CN113196424B - Molded coil and method of manufacturing the same - Google Patents
Molded coil and method of manufacturing the same Download PDFInfo
- Publication number
- CN113196424B CN113196424B CN201980083876.8A CN201980083876A CN113196424B CN 113196424 B CN113196424 B CN 113196424B CN 201980083876 A CN201980083876 A CN 201980083876A CN 113196424 B CN113196424 B CN 113196424B
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- pair
- bobbin
- joints
- wire
- coil
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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 is easy to manufacture without interference between a wire and a joint during a winding operation of the wire and can be corresponding to various connectors of an external device, and a manufacturing method thereof. The coil former (2) has: a tubular portion (21) around the periphery of which the wire (3) is wound, and a pair of flanges (22) provided at both ends of the tubular portion (21). A pair of relay terminals (4 a, 4 b) are provided on the coil bobbin (2) so as to avoid the winding portion of the wire (3) sandwiched by a pair of flanges (22), and lock the start and end of the wire (3). The joints (5 a, 5 b) are composed of a member different from the pair of relay terminals (4 a, 4 b), are disposed at positions opposed to the winding position of the wire (3), and are connected to the start end (31 a) or the end (31 b) of the wire (3). The support holes (26 a, 26 b) support the joints (5 a, 5 b) so as to be attachable to and detachable from the coil former (2).
Description
Technical Field
The present invention relates to a molded coil (hereinafter, referred to as a coil) and a method of manufacturing the same.
Background
The coil has: a bobbin having a tubular portion formed in a hollow tubular 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 to which the start and end of the wire are connected. Each connector is connected with a connector of an external device such as a power supply and a control device. The coil is excited by supplying electricity to the wire from an external device such as a power source or a control device through the joints.
Prior art literature
Patent literature
Patent document 1: japanese patent laid-open No. 2013-58578
In the coil, a wire is wound around the outer periphery of the cylindrical portion of the bobbin using an automatic winding machine. In this case, in order to prevent the plurality of or the single joint from interfering with the winding operation, it is necessary to dispose the wire so as to avoid the route from the automatic winding machine to the bobbin, 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, since each joint is a member for connecting the wire and the connector of the external device, the joint may have to be disposed on the outer periphery of the cylindrical portion of the bobbin, which may interfere with the winding operation, depending on the positional relationship between the connector and the coil. In such a case, in the conventional art, after the winding operation is completed, the plurality of contacts are bent in the connection direction of the connector.
However, bending the plurality of joints after the winding operation is completed increases the working time. Further, there are the following problems: the shape of the plurality of joints is limited to a bendable shape, and it is difficult to cope with the positions and directions of various connectors of the external device. In addition, when a plurality of joints are bent after the winding operation is completed, there are the following problems: deformation, so-called springback, occurs due to elasticity of the material of the joint, and it is difficult to ensure the bending position of the joint with high accuracy.
Further, since connection to various connectors (external connectors) included in an external device is required for the coils, it is necessary to manufacture various coils having different protruding directions and protruding dimensions of the contacts with respect to the bobbin, and there is a problem in that sharing of the 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 which is easy to manufacture and can cope with various connectors of an external device without interference between a wire and a plurality of joints during a wire rewinding operation, and a method for manufacturing the same.
Technical means for solving the technical problems
The injection molded coil of the present invention has the following features.
(1) And a bobbin having a cylindrical portion around which the 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 sandwiched between the pair of flanges, and having a start end and a terminal end of the wire engaged with the pair of relay terminals.
(3) And a pair of joints which are configured by a member different from the pair of relay terminals, are arranged at positions opposite to the winding positions of the wires, and are connected with the starting end and the terminal end of the wires.
(4) And a support portion that supports the joint so as to be attachable to and detachable from the coil 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 bending 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 a contact provided at a top end of the bent portion.
(2) The contact is formed by bending the tip of the bent portion in a direction parallel to the flange surface toward the outside of the coil.
(3) The coil bobbin has different lengths in the spool direction of the coil bobbin provided in the bent portions of the two joints, and a step portion is provided in at least one of the joints at a portion on the bent portion side of the bent portion or the contact, the step portion extending in the circumferential direction of the coil bobbin toward the other joint side facing the bent portion, and the contacts of the two joints are arranged in parallel with the spool direction of the coil bobbin on the outer periphery of the wire rod 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) The flange is provided with a support hole of a relay terminal in a direction along the support hole of the joint, and a base 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 a distal end side of the relay terminal; and a pair of locking portions provided at an inlet portion of the opening through the opening, wherein the joint includes a tab, a part of the tab is bendable, an end portion of the wire is locked to the pair of locking portions so as to span the opening, the tab provided at the joint is fitted into the opening, and the end portion of the wire which spans the opening is sandwiched between a surface of the joint and the tab.
The method for manufacturing an injection molded coil of the present invention includes the following steps.
(1) The start end of the wire is locked to one of the pair of intermediate terminals, and the wire is wound around the outer periphery of the cylindrical portion of the bobbin by a winding machine.
(2) The terminal end of the wire is locked to the other of the pair of relay terminals.
(3) A pair of tabs are secured to the flange of the bobbin or the pair of relay terminals.
(4) And connecting the start end or the end locked on the pair of relay terminals to the pair of connectors respectively.
(5) And injection molding a molding resin around the wire, the relay terminal, and the joint 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 at the time of winding the wire, the joint does not interfere with the winding operation. Further, since the connector is attached to the bobbin after winding, the position and the direction of various connectors included in the external device can be dealt with. In addition, by preparing a plurality of types of connectors and selecting an appropriate connector according to a connection method with an external device, it is possible to realize sharing of the coil bobbin and the relay terminal, and obtain various coils.
Drawings
Fig. 1 is a perspective view showing the internal structure of a coil according to a first embodiment.
Fig. 2 is a perspective view and a front view showing a state in which a connector housing is injection molded on the outer periphery of a coil of the first embodiment.
Fig. 3 is a perspective view showing a process of fixing a relay terminal to a bobbin in the coil of the first embodiment.
Fig. 4 is a perspective view showing a state in which a relay terminal is fixed to a bobbin in the coil of 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 joint to a bobbin in the coil of the first embodiment.
Fig. 7 is a perspective view showing a coil having a tab without a wire-holding tab.
Fig. 8 is a perspective view showing a coil including 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 joint 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 joint having contacts protruding in a direction parallel to the axis of the bobbin.
Detailed Description
[1 ] first embodiment ]
[1-1. Structure ]
The structure of the coil of the present embodiment will be described with reference to fig. 1 and 2. In the present embodiment, the direction in which the tab holder is provided on the bobbin of the coil is set as the upper direction, the opposite direction is set as the lower direction, and the direction in which the pair of wires connected to the injection-molded coil are arranged is set as the left-right direction, but the actual product is set in a suitably different direction depending on the application.
As shown in fig. 1, the coil has: a bobbin 2 made of a resin material such as ABS, polypropylene, PBT, or phenol, a wire 3 wound around the bobbin 2, a pair of relay terminals 4a and 4b supported by the bobbin 2, and a pair of contacts 5a and 5b.
The bobbin 2 has: a pair of flanges 22a, 22b provided to extend in the outer radial direction at both ends of the cylindrical portion 21, around which the wire rod is wound. A flat portion 24 extending in a mesa shape in the outer radial direction is provided in a part of one flange 22a, and support holes 25a and 25b for relay terminals 4a and 4b and support holes 26a and 26b for connectors 5a and 5b are provided in the flat portion 24. The support holes 25a and 25b extend 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 relatively large interval in the upper layer, and the support holes 26a and 26b for the connectors 5a and 5b are provided at a relatively small interval in the lower layer.
The relay terminals 4a and 4b are formed of a plate-like metal member, and include: a base 41, the base 41 being inserted into the support holes 25a, 25b from the outer circumferential direction (radially outer side of the bobbin 2); an opening 42, the opening 42 being cut out at the distal end side of the relay terminals 4a, 4 b; and a pair of locking portions 43, 44, the pair of locking portions 43, 44 being provided across the opening 42. The relay terminals 4a and 4b are engaged with the end portions of the wires 3, respectively, and the start end 31a of the wires 3 is engaged with one relay terminal 4a and the end 31b of the wires 3 is engaged with the other relay terminal 4b. In this case, the start end 31a and the end 31b of the wire rod 3 are stretched between the locking portions 43 and 44 of the corresponding relay terminals 4a and 4b so as to span 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: the coil bobbin 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 winding shaft direction of the coil bobbin 2 along the surface of the wire 3 wound around the coil 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 bending 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 in the two joints 5a and 5b in the spool direction of the bobbin 2 varies depending on the position of the contact 53 provided at the tip end thereof. The bent portion 52 of the contact 53 at the upper portion of the coil 5a is short, and the bent portion 52 of the contact 5b at the lower portion of the coil is long. Further, each of the joints 5a and 5b is provided with a step 54 between the bent portion 52 and the contact 53, and the step 54 extends along the circumferential direction of the bobbin 2 toward the other joint 5b side facing thereto. The contacts 53 of the two joints 5a and 5b are arranged parallel to the winding shaft direction of the bobbin 2 on the outer periphery of the wire 3 by the step 54. The cross-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 has a longitudinal shape having a longitudinal width longer than a cross-section having a plate thickness larger than the plate thickness. The bent portions 52 and the contacts 53 of the joints 5a and 5b are arranged so as to overlap with the winding portion (cylindrical portion 21) of the wire rod of the bobbin 2 when seen in the radial direction of the bobbin 2.
The joints 5a and 5b include a tab 55, and a part of the tab 55 can be bent. The tab 55 has a width that enters the inside of the opening 42 provided in the relay terminals 4a and 4b. The relay terminals 4a, 4b and the joints 5a, 5b are supported by the flange 22. The body surfaces of the joints 5a, 5b are joined by melting with the ends 31a, 31b of the wire rod 3 and the tabs 55 in a state where the ends 31a, 31b of the wire rod are sandwiched between the tabs 55 that enter the opening 42 and the body surfaces of the joints 5a, 5b. In addition, fusion is one type of resistance welding, and welding is performed by sandwiching a welding portion between upper and lower electrodes and applying electricity.
The outer periphery of the coil having the structure as shown in fig. 1 is covered with a molding resin by injection molding, and as shown in fig. 2 (a), a connector housing 6 fitted with 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 portion 61 wound around the base portion of the bobbin 2, the wire 3, the relay terminals 4a, 4b, and the joints 5a, 5 b; and a connector fitting portion 62 protruding 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 an external device-side connector is fitted inside the distal opening portion thereof. Contacts 53 of the contacts 5a and 5b are arranged inside the connector fitting portion 62. As shown in fig. 2 (b), the contacts 53 of the pair of contacts 5a and 5b are arranged vertically along the longitudinal direction, that is, along the winding shaft direction of the coil, on the wall surface where the contacts are in contact with the opening portion of the connector fitting portion 62 reaches the coil covering portion 61. Therefore, the contacts 53 of the pair of joints 5a, 5b overlap when viewed in the reel 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 coil bobbin 2
As shown in fig. 3, the relay terminals 4a, 4b are fixed to the bobbin 2 by inserting the base portions 41 of the relay terminals 4a, 4b into the support holes 25a, 25b provided in the flange 22.
(2) Winding the wire 3 around the bobbin 2
The start end 31a of the wire 3 pulled out from a supply reel of the wire of a winding machine (not shown) is wound around and locked to a pair of locking portions 43 and 44, and the pair of locking portions 43 and 44 are provided at one relay terminal 4a protruding to the outside of the bobbin 2. In this case, the starting end 31a stretches between the pair of locking portions 43, 44 so as to span the opening 42. In this state, the coil bobbin 2 is rotated, and the wire 3 is wound around the outer periphery of the cylindrical portion 21 in a plurality of layers. In this case, the relay terminals 4a and 4b are located on substantially the same plane as the flange 22, and are disposed so as to avoid the path of the wire wound from the automatic winding machine to the bobbin, and therefore, the wire 3 can be effectively wound around the cylindrical portion 21 of the bobbin 2, and the relay terminals 4a and 4b can be made to 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 rod 3 is completed, the terminal 31b of the wire rod 3 is wound and locked to a pair of locking portions 43 and 44 so as to span the opening 42, and the pair of locking portions 43 and 44 are provided at the other relay terminal 4b protruding to the outside of the bobbin 2. In this state, as shown in fig. 5, the start end 31a and the end 31b of the wire rod 3 are stretched between the pair of locking portions 43, 44 of the relay terminals 4a, 4b, respectively.
(4) Fixing the joints 5a, 5b to the coil former 2
As shown in fig. 6, the base portions 51 of the joints 5a, 5b are inserted into the support holes 26a, 26b provided in the flange 22, respectively, so that the joints 5a, 5b are fixed to the bobbin 2. At this time, as shown in fig. 1, the main body portions and the protruding pieces 55 of the joints 5a, 5b enter the inside of the opening 42 provided in the relay terminals 4a, 4b, and the start end 31a and the end 31b of the wire 3 stretched so as to span the opening 42 are sandwiched from above and below by the main body portions and the protruding pieces 55.
(5) Joining the wire 3 to the joints 5a, 5b
In the state shown in fig. 1, the tab 55 is tilted from the surface of the joint 5a, 5b. In this state, the tab 55, the leading end 31a or the trailing end 31b of the wire 3, and the main body portions of the joints 5a and 5b are pressed against each other by electrodes (not shown) of the fusion welding machine. After that, the leading end 31a or the trailing end 31b of the wire 3 is welded to the joints 5a, 5b.
(6) Injection molding a molding resin
After the joints 5a, 5b are joined to the ends 31a, 31b of the wire 3, the whole coil is placed in a mold for injection molding, and a molding resin is injection molded on the outer periphery of the coil. In this case, a plurality of split molds covering the entire coil are used as the molds. In the present embodiment, since the connector housing 6 having the cylindrical connector fitting portion 62 shown in fig. 2 (a) and (b) is molded by molding resin, it is not necessary to consider that an insert or the like is disposed 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 joints 5a and 5b are not fixed to the bobbin 2 during winding operation. The relay terminals 4a and 4b are also disposed at positions avoiding the path of the wire 3 wound around the bobbin 2, and therefore, the relay terminals 4a and 4b and the joints 5a and 5b do not interfere with the winding operation, and the winding operation can be easily and effectively performed. On the other hand, since the contacts 5a and 5b are fixed to the bobbin 2 after the winding operation is completed, the contacts of the contacts 5a and 5b can be arranged at positions where they are easily engaged with the connector of the external device.
(2) Since the joints 5a and 5b are fixed to the bobbin 2 after the winding of the wire 3, by preparing the joints 5a and 5b having various shapes in advance, it is possible to cope with external devices having various positions and directions of the connectors. In addition, the coil bobbin 2, the wire 3, the relay terminals 4a, 4b, and the like other than the joints 5a, 5b can be shared, and various coils can be manufactured without increasing the types of components and manufacturing facilities such as molds.
(3) The start end 31a and the end 31b of the wire rod 3 are stretched between a pair of locking portions 43 and 44 of the relay terminals 4a and 4b so as to span the opening 42. By sandwiching this portion between the joint body and the tab 55, the end portion of the wire 3 and the joints 5a and 5b can be accurately positioned. The end of the wire rod 3 is stretched linearly on the surface of the joint body, and the two can be brought into close contact with each other to overlap each other. As a result, the end portion of the wire rod 3 can be held with high accuracy by the upper and lower electrodes during fusion welding, and the both can be reliably joined.
[2 ] other embodiments ]
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 in various other modes, 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 and the equivalent scope of the invention described in the content to be protected by the invention, as are included in the scope and gist of the invention. The following is an example thereof.
(1) In the above embodiment, the joints 5a, 5b sandwich and melt the start end 31a and the end 31b of the wire 3 by the joint body and the tab 55, but the joints 5a, 5b may not have the tab 55. For example, as shown in fig. 7, the joints 5a and 5b without the tab 55 may be joined to the start end 31a and the end 31b of the wire 3 by melting, soldering, or the like. When the joints 5a and 5b having no tab 55 are used, the crimping operation of the tab 55 to the end of the wire 3 is not required, and this is advantageous when the wire 3 is joined by soldering or the like without using upper and lower sandwiching electrodes.
(2) In the above embodiment, the relay terminals 4a and 4b are members capable of stretching the leading end 31a or the terminating end 31b of the wire rod through 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 thereto. 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 starting end 31a or the terminating end 31b of the wire 3 may be pulled between the locking portion 43 and the edge of the flange 22, so that the wire 3 may be welded by sandwiching the end portion of the wire 3 by the protruding piece 55 provided in the joints 5a and 5b. This can reduce the size and simplify the shape of the relay terminals 4a and 4b.
(3) In the above embodiment, the two contacts 53 of the joints 5a, 5b are protruded to the outside of the bobbin 2 in a state of being longitudinally aligned, but the alignment direction and the protruding direction of the contacts 53 are not limited thereto. For example, as shown in fig. 9, as the two joints 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 direct bobbin 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, a member having the same length as the bending portion 52 may be used, and the bending portion 52 may be disposed along the outer peripheral surface of the wire rod 3 and the tip thereof may be provided with a contact 53. As described above, according to the present invention, by enabling the fitting 5a, 5b to be attached to and detached from the bobbin 2, various coils of a system for coping with connectors of external devices can be easily obtained.
(4) In the above embodiment, the support portions of the relay terminals 4a, 4b and the joints 5a, 5b are formed integrally with the flange 22a, but the present invention is not limited thereto. A joint holder having a support hole for the relay terminals 4a and 4b and a support hole for the joint, which is a different member from the bobbin 2, may be prepared, and after the joint holder is fixed to the bobbin 2, the joint holder may be made to support the relay terminals 4a and 4b and the joints 5a and 5b. Instead of inserting the relay terminals 4a and 4b into the flange 22, the base portions 41 of the relay terminals 4a and 4b may be fixed to a part of the flange 22 by insert molding during molding of the bobbin 2. Further, the relay terminals 4a and 4b and the support portions of the joints 5a and 5b may be provided to the relay terminals 4a and 4b without being provided to the bobbin 2. In short, the relay terminals 4a, 4b and the joints 5a, 5b are not limited as long as they are directly or indirectly supported by the coil bobbin 2.
(5) In the above embodiment, the relay terminals 4a, 4b are formed of a plate-shaped metal member, but the material of the relay terminals 4a, 4b is not limited thereto. The relay terminals 4a and 4b may be made of a material having no conductivity, such as a resin or ceramic. In addition, a part of the resin bobbin 2 may be protruded to function as the relay terminals 4a and 4b.
(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 relay terminals and joints fixed to the flange 22 is not limited thereto. For example, a center tap may be provided to the wire 3 wound around the coil bobbin 2, and a relay terminal and a joint connected to the center 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 terminal connected to the secondary winding may be fixed to the flange 22. For example, in the case of a coil in which a wire has a center tap and a coil in which a wire constituting a secondary winding is wound, the center tap portion and the end of the secondary winding can be connected to an external device by using the same relay terminal and the same terminal as those of the first embodiment.
(7) In the above embodiment, the start end 31a and the end 31b of the wire rod 3 fixed to the relay terminals 4a and 4b are joined to the protruding piece 55 by melting, but may be joined by a connection by soldering, a welding by laser welding, or caulking.
In the above embodiment, the connector fitting portion 62 extending in the radial direction of the coil bobbin 2 has been described as an example, but it is needless to say that the connector fitting portion may extend in the winding shaft direction of the coil bobbin 2. In this case, the contact portions of the contacts 5a, 5b on the inner side of 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 with 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 joint 5b are arranged so as to overlap the cylindrical portion 21 of the bobbin 2. In addition, when the bent portion 52 that does not form the joint 5a is used, and the joint 5a having a contact formed on the tip end side extending in the radial direction from the joint base 51, the contact of the joint 5a is also arranged so as not to overlap the cylindrical portion 21 of the bobbin 2 when seen in the radial direction of the bobbin 2.
In the above embodiment, the injection molded coil was described, but the present invention is of course applicable to a mold coil.
Symbol description
2 coil rack
3.wire rod
4a, 4b relay terminal
5a, 5b. Linker
6 connector housing
21 cylindrical portion
22. Flange
24 flat part
25a, 25b relay terminal support hole
26a, 26b. Support holes for the joints
31 a. Wire starting end
31b & gtwire termination
41. Relay terminal base
42 opening part
43. 44 locking part
51. Base of linker
52 bending part
53 contact
54 steps
55. Tabs
Claims (5)
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 which are provided in the bobbin so as to avoid a winding portion of the wire rod sandwiched by the pair of flanges when seen in a radial direction of the bobbin, and are connected to a start end and a terminal end of the wire rod, respectively; and
a pair of joints which are formed of a member different from the pair of relay terminals and are electrically connected to the start and end of the wire rod, respectively,
at least one of the pair of joints is arranged to overlap the cylindrical portion when viewed in a radial direction of the bobbin,
the joint has: a contact portion; a base portion supported by the coil bobbin; and a bending portion disposed between the contact portion and the base portion,
the lengths of the bending portions of the pair of joints in the spool direction of the bobbin are different,
one of the pair of contacts is provided with a step portion extending along the circumferential direction of the bobbin between the bending portion and the contact portion,
the other joint of the pair of joints is provided with a step portion extending along the circumferential direction of the bobbin between the base portion and the bending portion,
the contact portions of the pair of joints overlap when viewed from the reel direction,
the pair of relay terminals each include: an opening formed by cutting a distal end side of the relay terminal; and a pair of locking parts provided at an inlet portion of the opening through the opening,
the pair of connectors each have a tab, a portion of which can be bent,
the end portions of the wire rod are locked to the pair of locking portions so as to span the opening portion,
a tab provided to the connector is fitted into the opening,
the end of the wire across the opening is clamped by the surface of the tab and the tab.
2. The molded coil of claim 1, wherein,
also has a connector fitting portion, which is provided with a contact portion of the connector on the inner side,
the contact portion of the joint extends in a radial direction of the bobbin.
3. A molded coil as in claim 2 wherein,
the contact portion is disposed inside the connector fitting portion,
the bending portion extends in the spool direction.
4. A molded coil as claimed in any one of claims 1 to 3,
the flange is provided with a support hole into which the pair of relay terminals and the base portions of the pair of joints are inserted from the outer circumferential direction, and supports the pair of relay terminals and the base portions of the pair of joints.
5. A method of manufacturing a molded coil, comprising the steps of:
the method comprises the steps of clamping the initial end of a wire rod on one of a pair of intermediate terminals, and winding the wire rod on the outer periphery of a cylindrical part of a coil frame through a winding machine;
locking the end of the wire rod to the other of the pair of relay terminals;
fixing a pair of joints to a flange of the bobbin or the pair of relay terminals;
the starting end and the terminating end of the wire rod clamped to the pair of relay terminals are respectively connected to the pair of joints by sandwiching the starting end and the terminating end of the wire rod between the pair of joints; and
and molding an outer periphery of the wire rod, the relay terminal, and the joint wound 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 CN113196424A (en) | 2021-07-30 |
| CN113196424B true CN113196424B (en) | 2023-07-21 |
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ID=71100445
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 |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4728916A (en) * | 1986-06-05 | 1988-03-01 | Lectron Products, Inc. | Solenoid operated fluid control valve |
| JP3017702B2 (en) * | 1997-09-10 | 2000-03-13 | 川崎重工業株式会社 | solenoid |
| JP3907967B2 (en) * | 2001-05-22 | 2007-04-18 | 株式会社ジェイテクト | Bobbin for solenoid and method for manufacturing 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 |
| US7902954B2 (en) * | 2009-04-09 | 2011-03-08 | Eaton Corporation | Dual sided connector block |
| JP2012156188A (en) * | 2011-01-24 | 2012-08-16 | Saginomiya Seisakusho Inc | Coil and solenoid valve using coil |
| JP2017141885A (en) * | 2016-02-10 | 2017-08-17 | 日本電産トーソク株式会社 | Solenoid of electromagnetic valve |
| 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 WO PCT/JP2019/044920 patent/WO2020129500A1/en active Application Filing
- 2019-11-15 CN CN201980083876.8A patent/CN113196424B/en active Active
Also Published As
| Publication number | Publication date |
|---|---|
| JP7201222B2 (en) | 2023-01-10 |
| JP2020098850A (en) | 2020-06-25 |
| WO2020129500A1 (en) | 2020-06-25 |
| CN113196424A (en) | 2021-07-30 |
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