JPH10172852A - Production of coil parts - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the number of production steps greatly, realize the reduction of cost and improvement of mass producibility, improve reliability and quality, and to assure constant performance by forming first and second coil parts continuously. SOLUTION: First, a flay type lead wire W is wound vertically to produce a uniaxial coil 3s. Next, the intermediate part 3k of the coil 3s is widened in a manner to make the curvature of the lead wire Wk large, thereby dividing it into first and second coil parts 3a and 3b, and further the axial core of the second coil part 3b is offset against that of the first coil part 3a. Then, the leak wire Wk in the intermediate part 3k is twisted so as to fold the second coil part 3b 180 deg. degrees against the first coil part 3a. Thus, a coil can be produced through such steps.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a coil component for manufacturing a coil component having a first coil portion and a second coil portion in which a rectangular conductor is vertically wound.

[0002]

2. Description of the Related Art In general, a choke (inductor) is provided on a power supply line of an inverter circuit operated by a high-frequency voltage.
To remove the generated n-th harmonic signal.
This type of choke has high efficiency in removing harmonic signals,
Moreover, coils that are vertically wound with a rectangular conductor that can be downsized due to the superiority of space efficiency are often used.
The coil is divided into a 第一 first coil portion and a second coil portion,
Each coil part is attached to each opposing core part of the O-shaped cut core (see FIG. 6).

[0003] When a flat rectangular wire is vertically wound, a plastic deformation such as a thick portion or a bent portion occurs in an inner curved portion.
In addition to the need for a special dedicated hoist,
For example, it is necessary to perform flattening by a coil surface leveling device using a roller disclosed in Japanese Patent No. -68222 or the like.

Therefore, it is difficult to continuously manufacture the first coil portion and the second coil portion. Therefore, conventionally, as shown in FIG.
2 were manufactured separately, and at the time of assembly, one end 31x of the flat wire W in the first coil portion 31 and one end 32x of the flat wire W in the second coil portion 32 were connected by soldering. Here, 31y indicates the other end of the rectangular conductor W in the first coil portion 31, and 32y indicates the other end of the rectangular conductor W in the second coil portion 32, respectively.

[0005]

However, the above-described conventional method of manufacturing a coil has the following problems.

First, two types of first coil portions 31 and second coil portions 32 are required, and furthermore, a connection process by soldering or the like, an insulation process of the connection portion, and a connection portion related thereto are required. Since an electrical characteristic inspection step, an electrical insulation characteristic inspection step, and the like are required, the number of manufacturing steps is increased, the mass productivity is deteriorated, and the cost is significantly increased.

Secondly, since there is a connecting portion to be contacted and the connecting portion is located outside the coil, the reliability is inferior and the performance is disadvantageous in that the quality is easily varied and loss is liable to occur. Become.

The present invention has been made to solve the problems existing in the prior art, and by forming the first coil portion and the second coil portion continuously, the number of manufacturing steps can be greatly reduced, and the cost can be reduced. It is an object of the present invention to provide a method for manufacturing a coil component capable of improving mass productivity, improving reliability and quality, and further ensuring constant performance.

[0009]

In order to achieve the above-mentioned object, a manufacturing method according to the present invention provides a manufacturing method according to the present invention, in which a flat rectangular wire W is vertically attached to opposing core portions 2p and 2q in an O-shaped cut core 2. Wound first coil portion 3a and second coil portion 3b
When manufacturing coil parts that are equipped with
The first coil portion 3a and the second coil portion 3b are formed by vertically winding the rectangular wire W to manufacture the uniaxial coil 3s, and by expanding the curvature of the rectangular wire Wk in the intermediate portion 3k of the coil 3s in a direction to increase the curvature. And the second coil portion 3b
Offsetting the axis of the first coil portion 3a with respect to the axis of the first coil portion 3a, and twisting the flat wire Wk of the intermediate portion 3k, thereby moving the second coil portion 3b to the first coil portion 3a by 18 degrees.
It is characterized by having a manufacturing process of the coil 3 (3i, 3o) including a process of folding back by 0 °. Thereby, the first coil part 3a and the second coil part 3b are continuous, and both the coil parts 3a
And the connection process of 3b and the insulating process are not required.

The manufacturing method according to the present invention can be applied to the manufacture of a choke 1c using one coil 3 and the transformer 1t using two coils 3i and 3o having different winding diameters. In this case, a coil 3i having a small winding diameter is inserted into a coil 3o having a large winding diameter.

[0011]

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

First, a method of manufacturing a coil component according to the first embodiment will be described with reference to the process chart shown in FIG. 1 and FIGS. The first embodiment exemplifies a case where the present invention is applied to a choke 1c as a coil component.

First, a rectangular conductor W having a thickness to width ratio of about 1: 5 is prepared and set on a hoist (not shown) (step S).
1). Then, the flat wire W is vertically wound by the hoist,
The uniaxial coil 3s shown in FIG. 2 is manufactured (Step S2).
At this time, both ends of the rectangular conductor W are bent in the axial direction by a predetermined length, and terminal mounting portions 4a and 4b are provided on both sides of the coil 3s.

The rectangular conductor Wk in the intermediate portion 3k of the manufactured coil 3s is widened in a direction in which the curvature becomes large as shown in FIG. 3, whereby the coil 3s is divided into the first coil portion 3a and the second coil portion 3b. (Step S3). As a result, the axis of the second coil section 3b is offset from the axis of the first coil section 3a. The distance (gap) Ls (see FIG. 4) between the first coil unit 3a and the second coil unit 3b is set according to the offset amount.

Next, as shown in FIGS. 4 and 5, the flat wire Wk in the middle portion 3k of the coil 3s is twisted to move the second coil portion 3b to the first coil portion 3a by one.
It is folded back by 80 ° (step S4). At this time, the twisted portion 5 generated in the flat wire Wk may be left as it is, or may be flattened by crushing.

Thus, the production of the continuous coil 3 including the first coil portion 3a and the second coil portion 3b is completed. Therefore, a connection step and an insulation processing step of the first coil section 3a and the second coil section 3b, and an electrical property inspection step and an electrical insulation property inspection step of a connection portion related thereto are not required, and the number of manufacturing steps is greatly reduced. To be reduced. As a result, cost reduction and mass productivity can be improved, and reliability and quality can be improved.

On the other hand, an O-shaped cut core 2 is mounted on the manufactured coil 3 as shown in FIG. In this case, the cut core 2 is a pair of U-shaped core halves 2m and 2n.
Consists of At the time of mounting, the core halves 2m and 2n are inserted into the first coil portion 3a and the second coil portion 3b from both sides, respectively, and the tips of the core halves 2m and 2n are connected to the first coil portion 3a. Butting is performed inside the second coil portion 3b. As a result, an O-shaped cut core 2 is obtained (step S).
5).

Then, a band (not shown) is attached to the outer peripheral surface of the cut core 2 to fix the cut core 2 (step S).
6). The connection terminals 11a and 11b are respectively attached to the pair of terminal attachment portions 4a and 4b, and the attachment plate 12 is fixed to the lower end of the cut core 2 with bolts and nuts, and necessary finishing is performed. (Step S7). Thereby, the manufacture of the choke 1c is completed.

Next, a method of manufacturing a coil component according to a second embodiment will be described with reference to FIG. The second embodiment exemplifies a case in which the present invention is applied to a transformer 1t using two coils 3i and 3o as coil components.

The transformer 1t uses two coils having different winding diameters, that is, a coil 3i having a small winding diameter and a coil 3o having a large winding diameter. Each of the coils 3i and 3o is manufactured in the same manner as in the first embodiment. In this case, as shown in FIG.
The size and shape are selected so that the coil 3i having a small winding diameter can be inserted into the coil 3o having a large winding diameter. FIG.
In the middle coil 3i, 3ia is a first coil portion, 3i
b is a second coil part, 4ia and 4ib are terminal mounting parts, 5i
Indicates a twisted portion. In the coil 3o,
3oa is the first coil portion, 3ob is the second coil portion, 4o
Reference numerals a and 4ob denote terminal attachment portions and reference numeral 5o denotes a twisted portion.

Therefore, at the time of manufacturing, as shown in FIG. 7, the terminal mounting portions 4ia and 4ib and the terminal mounting portions 4oa and 4oa
position each coil 3i and 3o so that ob faces each other,
The first coil part 3ia having a small winding diameter is coaxially inserted into the first coil part 3oa having a large winding diameter, and the second coil part 3o having a small winding diameter is inserted into the second coil part 3ob having a large winding diameter.
If a is inserted coaxially and a cut core and connection terminals are attached in the same manner as in the first embodiment, a transformer 1t having a primary winding and a secondary winding can be manufactured.

The embodiment has been described in detail above.
The present invention is not limited to such an embodiment,
The configuration, shape, quantity, material, and the like of the details can be arbitrarily changed without departing from the spirit of the present invention.

For example, the choke and the transformer are exemplified as the coil components, but the present invention can be applied to any other coil components. The order of each step can be changed as needed.

[0024]

As described above, the method for manufacturing a coil component according to the present invention includes a step of manufacturing a uniaxial coil by longitudinally winding a rectangular conductor, and a method of increasing the curvature of the rectangular conductor in the middle portion of the coil. By expanding, by dividing the first coil portion and the second coil portion, and the step of offsetting the axis of the second coil portion with respect to the axis of the first coil portion, by twisting the rectangular conductor of the intermediate portion, Since the method includes the step of turning the second coil portion 180 degrees with respect to the first coil portion, the following remarkable effects are obtained.

In order to form the first coil portion and the second coil portion continuously, a connection process and an insulation process process of the two coil portions, and an electrical characteristic inspection process and an electrical insulation characteristic inspection process of a connection portion related thereto are performed. This eliminates the necessity, so that the number of manufacturing steps can be significantly reduced, and cost reduction and mass productivity can be improved.

Since there are no connecting portions that come into contact, reliability and quality can be improved, and constant performance can be ensured.

[Brief description of the drawings]

FIG. 1 is a process diagram including a method for manufacturing a coil component according to a first embodiment of the present invention,

FIG. 2 is a partially sectional front view showing a uniaxial coil manufactured by the same manufacturing method;

FIG. 3 is a partial cross-sectional front view showing an offset state of a coil manufactured by the manufacturing method;

FIG. 4 is a partial sectional front view of a coil manufactured by the same manufacturing method;

FIG. 5 is a bottom view of a coil manufactured by the same manufacturing method;

FIG. 6 is a front view of a coil component (choke) manufactured by the same manufacturing method;

FIG. 7 is a partial sectional front view of two coils manufactured by the method for manufacturing a coil component according to the second embodiment of the present invention;

FIG. 8 is a bottom view of a first coil portion and a second coil portion when manufactured by a manufacturing method according to a conventional technique;

[Explanation of symbols]

 1c choke 1t transformer 2 cut core 2p core 2q core 3 coil 3i coil 3o coil 3a first coil 3b second coil 3s coil 3k middle part W rectangular conductor Wk rectangular conductor

Claims (4)

[Claims] When manufacturing a coil component in which a first coil portion and a second coil portion each having a flat rectangular wire wound vertically are mounted on opposing core portions of an O-shaped cut core, the flat rectangular wire is vertically extended. Winding to produce a uniaxial coil, and by expanding in the direction of increasing the curvature of the rectangular wire in the middle of the coil, divided into a first coil portion and a second coil portion, and the second coil portion A step of offsetting an axis with respect to an axis of the first coil portion, and a step of turning the second coil portion by 180 ° with respect to the first coil portion by twisting the rectangular conductor of the intermediate portion. A method for manufacturing a coil component, comprising a coil manufacturing process. 2. The method for manufacturing a coil component according to claim 1, wherein the method is applied to manufacture of a choke using one coil. 3. The method for manufacturing a coil component according to claim 1, wherein the method is applied to manufacturing a transformer using two coils having different winding diameters. 4. The method according to claim 3, wherein a coil having a small winding diameter is inserted into a coil having a large winding diameter.