CN113196424A - Molded coil and method of manufacturing the same - Google Patents
Molded coil and method of manufacturing the same Download PDFInfo
- Publication number
- CN113196424A CN113196424A CN201980083876.8A CN201980083876A CN113196424A CN 113196424 A CN113196424 A CN 113196424A CN 201980083876 A CN201980083876 A CN 201980083876A CN 113196424 A CN113196424 A CN 113196424A
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- Prior art keywords
- pair
- bobbin
- wire
- relay terminals
- joints
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/29—Terminals; Tapping arrangements for signal inductances
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F7/00—Magnets
- H01F7/06—Electromagnets; Actuators including electromagnets
Abstract
The invention provides an injection molding coil which has no interference between a wire and a joint during the winding operation of the wire, is easy to manufacture and can be corresponding to various connectors of an external device, and a manufacturing method thereof. The coil bobbin (2) has: the wire harness comprises a cylindrical part (21) and a pair of flanges (22), wherein the wire (3) is wound on the outer periphery of the cylindrical part, and the pair of flanges are arranged at two ends of the cylindrical part (21). The pair of relay terminals (4a, 4b) are provided on the bobbin (2) so as to avoid the winding portion of the wire (3) sandwiched by the pair of flanges (22), and the start end and the end of the wire (3) are locked. The joints (5a, 5b) are formed by members different from the pair of relay terminals (4a, 4b), are arranged at positions opposite to the winding positions of the wire (3), and are connected with the starting end (31a) or the terminal end (31b) of the wire (3). The support holes (26a, 26b) support the joints (5a, 5b) so as to be attachable/detachable with respect to the bobbin (2).
Description
Technical Field
The present invention relates to a molded coil (hereinafter, referred to as a coil) and a method for manufacturing the same.
Background
The coil has: a bobbin having a cylindrical portion formed in a hollow cylindrical shape; a wire (generally, referred to as a magnet wire) wound around an outer periphery of the cylindrical portion of the bobbin; and a pair of joints connecting a start end and a finish end of the wire. Each connector is connected to a connector of an external device such as a power supply and a control device. The coil is excited by supplying electricity from an external device such as a power supply or a control device to the wire through the joints.
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open publication No. 2013-58578
In the coil, a wire material is wound around the outer periphery of a cylindrical portion of a bobbin using an automatic winding machine. In this case, in order that the plurality of or the single joints do not interfere with the winding operation, the wire needs to be arranged so as to avoid the route of the wire reaching the bobbin from the automatic winding machine, that is, so as to avoid the outer peripheral portion of the cylindrical portion of the bobbin (the portion sandwiched between the two flanges of the bobbin).
On the other hand, each of the joints is a member of a connector for connecting the wire to an external device, and therefore, depending on the positional relationship between the connector and the coil, the joint may have to be disposed on the outer periphery of the cylindrical portion of the bobbin which hinders the winding operation. In such a case, conventionally, after the winding operation is completed, the plurality of contacts are bent in the connection direction of the connector.
However, bending the plurality of tabs after the winding operation is completed increases the number of operation steps. Moreover, there are problems as follows: the shape of the plurality of joints is limited to a bendable shape, and it is difficult to cope with the position and direction of various connectors included in the external device. In addition, when the plurality of tabs are bent after the winding operation is completed, there are problems as follows: deformation, so-called springback, occurs due to the elasticity of the material of the joint, and it is difficult to secure the bending position of the joint with high accuracy.
Further, since the coil is required to be connected to various connectors (external connectors) of an external device, it is necessary to manufacture a plurality of coils having different protruding directions and protruding sizes of contacts with respect to the bobbin, and there is a problem that sharing of components is difficult.
Disclosure of Invention
The present invention has been made to solve the above-described problems, and an object of the present invention is to provide an injection-molded coil and a method for manufacturing the same, which are capable of preventing interference between a wire and a plurality of terminals during a wire rewinding operation, facilitating manufacturing, and being compatible with various connectors included in an external device.
Means for solving the problems
The injection-molded coil of the present invention has the following features.
(1) A bobbin having a cylindrical portion around the outer periphery of which a wire is wound, and a pair of flanges provided at both ends of the cylindrical portion.
(2) And a pair of relay terminals provided on the bobbin so as to avoid a winding portion of the wire rod sandwiched between the pair of flanges, and having a start end and a finish end of the wire rod locked thereto.
(3) And a pair of terminals which are formed of a member different from the pair of relay terminals, are arranged at positions facing the winding positions of the wire material, and connect the start ends and the end ends of the wire material.
(4) A support portion that supports the joint to be attachable/detachable with respect to the bobbin.
In the injection-molded coil of the present invention, the following configuration may be adopted.
(1) The joint has: a base extending parallel to a surface of the flange; a bent portion formed by bending the base portion and extending in a direction of a winding shaft of the bobbin along a surface of the wire wound around the cylindrical portion; and the contact is arranged at the top end of the bending part.
(2) The contact is formed by bending the tip of the bent portion outward of the coil in a direction parallel to the flange surface.
(3) The lengths of the bent portions of the two joints in the direction of the winding shaft of the bobbin are different from each other, and at least one of the joints has a step portion provided in a portion of the bent portion or the contact on the bent portion side, the step portion extending in the circumferential direction of the bobbin toward the other joint side opposite to the other joint side, and the contacts of the two joints are arranged in parallel to the direction of the winding shaft of the bobbin on the outer periphery of the wire by the step portion.
(4) The support portion is a support hole provided in the flange in a direction parallel to the flange surface and along a radial direction of the flange, and the base portion of the joint is inserted into the support hole from an outer circumferential direction of the flange.
(5) In the flange, a support hole of a relay terminal is provided in a direction along the support hole of the terminal, and a base portion of the relay terminal is inserted into the support hole from an outer circumferential direction of the flange.
(6) The pair of relay terminals includes: an opening formed by cutting the tip end side of the relay terminal; and a pair of locking portions provided at an entrance portion of the opening portion with the opening portion interposed therebetween, wherein the joint includes a protruding piece, a part of the protruding piece is bendable, an end portion of the wire is locked to the pair of locking portions so as to straddle the opening portion, the protruding piece provided at the joint is fitted into the opening portion, and the end portion of the wire straddling the opening portion is sandwiched by a surface of the joint and the protruding piece.
The method for manufacturing an injection-molded coil of the present invention includes the following steps.
(1) The starting end of the wire is locked to one of the pair of relay terminals, and the wire is wound around the outer periphery of the cylindrical portion of the bobbin by a winding machine.
(2) And locking the end of the wire to the other of the pair of relay terminals.
(3) A pair of terminals are fixed to the flanges of the bobbin or the pair of relay terminals.
(4) The starting ends or the terminal ends locked to the pair of relay terminals are connected to the pair of contacts, respectively.
(5) And injection molding a molding resin around the outer circumferences of the wire, the relay terminal, and the connector wound around the bobbin.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, since no joint is present on the outer periphery of the cylindrical portion of the bobbin when the wire is wound, the joint does not interfere with the winding operation. Further, since the terminal is attached to the bobbin after winding, it is possible to cope with the position and direction of various connectors included in the external device. Further, by preparing a plurality of types of connectors and selecting an appropriate connector according to the connection method with the external device, it is possible to share the bobbin and the relay terminal, and obtain various types of coils.
Drawings
Fig. 1 is a perspective view showing an internal structure of a coil according to a first embodiment.
Fig. 2 is a perspective view and a front view showing a state where the connector housing is injection-molded on the outer periphery of the coil of the first embodiment.
Fig. 3 is a perspective view showing a process of fixing the relay terminal to the bobbin in the coil according to the first embodiment.
Fig. 4 is a perspective view showing a state in which the relay terminal is fixed to the bobbin in the coil according to the first embodiment.
Fig. 5 is a perspective view showing a process of winding a wire around a bobbin in the coil according to the first embodiment.
Fig. 6 is a perspective view showing a process of fixing a tab to a bobbin in the coil according to the first embodiment.
Fig. 7 is a perspective view showing a coil provided with a tab having no wire-clamping protrusion.
Fig. 8 is a perspective view showing a coil provided with a relay terminal provided with a locking portion of one wire end portion and a manufacturing process thereof.
Fig. 9 is a perspective view showing a coil provided with a terminal having contacts arranged in a direction perpendicular to the axis of the bobbin.
Fig. 10 is a perspective view showing a coil provided with a terminal having a contact projecting in a direction parallel to the axis of the bobbin.
Detailed Description
[1. first embodiment ]
[1-1. Structure ]
The structure of the coil according to the present embodiment will be described with reference to fig. 1 and 2. In the present embodiment, for convenience, the direction in which the tab holder is provided on the bobbin of the coil is referred to as the upper direction, the opposite direction is referred to as the lower direction, and the direction in which the pair of leads connected to the injection-molded coil are arranged is referred to as the left-right direction.
As shown in fig. 1, the coil has: the coil bobbin 2 is formed of a resin material such as ABS, polypropylene, PBT, phenol, or the like, the wire 3 wound around the coil bobbin 2, a pair of relay terminals 4a, 4b supported by the coil bobbin 2, and a pair of connectors 5a, 5 b.
The bobbin 2 has: a cylindrical portion 21 around which a wire is wound, and a pair of flanges 22a, 22b provided at both ends of the cylindrical portion 21 so as to project in the outer diameter direction. A flat portion 24 protruding in a step shape in the outer diameter direction is provided in a part of one flange 22a, and support holes 25a and 25b for the relay terminals 4a and 4b and support holes 26a and 26b for the contacts 5a and 5b are provided in the flat portion 24. The support holes 25a and 25b are holes extending in the inner diameter direction of the flange 22a, and as shown in fig. 3, the support holes 25a and 25b for the relay terminals 4a and 4b are provided at a large interval in the upper layer, and the support holes 26a and 26b for the contacts 5a and 5b are provided at a slightly narrow interval in the lower layer.
The relay terminals 4a and 4b are formed of a plate-shaped metal member, and include: a base 41, the base 41 being inserted into the support holes 25a, 25b from the outer circumferential direction (radially outside of the bobbin 2); an opening 42 formed by cutting the opening 42 on the tip end side of the relay terminals 4a and 4 b; and a pair of locking portions 43, 44, the pair of locking portions 43, 44 are provided with the opening portion 42 therebetween. The relay terminals 4a and 4b are respectively locked to the end portions of the wire 3, and a start end 31a of the wire 3 is locked to one relay terminal 4a and a terminal end 31b of the wire 3 is locked to the other relay terminal 4 b. In this case, the leading end 31a and the terminating end 31b of the wire 3 are stretched between the engaging portions 43 and 44 of the corresponding relay terminals 4a and 4b so as to straddle the opening 42.
The joints 5a and 5b are formed by bending a plate-shaped metal member. Each of the joints 5a and 5b includes: a base portion 51 extending parallel to the surface of the flange 22a, a bent portion 52 formed by bending the base portion 51 and extending in the direction of the winding shaft of the bobbin 2 along the surface of the wire 3 wound around the bobbin 2, and a contact 53 (contact portion) provided at the tip of the bent portion 52. The contact 53 is formed by bending the tip of the bent portion 52 outward of the coil (in the radial direction of the bobbin 2) in a direction parallel to the surface of the flange 22 a.
The length of each bent portion 52 provided to the two joints 5a and 5b in the winding direction of the bobbin 2 differs depending on the position of the contact 53 provided to the tip end thereof. The bent portion 52 of the contact 53 located at the upper portion 5a of the coil is short, and the bent portion 52 of the contact located at the lower portion 5b of the coil is long. In each of the tabs 5a and 5b, a stepped portion 54 is provided between the bent portion 52 and the contact 53, and the stepped portion 54 extends in the circumferential direction of the bobbin 2 toward the other opposing tab 5 b. The contact points 53 of the two tabs 5a and 5b are arranged parallel to the winding direction of the bobbin 2 on the outer periphery of the wire 3 by the step 54. The sectional shape of the contact 53 is not particularly limited, but in the present embodiment, the contact 53 is bent by 90 ° with respect to the bent portion 52, and thereby is formed into a shape in which the width in the longitudinal direction is longer than the sectional direction in which the plate thickness is large. The bent portions 52 of the joints 5a and 5b and the contacts 53 are arranged to overlap the winding portion (cylindrical portion 21) of the wire of the bobbin 2 when viewed in the radial direction of the bobbin 2.
The joints 5a and 5b are provided with projecting pieces 55, and a part of the projecting pieces 55 can be bent. The protruding piece 55 has a width that enters the inside of the opening 42 provided in the relay terminals 4a and 4 b. The relay terminals 4a and 4b and the joints 5a and 5b are supported by the flange 22. In a state where the end portions 31a and 31b of the wire are sandwiched between the protruding piece 55 that enters the opening 42 and the body portions surfaces of the joints 5a and 5b, the protruding piece 55, and the end portions 31a and 31b of the wire 3 are joined by melting. Melting is one type of resistance welding, and welding is performed by applying electricity to a welding portion between upper and lower electrodes.
The outer periphery of the coil having the configuration as shown in fig. 1 is covered with a mold resin by injection molding, and as shown in fig. 2(a), a connector housing 6 that fits a connector of an external device is integrally molded. That is, the connector housing 6 includes: a coil bobbin 2 covering the coil, a substantially cylindrical coil covering 61 wound around the bobbin 2, the wire 3, the relay terminals 4a, 4b, and the base portions of the connectors 5a, 5 b; and a connector fitting portion 62 projecting laterally (in the radial direction of the bobbin 2) from the upper outer periphery of the coil covering portion 61. The connector fitting portion 62 is a cylindrical member having an elliptical cross section, and a connector on the external device side is fitted inside the distal end opening portion. The contacts 53 of the contacts 5a and 5b are arranged inside the connector fitting portion 62. The inside of the opening of the connector fitting portion 62 reaches the coil covering portion 61, and as shown in fig. 2(b), the contacts 53 of the pair of contacts 5a, 5b are arranged vertically along the longitudinal direction, that is, along the winding axis direction of the coil, on the wall surface where they come into contact. Therefore, the contacts 53 of the pair of tabs 5a, 5b overlap when viewed from the spool direction.
[1-2. Effect ]
Next, a method for manufacturing a coil according to the present embodiment will be described with reference to fig. 3 to 6.
(1) The relay terminals 4a, 4b are fixed to the bobbin 2
As shown in fig. 3, the base portions 41 of the relay terminals 4a and 4b are inserted into the support holes 25a and 25b provided in the flange 22, and the relay terminals 4a and 4b are fixed to the bobbin 2.
(2) Winding the wire 3 around the bobbin 2
The leading end 31a of the wire 3 drawn out from a supply reel of the wire by a winding machine (not shown) is wound around and locked by a pair of locking portions 43, 44, and the pair of locking portions 43, 44 is provided in one of the relay terminals 4a protruding outward of the bobbin 2. In this case, the leading end 31a is stretched between the pair of locking portions 43 and 44 so as to straddle the opening 42. In this state, the bobbin 2 is rotated, and the wire 3 is wound around the outer periphery of the cylindrical portion 21 in multiple layers. In this case, the relay terminals 4a and 4b are positioned on substantially the same plane as the flange 22 and are arranged so as to avoid the path of the wire wound around the bobbin from the automatic winding machine, and therefore, the wire 3 can be efficiently wound around the cylindrical portion 21 of the bobbin 2, and the relay terminals 4a and 4b do not interfere with the winding operation of the wire.
(3) Fixing the terminal 31b of the wire 3 to the relay terminal 4b
After the winding operation of the wire 3 is completed, the terminal 31b of the wire 3 is wound and locked to the pair of locking portions 43 and 44 so as to straddle the opening 42, and the pair of locking portions 43 and 44 is provided to the other relay terminal 4b protruding outward of the bobbin 2. In this state, as shown in fig. 5, the leading end 31a and the terminating end 31b of the wire 3 are respectively stretched between the pair of locking portions 43 and 44 of the relay terminals 4a and 4 b.
(4) Fixing the joints 5a, 5b to the coil frame 2
As shown in fig. 6, the base portions 51 of the joints 5a and 5b are inserted into the support holes 26a and 26b provided in the flange 22, respectively, and the joints 5a and 5b are fixed to the bobbin 2. At this time, as shown in fig. 1, the main body portions of the contacts 5a and 5b and the projecting pieces 55 enter the inside of the openings 42 provided in the relay terminals 4a and 4b, and the start end 31a and the end 31b of the wire 3 stretched so as to straddle the openings 42 are sandwiched from above and below by the main body portions and the projecting pieces 55.
(5) Joining the wire 3 to the joints 5a, 5b
In the state shown in fig. 1, the tab 55 is lifted from the surface of the joint 5a, 5 b. In this state, the tab 55, the start end 31a or the end 31b of the wire 3, and the main body portions of the tabs 5a and 5b are pressed by an electrode (not shown) of the fusion welding machine to be in close contact therewith. Thereafter, the starting end 31a or the terminating end 31b of the wire 3 is welded to the joints 5a, 5 b.
(6) Injection molding of molding resin
After the joints 5a and 5b are joined to the ends 31a and 31b of the wire 3, the entire coil is placed in a mold for injection molding, and a molding resin is injected and molded around the outer periphery of the coil. In this case, a plurality of divided molds covering the entire coil are used as the mold. In the present embodiment, the connector housing 6 having the cylindrical connector fitting portion 62 shown in fig. 2(a) and (b) is molded by molding resin, and therefore, it is not necessary to consider arranging an insert or the like in the connector fitting portion 62.
[1-3. Effect ]
The effects of the present embodiment having the above-described configuration are as follows.
(1) In the present embodiment, the tabs 5a, 5b are not fixed to the bobbin 2 during the winding operation. Since the relay terminals 4a and 4b are also disposed at positions avoiding the path of the wire 3 wound around the bobbin 2, the relay terminals 4a and 4b and the connectors 5a and 5b do not interfere with the winding operation, and the winding operation can be easily and efficiently performed. On the other hand, since the terminals 5a and 5b are fixed to the bobbin 2 after the winding operation is completed, the contacts of the terminals 5a and 5b can be arranged at positions where they can be easily engaged with the connector of the external device.
(2) Since the joints 5a and 5b are fixed to the bobbin 2 after the wire 3 is wound, it is possible to cope with external devices having various connector positions and directions by preparing the joints 5a and 5b having various shapes in advance. Further, the bobbins 2, the wires 3, the relay terminals 4a, 4b, and the like other than the joints 5a, 5b can be shared, and various types of coils can be manufactured without increasing the number of types of parts, manufacturing facilities such as molds, and the like.
(3) The leading end 31a and the terminating end 31b of the wire 3 are respectively stretched between the pair of engaging portions 43, 44 of the relay terminals 4a, 4b so as to straddle the opening 42. By sandwiching this portion between the joint main body and the projecting piece 55, the end of the wire 3 and the joints 5a and 5b can be accurately positioned. The end of the wire 3 is linearly stretched on the surface of the joint body, and the two can be closely overlapped. As a result, the end portions of the wire 3 can be sandwiched with high accuracy by the upper and lower electrodes at the time of fusion welding, and both can be reliably joined.
[2 ] other embodiments ]
The embodiments of the present invention have been described, but these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be implemented by various other embodiments, and various omissions, substitutions, and changes can be made without departing from the spirit of the invention. These embodiments and modifications are included in the invention described in the claims and the equivalent scope thereof as long as the embodiments and modifications are included in the scope and gist of the invention. The following is an example thereof.
(1) In the above embodiment, the joints 5a and 5b sandwich and fuse the starting end 31a and the terminating end 31b of the wire 3 by the joint main body and the projecting piece 55, but the joints 5a and 5b may not have the projecting piece 55. For example, as shown in fig. 7, the tabs 5a and 5b having no projecting piece 55 may be joined to the starting end 31a and the terminating end 31b of the wire 3 by melting, soldering, or the like. When the tabs 5a and 5b without the projecting pieces 55 are used, the operation of pressure-bonding the projecting pieces 55 and the end portions of the wire 3 is not necessary, and it is advantageous in the case where the wire 3 is joined by means such as soldering without using upper and lower sandwiching electrodes.
(2) In the above embodiment, the relay terminals 4a and 4b are formed by using a member capable of stretching the leading end 31a or the trailing end 31b of the wire material in the opening 42 between the pair of locking portions 43 and 44, but the shapes of the locking portions 43 and 44 are not limited to this. For example, as shown in fig. 8, only one locking portion 43 may be provided in each of the relay terminals 4a and 4b, and the end portion of the wire 3 may be sandwiched between the protruding pieces 55 provided in the joints 5a and 5b by stretching the start end 31a or the end 31b of the wire 3 between the locking portion 43 and the edge of the flange 22, thereby performing welding. This makes it possible to reduce and simplify the shapes of the relay terminals 4a and 4 b.
(3) In the above embodiment, the two contacts 53 of the terminals 5a and 5b are projected outward of the bobbin 2 in a state of being arranged in the vertical direction, but the arrangement direction and the projecting direction of the contacts 53 are not limited to this. For example, as shown in fig. 9, as the two terminals 5a and 5b, a member having the same length as the bent portion 52 may be used, and the tip end of the bent portion 52 may be bent outward of the bobbin directly to form the contact 53, whereby the two contacts arranged in the lateral direction may be protruded outward of the bobbin 2. As shown in fig. 10, as the two joints 5a and 5b, members having the same length of the bent portion 52 may be used, the bent portion 52 may be disposed along the outer peripheral surface of the wire 3, and the contact 53 may be provided at the tip end thereof. As described above, according to the present invention, the connectors 5a and 5b can be attached to and detached from the bobbin 2, and thus various types of coils can be easily obtained in a connector system for external devices.
(4) In the above embodiment, the support portions of the relay terminals 4a and 4b and the joints 5a and 5b are formed integrally with the flange 22a, but the present invention is not limited thereto. A joint holder that is a separate member from the bobbin 2 and has support holes for the relay terminals 4a and 4b and support holes for the joints may be prepared, and the relay terminals 4a and 4b and the joints 5a and 5b may be supported by the joint holder after the joint holder is fixed to the bobbin 2. Further, the relay terminals 4a and 4b may not be inserted and fixed to the flange 22, but the base portions 41 of the relay terminals 4a and 4b may be fixed to a part of the flange 22 by insert molding at the time of molding the bobbin 2. Further, the relay terminals 4a and 4b and the support portions of the connectors 5a and 5b may be provided on the relay terminals 4a and 4b instead of the bobbin 2. In short, the relay terminals 4a and 4b and the terminals 5a and 5b may be supported directly or indirectly by the bobbin 2, and the mode thereof is not limited.
(5) In the above embodiment, the relay terminals 4a and 4b are formed of a plate-shaped metal member, but the material of the relay terminals 4a and 4b is not limited thereto. The relay terminals 4a and 4b may be made of a material having no conductivity, such as resin or ceramic. Further, a part of the resin bobbin 2 may be projected to function as the relay terminals 4a and 4 b.
(6) In the above embodiment, the two relay terminals 4a, 4b and the two joints 5a, 5b are fixed to the flange 22, but the number of the relay terminals and the joints fixed to the flange 22 is not limited to this. For example, an intermediate tap may be provided in the wire 3 wound around the bobbin 2, and a relay terminal and a joint connected to the intermediate tap may be fixed to the flange 22. The wire 3 constituting the secondary winding may be wound around the bobbin 2, or a relay terminal and a joint connected to the secondary winding may be fixed to the flange 22. For example, in the case of a coil in which a wire rod has a center tap and a coil in which a wire rod constituting a secondary winding is wound, the center tap portion and the end of the secondary winding can be connected to an external device using the same relay terminal and joint as in the first embodiment.
(7) In the above embodiment, the start end 31a and the end 31b of the wire 3 fixed to the relay terminals 4a and 4b are respectively joined to the protruding pieces 55 by melting, but may be joined by connection by soldering, welding by laser welding, or caulking.
In the above-described embodiment, the example of the connector fitting portion 62 extending in the radial direction of the bobbin 2 has been described, but it is needless to say that the connector fitting portion may be a connector fitting portion extending in the reel direction of the bobbin 2. In this case, the contact portions of the contacts 5a and 5b inside the connector fitting portion are also arranged to extend in the reel direction.
In the above embodiment, the bent portion 52 of the joint 5a is extended downward, but if the bent portion 52 of the joint 5a is bent upward, the bent portion 52 of the joint 5a and the contact 53 do not overlap the cylindrical portion 21 of the bobbin 2 when viewed in the radial direction of the bobbin 2. That is, when viewed in the radial direction of the bobbin 2, only the bent portion 52 and the contact 53 of the tab 5b are disposed so as to overlap the cylindrical portion 21 of the bobbin 2. In the case of using the tab 5a in which the contact is formed on the distal end side extending in the radial direction from the base 51 of the tab without forming the bent portion 52 of the tab 5a, the contact of the tab 5a is also arranged so as not to overlap the cylindrical portion 21 of the bobbin 2 when viewed in the radial direction of the bobbin 2.
In the above-described embodiment, the coil was described as being injection molded, but the present invention can be applied to a mold coil, as a matter of course.
Description of the symbols
2. coil rack
3. wire rod
4a, 4 b. relay terminal
5a, 5 b. Joint
6. connector housing
21. cylindrical part
22. flange
24. flat part
25a, 25 b. supporting hole of relay terminal
26a, 26 b. support holes for the joints
31 a. the beginning of the wire
31 b. end of wire
41 base of relay terminal
42. opening part
43. 44. locking part
51 base of joint
52. bending part
53. contact
54. step part
55. Tab
Claims (8)
1. A molded coil, comprising:
a bobbin having a cylindrical portion around which a wire is wound, and a pair of flanges provided at both ends of the cylindrical portion;
a pair of relay terminals provided on the bobbin so as to avoid a winding portion of the wire rod sandwiched between the pair of flanges when viewed in a radial direction of the bobbin, and connected to a start end and a finish end of the wire rod, respectively; and
a pair of terminals which are formed of a member different from the pair of relay terminals and are electrically connected to a start end and a finish end of the wire rod, respectively,
at least one of the pair of joints is disposed so as to overlap the cylindrical portion when viewed in a radial direction of the bobbin.
2. The molded coil of claim 1,
further comprises a connector fitting part in which a contact part of the contact is arranged,
the contact portion of the joint extends in the direction of the winding axis of the bobbin.
3. The molded coil of claim 1,
further comprises a connector fitting part in which a contact part of the contact is arranged,
the contact portion of the terminal extends in a radial direction of the bobbin.
4. The molded coil of claim 3,
the joint has: the contact portion disposed inside the connector fitting portion; a base supported by the bobbin; and a bent portion disposed between the contact portion and the base portion,
the bent portion extends in the direction of the reel.
5. The molded coil of claim 4,
the lengths of the bent portions of the pair of joints in the direction of the reel are different,
one of the pair of tabs is provided with a step portion extending along the circumferential direction of the bobbin between the bent portion and the contact portion,
the other of the pair of tabs is provided with a step portion extending in the circumferential direction of the bobbin between the base portion and the bent portion,
the contact portions of the pair of tabs overlap when viewed from the direction of the spool.
6. The molded coil according to any one of claims 1 to 5,
the flange is provided with a support hole into which the base portions of the pair of relay terminals and the pair of contacts are inserted from the outer circumferential direction and which supports the base portions of the pair of relay terminals and the pair of contacts.
7. The molded coil according to any one of claims 1 to 6,
the pair of relay terminals each include: an opening formed by cutting the tip end side of the relay terminal; and a pair of locking portions provided at an entrance portion of the opening portion with the opening portion interposed therebetween,
the pair of joints are respectively provided with a protruding piece, a part of the protruding piece can be bent,
the end portions of the wire are locked to the pair of locking portions so as to straddle the opening portion,
a protruding piece arranged on the joint is embedded into the opening part,
the end of the wire spanning the opening is sandwiched by the surface of the tab and the tab.
8. A method of manufacturing a molded coil, comprising the steps of:
clamping a starting end of a wire rod to one of the pair of relay terminals, and winding the wire rod on the outer periphery of the cylindrical part of the coil frame through a winding machine;
clamping the terminal of the wire to the other of the pair of relay terminals;
fixing a pair of joints to the flanges of the bobbin or the pair of relay terminals;
connecting a start end or a terminal end of the wire rod latched to the pair of relay terminals to the pair of tabs, respectively; and
molding the outer peripheries of the wire, the relay terminal, and the joint around the bobbin.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2018236078A JP7201222B2 (en) | 2018-12-18 | 2018-12-18 | Molded coil and its manufacturing method |
| JP2018-236078 | 2018-12-18 | ||
| PCT/JP2019/044920 WO2020129500A1 (en) | 2018-12-18 | 2019-11-15 | Molded coil and production method for same |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN113196424A true CN113196424A (en) | 2021-07-30 |
| CN113196424B CN113196424B (en) | 2023-07-21 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201980083876.8A Active CN113196424B (en) | 2018-12-18 | 2019-11-15 | Molded coil and method of manufacturing the same |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP7201222B2 (en) |
| CN (1) | CN113196424B (en) |
| WO (1) | WO2020129500A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116900199B (en) * | 2023-06-29 | 2024-04-05 | 诸暨市金闽辉电子科技有限公司 | Pin inserting and bending device on coil framework of electronic expansion valve |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6357974A (en) * | 1986-06-05 | 1988-03-12 | レクトロン プロダクツ インコ−ポレ−テツド | Electromagnetic type fluid control valve and size regulating method thereof |
| JPH1187133A (en) * | 1997-09-10 | 1999-03-30 | Kawasaki Heavy Ind Ltd | Solenoid |
| JP2002353026A (en) * | 2001-05-22 | 2002-12-06 | Toyoda Mach Works Ltd | Bobbin for solenoid, and manufacturing method of the solenoid |
| DE202005006010U1 (en) * | 2004-06-16 | 2005-06-30 | Hydac Electronic Gmbh | Valve actuating magnet especially for vehicle technology, has contact device with precision-fit parts in recess of retention device |
| CN101944676A (en) * | 2009-04-09 | 2011-01-12 | 伊顿公司 | The double-sided connector module |
| CN102606789A (en) * | 2011-01-24 | 2012-07-25 | 株式会社鹭宫制作所 | Coil and solenoid valve using the same |
| CN107061839A (en) * | 2016-02-10 | 2017-08-18 | 日本电产东测有限公司 | The solenoid of magnetic valve |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102016116981A1 (en) | 2016-09-09 | 2018-03-15 | Kendrion (Villingen) Gmbh | Electromagnetic adjusting device, in particular for camshaft adjustment |
-
2018
- 2018-12-18 JP JP2018236078A patent/JP7201222B2/en active Active
-
2019
- 2019-11-15 CN CN201980083876.8A patent/CN113196424B/en active Active
- 2019-11-15 WO PCT/JP2019/044920 patent/WO2020129500A1/en active Application Filing
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6357974A (en) * | 1986-06-05 | 1988-03-12 | レクトロン プロダクツ インコ−ポレ−テツド | Electromagnetic type fluid control valve and size regulating method thereof |
| JPH1187133A (en) * | 1997-09-10 | 1999-03-30 | Kawasaki Heavy Ind Ltd | Solenoid |
| JP2002353026A (en) * | 2001-05-22 | 2002-12-06 | Toyoda Mach Works Ltd | Bobbin for solenoid, and manufacturing method of the solenoid |
| DE202005006010U1 (en) * | 2004-06-16 | 2005-06-30 | Hydac Electronic Gmbh | Valve actuating magnet especially for vehicle technology, has contact device with precision-fit parts in recess of retention device |
| CN101944676A (en) * | 2009-04-09 | 2011-01-12 | 伊顿公司 | The double-sided connector module |
| CN102606789A (en) * | 2011-01-24 | 2012-07-25 | 株式会社鹭宫制作所 | Coil and solenoid valve using the same |
| CN107061839A (en) * | 2016-02-10 | 2017-08-18 | 日本电产东测有限公司 | The solenoid of magnetic valve |
Also Published As
| Publication number | Publication date |
|---|---|
| CN113196424B (en) | 2023-07-21 |
| JP7201222B2 (en) | 2023-01-10 |
| JP2020098850A (en) | 2020-06-25 |
| WO2020129500A1 (en) | 2020-06-25 |
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