JPH0442809B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention relates to a method for manufacturing coil components used in various electronic devices.

Conventional technology Conventionally, this type of coil component has been manufactured as shown in Figs.
The configuration was as shown in FIG. In Fig. 7, 20 is a mouth-shaped closed magnetic circuit magnetic core made of ferrite, 21 and 22 are bobbins formed by injection molding polypropylene, 23 is a terminal plate injection molded from phenolic resin, and 24 is implanted in the terminal plate 23. The pin terminal 25 is a gear formed on the circumferential surfaces of the bobbins 21 and 22 at the same time. Further, in FIG. 8, 26 is a coil, and 27 is a wire fixing adhesive using polyamide.

In addition, in FIG. 9, 28 and 29 are lead grooves, 30 and 31 are winding start leads, 25 is a gear,
32 is a driving gear. In the conventional manufacturing method of the coil component configured as described above, the tips of the leads are inserted into the lead grooves 28 and 29 provided in the bobbins 21 and 22, and the ends of the leads are inserted into the magnetic core 20 when the bobbin is rotated.
The driving gear 32 is engaged with the gear 25, and the bobbins 21 and 22 are rotated to start winding. After the winding is completed, the wire is fixed with a wire fixing adhesive 27 shown in FIG. 8 so that the wire does not come loose. After that, raise the winding start leads 30, 31 from the lead grooves 28, 29, and connect the terminal plate 23 and bobbin 2.
1 and 22 are fitted and fixed, and both the winding start lead and the winding end lead are wound around the pin terminal 24 and soldered.

Problems to be Solved by the Invention In this conventional method, the winding start lead 3
Although lead grooves 28 and 29 are necessary to support 0 and 31, they are completely unnecessary after manufacturing. In addition, the gear 25 is completely unnecessary after manufacturing, and therefore affects the space constraints for the coil section, increasing the magnetic path length of the closed magnetic circuit magnetic core 20, decreasing the cross-sectional area, and decreasing the number of turns, resulting in a decrease in inductance or direct current This was unfavorable in terms of performance, such as an increase in resistance.
Furthermore, the inside of the closed magnetic circuit magnetic core 20 is connected to the bobbins 21 and 22.
Since the wires are rotated and wound, the pin terminals 24 cannot be placed directly on the bobbins 21 and 22, and the terminal board 23 must be prepared for molding and the pin terminals 24 must be placed in advance, which reduces the number of parts. The cost will increase. still,
In this case, as a solution, there is a method of increasing the internal dimensions of the closed magnetic circuit magnetic core 20 within a range in which the pin terminal 24 can rotate, but the bobbin 21 of the pin terminal 24,
Since the protrusion dimension from 22 is required to be 3 to 5 mm, the coil part that was originally about 10 mm in height is 15 to 17 mm.
and is not practical. Furthermore, bobbins 21 and 22
A disadvantage of the configuration in which the winding start leads 30 and 31 are separated from the terminal board 23 is that the winding start leads 30 and 31 are first supported in the lead grooves 28 and 29, and after winding is completed, they are raised and the terminal board 23 is
After fitting to the bobbins 21 and 22, it is necessary to wind the pin terminal 24. Similarly, the lead at the end of the winding cannot be wrapped directly around the pin terminal 24, so it must be fixed with wire fixing adhesive 27.
After fitting the terminal plate 23 to the bobbins 21 and 22, it is necessary to wrap it around the pin terminal 24. In this manufacturing method, the winding work of the winding start lead, the winding end lead, and the pin winding wiring work are separated, so it is difficult to mechanize and becomes a manual process, which is not suitable for mass production. However, there were many problems such as an increase in incidental work and high costs.

The present invention solves these problems,
The purpose of the present invention is to provide a method for manufacturing coil components that enables mechanization of winding and wiring work without increasing the internal dimensions of the closed magnetic circuit core, and that achieves low cost and improved productivity. It is something to do.

Means for Solving the Problem In order to solve this problem, the present invention involves fitting two divided coil bobbins with flanges at both ends to a magnetic core configured with a closed magnetic path, and A hole is provided inside the brim that passes through both the two-split coil bobbin in the same direction as the brim surface, a pin terminal is inserted into the hole with the protrusion, and the coil winding start lead is directly wound on the protruding pin terminal. A gear rotated by a drive source is meshed with a gear provided in a part of the coil bobbin to rotate the coil, and the winding end lead is directly wound on another protruding pin terminal. After moving the pin terminal toward the winding part while holding it so that it does not move, the pin terminal and the lead are soldered.

Function As mentioned above, two coil bobbins are fitted to the magnetic core configured with a closed magnetic path, and the pin terminal is inserted into the collar of the coil bobbin with the pin terminal protruding, and the winding is started.
By wrapping the end-of-winding lead directly around the protruding pin terminal and moving the pin terminal toward the wrapped part while holding the wrapped part from moving,
Conventional winding and wiring machines will facilitate the work.

Embodiment FIGS. 1 and 2 are according to an embodiment of the present invention. FIG. 1 is an exploded perspective view of a coil component, and FIG. 2 is an assembled version of FIG. It is a perspective view of the coil component in front of a wire. Figure 3 is a perspective view of the completed coil component, where 1 is a square-shaped magnetic core made of ferrite, 2 and 4 are holes for pin terminals to pass through, and 3 and 5 are molded from resin. A bobbin is divided into two halves with flanges at both ends, and by butting the two halves together, a single bobbin is constructed. 6 and 7 are gears molded onto parts of the bobbins 3 and 5 at the same time. 8 is a pin terminal, 9 is a winding start lead, 10 is a pin terminal winding part, 1
1 and 11' are coils, and 12 is a drive gear for rotating the gears made by 6 and 7.

In the method for manufacturing a coil component according to the present invention configured as described above, a winding start lead is attached to the pin terminal 8 inserted through the fitted bobbins 3 and 5 so as not to contact the magnetic core 1. Winding is performed by winding 9 directly. After winding is completed, wrap the final lead directly around the remaining pin terminal 8, move the pin terminal 8 toward the wrapped part while holding the wrapped part so that it does not move, and then connect the pin terminal 8 and lead 9. Perform soldering. Here, in the embodiment shown in FIG. 1, the case where the gear is provided in the center rib has been explained, but when the gear is provided on the circumferential surface of both or one side of the ribs at both ends, winding and winding can be similarly performed. It can be performed. In the above embodiment, the square-shaped magnetic core is fixed vertically, but it goes without saying that it is also possible to fix the square-shaped magnetic core horizontally as shown in FIG. Furthermore, as shown in Figure 6,
It is also possible to wind the wire by combining a bobbin with the central magnetic path portion of the letter-shaped magnetic core.

Effects of the Invention As described above, according to the present invention, by eliminating the lead groove and providing the gear in the center or on the flange surface, it is possible to shorten the magnetic path length with the cross-sectional area of the conventional magnetic core, and it is possible to reduce the inductance. , pin terminals can be directly provided on the bobbin without deteriorating performance such as direct current resistance. This makes it possible to eliminate the conventional terminal board, and since winding work and wiring work are not separated, mechanization becomes possible and contributes to improved productivity, resulting in significant cost reductions. , excellent effects can be obtained.

[Brief explanation of drawings]

FIG. 1 is an exploded perspective view of a coil component according to an embodiment of the present invention, and FIG. 2 is a perspective view of a coil component according to an embodiment of the present invention after assembling FIG. 1 and inserting a pin terminal before winding. FIG. 3 is a perspective view of a completed coil component according to an embodiment of the present invention, FIG. 4 is a side view of a coil component in the process of winding according to an embodiment of the present invention, and FIGS. 5 and 6 are other views. FIG. 7 is an exploded perspective view of a conventional coil component; FIG. 8 is a perspective view of a conventional coil component completed by assembling FIG. 7; FIG. 9 1 is a side view of a conventional coil component in the middle of a winding process. 1...Magnetic core, 2, 4...Pin terminal through hole, 3,
5... Bobbin, 6, 7... Gear, 8... Pin terminal, 9... Winding start lead, 10... Pin terminal winding part, 11, 11'... Coil, 12... Drive gear.

Claims (1)

[Claims] 1 A coil bobbin with flanges at both ends is divided into two parts in the same direction as the magnetic core, and
The coil bobbin is fitted using the split part, and at least two holes are provided inside the brim of the coil bobbin that penetrate both halves of the coil bobbin in the same direction as the brim surface. At the beginning of winding, the lead is directly wound around the protruding pin terminal, and a gear rotated by a drive source is engaged with a gear provided in advance on a part of the coil bobbin, and the coil bobbin is rotated to wind the wire. The lead is directly wrapped around another protruding pin terminal, the pin terminal is moved toward the wrapped portion while holding the wrapped portion from moving, and then the pin terminal and the lead are soldered. Method of manufacturing coil parts.