the flange body can be made thinner, and even a smaller winding component can be efficiently wound.

The terminal pins 6 are implanted in the flanges 3a, 3b as necessary after the winding component is constructed, but the implantation position and number of the terminal pins 6 can be determined arbitrarily. Further, the terminal pin 6 can be fixed at the same time as the molding of the collar body is formed. That is, a mold hole in which the terminal pin 6 is placed is provided in the forming mold 1, and the terminal pin 6 is placed in the mold hole so that one end portion of the terminal pin 6 protrudes into the collar mold hole, and then the melted resin material is applied. All you have to do is fill it up.

After winding, as shown in FIG. 4, the support member 4 is cut and removed from the collar body 3a. This support member 4 can be broken off from the collar body 3a by forming a groove 4a in its base. The grooves 4a may be formed by molding, or may be formed after die cutting. However, when the support member 4 is cut and removed, the groove 4a is not necessarily required, and the groove 4a may be provided not only in the entire circumference of the support member 4 but also in a part of the circumference.

Next, FIG. 5 is a cross-sectional view schematically showing a bobbin forming die, in which the forming die 7 has a die hole in which the ferrite core 2 is placed, and flanges 8a, 8 of the bobbin 8.
A mold hole for forming b and a mold hole for forming the support member 4 are provided in the same way as in the above embodiment, except that
In this embodiment, the diameter of the mold hole of the ferrite core 2 is made slightly larger than the thickness of the core 2. With this configuration, the melted resin material filled in the forming mold 7 enters around the ferrite core 2. As a result, along with the formation of the flanges 8a and 8b, a membrane-like bobbin portion 8 is formed around the ferrite core 2.
I can do c. FIG. 6 is a partially cutaway perspective view of the winding part produced by the above embodiment. As can be seen from this drawing, the winding part of the bobbin 8 has a film-like shape and has a very thin wall thickness. Further, the ferrite core 2 is buried inside the bobbin 8, and the ferrite core 2 and the bobbin 8 are integrally fixed.

The rest of the structure and production method are the same as those of the embodiment shown in FIGS. 1 and 2, and 8a' and 8b' are grooves for leading out the ends of the coil.

FIG. 7 shows a winding component in which both end faces of a ferrite core 2 are formed with convex portions, and the convex portions 2a, 2b are buried in flanges 3a, 3b to fix the core 2 and the flanges. The method for producing wire parts is the same as in the above embodiment.

Further, if the protrusions 2a, 2b are provided with cut grooves 2c as shown in an enlarged partial view in FIG. 8, the flanges 3a, 3b can be more firmly fixed.

As described above, in the present invention, the support member for mechanical winding that is removed after winding is integrally formed with the bobbin or collar body fixed to the ferrite core, so that the support member is held in the fixture of the winding machine. By winding the wire in such a way that the winding component does not swing or rotate or tilt, it is possible to prevent the winding component from coming off during the winding process or breaking the component. According to the present invention, the bobbin or the flange body can be integrally fixed to the ferrite core as the bobbin or the flange body is formed, and the winding portion of the bobbin can be formed to have a film-like thickness. Therefore, it is extremely advantageous for improving the accuracy of transformers, chiyoke coils, etc. that are constructed with a bobbin interposed.

Furthermore, in the present invention, the bobbin or collar body fixed to the ferrite core is produced by die-cutting, and the support member for mechanical winding is integrally formed, so the production of the winding parts is simple and suitable for mass production. Wire-wound components may be provided.

Although the support member 4 is prismatic in the above embodiment, it may be cylindrical, and the present invention is applicable even if the ferrite core 2, bobbin 8, flanges 3a, 3b, etc. are prismatic. The fixing device provided in the winding machine that holds the support member 4 is not limited to the chuck, but any suitable fixing device that fixes the support member 4 when it is inserted may be used.

[Brief explanation of drawings]

The drawings show embodiments of the present invention, and FIG. 1 is a cross-sectional view schematically showing a mold for forming an insulating flange body, and FIG. 2 is a diagram showing a winding component produced by the mold shown in FIG. 3 is a simplified diagram showing the winding state, FIG. 4 is a side view showing the completed electrical component, FIG. 5 is a sectional view showing a simplified bobbin forming mold, and FIG. 5
FIG. 7 is a partially cutaway perspective view of a winding component produced by the forming mold shown in the figure; FIG. FIG. 8 is a sectional view showing another embodiment in which a portion where the ferrite core and the flange body are fixed is shown in an enlarged manner. 1... Forming mold of the collar body, 2... Ferrite core,
3a, 3b...flange body, 4...support member, 4a...
Groove, 5...Chuck, 7...Bobbin forming mold, 8
...Bobbin, 8a, 8b...flange, 8c...bobbin part.

Claims (1)

[Scope of Claims] 1. A support member for mechanical winding that is removed after winding is formed integrally with a bobbin or an insulating flange fixed to a ferrite core, and protrudes in the direction in which the winding portion of the core or bobbin extends. electrical winding parts. 2 A forming hole for a support member for mechanical winding is provided in a mold for forming a bobbin or an insulating flange body, a ferrite core is placed inside this mold, and then a melted resin material is filled and solidified to be integrally fixed to the ferrite core. A method for producing an electric winding component, in which a bobbin or a collar body is formed, and at the same time the support member described above is formed integrally with the bobbin or collar body.