EP0811995B1 - Magnet coil and method for manufacturing the same - Google Patents

Description

The invention relates to a magnetic coil and a method for their manufacture.

• einem Spulenkörper aus gewickeltem Spulendraht, dessen beide Enden nach außen geführt sind,
• zwei Kontaktstiften, die jeweils mit einem Ende des Spulendrahts umwickelt sind,
• zwei mit den Kontaktstiften koppelbare Anschlußzungen sowie
• einer Kunststoffummantelung.

Magnetic coils consisting of are known from practice

• a coil body made of wound coil wire, the two ends of which are led outwards,
• two contact pins, each wrapped with one end of the coil wire,
• two connecting tongues that can be coupled with the contact pins and
• a plastic jacket.

The establishment of the electrical connection between the contact pins and the one that is usually insulated with varnish Coil wire is made by suitable mechanical or electrical Energy exposure causes. From DE-A-43 13 608 becomes the contact pin and the coil wire by coupling vibrations in the ultrasonic range excited by the friction between the pre-tensioned coil wire and individual, the wound coil wire touching areas of the Contact pins are made. The connecting tongues are usually welded to the contact pins. The resulting relatively rigid connection leads to the mass production of such magnetic coils to a relatively high failure rate due to demolition of the usually very thin coil wire, which may only 0.04 mm is thick. This demolition is caused by the inevitable Relative movements of the connecting tongues to the coil body when inserting and processing in the plastic coating form.

The invention is therefore based on the object, the magnetic coil and the process for their manufacture in To improve in terms of a lower failure rate while simplifying manufacturing.

This object is achieved by the features of claims 1 and 6 solved.

Further refinements of the invention are the subject of subclaims.

By connecting the tabs with the contact pins in such a way be coupled that on the one hand an electrical connection and on the other hand a displaceability of the connecting tongue opposite the contact pin in its longitudinal direction is guaranteed, there is a relative flexible connection between contact pin and connecting tongues. This connection catches the inevitable relative movements the connecting tongues with respect to the On the bobbin without breaking the coil wire comes on the contact pin.

Allowed in a particularly advantageous embodiment the connection between the connecting tongue and the contact pin not just a relative shift in the longitudinal direction of the Contact pin, but also in addition to this Direction. This creates an additional degree of freedom provided an even more flexible connection between the tongue and the contact pin or coil body guaranteed.

According to the invention, the coil wire, which is usually is covered with an insulating varnish layer Dip soldering contacted with the contact pins. To becomes the area of the contact pins that connects to the coil wire is wrapped, immersed in a solder bath, the The temperature is so high that the insulating varnish dissolves and an electrical connection through the solder between contact pin and coil wire results.

Further advantages and refinements of the invention will be based on the following description of an embodiment and the drawing explained in more detail.

Fig.1

eine Schnittdarstellung einer erfindungsgemäßen Magnetspule,

Fig.2

eine Schnittdarstellung längs der Linie II-II der Fig.1,

Fig.3

eine vergrößerte Detailansicht im Bereich der Kontaktierung zwischen Anschlußzunge und Kontaktstift,

Fig.4

eine Schnittdarstellung an der Linie IV der Fig.1;

Fig.5

eine Aufsicht auf einen Anschlußzungenträger sowie

Fig.6

eine Schnittdarstellung eines zweiten Ausführungsbeispieles.

Show in the drawing

Fig. 1

2 shows a sectional illustration of a magnetic coil according to the invention,

Fig. 2

2 shows a sectional illustration along the line II-II of FIG. 1,

Fig. 3

an enlarged detail view in the area of contact between the connecting tongue and contact pin,

Fig. 4

a sectional view on the line IV of Figure 1;

Fig. 5

a supervision of a tongue carrier as well

Fig. 6

a sectional view of a second embodiment.

The magnetic coil shown in Fig.1 consists essentially from a bobbin 1 with wound Coil wire 2, a magnetic core 3 and an armature 4.

Furthermore, two contact pins 5, 6 are provided to the one end of the coil wire 2 is wound in each case. These contact pins 5, 6 are at one end in the bobbin 1 and are at their other ends coupled with a tongue 7, 8.

The two connecting tongues 7, 8 are on a tongue carrier 9 arranged on a magnetic yoke 10 the solenoid is held.

The connecting tongues 7, 8 have for coupling with the Contact pins 5, 6 clamping means on the one hand electrical connection and on the other hand a displaceability the connecting tabs opposite the contact pins ensure in the longitudinal direction. In the in the Figures shown preferred embodiment these clamping means also allow additional relative displaceability of the connecting tongues compared to the Contact pins transverse to the longitudinal direction of the contact pins.

These clamping means are in the illustrated embodiment as slots 11, 12 in the connecting tongues 7, 8 formed, the contact pins 5, 6 between the the flanks 11a, 11b delimiting the slot 11, 12 or 12a, 12b are held. The two flanks 11a, 11b and 12a, 12b are slightly bent, whereby the resulting slot width is slightly less than that Width of the contact pins, preferably square in cross section. Have the two flanks of a slot resilient effect, so that when plugging on a contact pin for a secure electrical connection is guaranteed. Even after plugging in there is one Movability of the connecting tongues in the longitudinal direction of the contact pins possible (double arrow 13).

As can be seen in particular from FIG. 4, this is made possible this type of coupling also a relative mobility across the length of the pins, like that through the double arrow 14 is indicated. One finds Displacement of the contact pins in the direction of the slots 11, 12 instead.

The two connecting tongues 7, 8 are on the in Fig.5 Connection carrier 9 shown arranged, this connection carrier 9 has two snap hooks 15, 16 which can be coupled to the magnetic yoke 10. Doing so at the same time an electrical contact between one Ground terminal tongue 17 and the magnet yoke 10 are produced. While the individual connection tabs made of electrical conductive material, in particular metal, the connection carrier 9 is made of non-conductive material, preferably made of plastic.

6 shows a second exemplary embodiment according to the invention shown, which differs from the previously described Variant differs only in that the Connection tongues 7, 8 are not arranged on a connection carrier are.

The following are the individual process steps in the manufacture of the magnetic coils according to the invention explained in more detail:

In a first step, the two ends of the coil wire 2 automated to one of each two contact pins 5, 6 wound. Subsequently are the contact pins to relieve the wound Coil wire pressed deeper into the coil body 1.

After the coil wire is usually insulated Lacquer layer is covered in this No electrical connection yet between coil wire and contact pin. This will now manufactured according to the invention that with end of the contact pin wound around the coil wire a solder bath is immersed which has a temperature of has more than 350 ° C, preferably more than 450 ° C. At this temperature, the insulation layer of the Coil wire 2 dissolved and the solder provides an electrical Connection between the coil wire and the Contact pin.

In a next step, the connecting tabs 7, 8 plugged onto the contact pins 5, 6. In the embodiment described in Figures 1 to 5 the connection tongues are held on the connection carrier, so that the attachment process for both connecting tongues takes place simultaneously. The bracket of the connection carrier is ensured via the snap hooks 15, 16.

In a last step, the solenoid is in a suitable shape encased in plastic.

The special type of coupling of contact pins 5, 6 and connecting tongues 7, 8 results in a relatively flexible Connection. This can make the inevitable relative movements between tabs and coil without a relative movement between the contact pin and coil is done. These inevitable relative movements occur in particular in the last process step, namely with the plastic casing 18, on. The extremely thin coil wire, which may only one Having a diameter of 0.04 mm is therefore essential more reliable before tearing off at this stage of the process protected.

In addition, the type of connection of coil wire 2 and contact pins 5, 6 on the one hand and the clamping means of the connecting tongues represent the manufacturing process simplify itself per se. So in particular when contacting the connecting tongues on one Welding process can be dispensed with. So they can be Solenoids according to the invention not only with less Effort but also with a lower reject rate produce.

Magnetic coils of this type are used, for example, in connection used with solenoid valve coils with which Valves can be controlled by fluid lines.

Claims (7)

1. Magnetic coil consisting of

   a coil body (1) with wound coil wire (2), the two ends of which are led outwards,

   two contact pins (5, 6) which are each wound round with one end of the coil wire (2),

   two connection tabs (7, 8) which can be coupled to the contact pins (5, 6) and

   a plastic sheath (18),

   characterised in that

   the coil wire (2) wound onto the contact pins (5, 6) is dip soldered and

   the connection tabs (7, 8) for coupling to the contact pins (5, 6) have clamping means which on the one hand ensure an electrical connection and on the other hand ensure a movability of the connection tab relative to the contact pin the longitudinal direction thereof.
2. Magnetic coil as claimed in Claim 1, characterised in that the clamping means also permit a displacement of the connection tabs (7, 8) relative to the contact pins (5, 6) transversely with respect to the longitudinal direction of the contact pins.
3. Magnetic coil as claimed in Claim 1, characterised in that the clamping means are formed by a slot (11, 12) in the connection tab (7, 8), the contact pin (5, 6) being held between the flanks (11a, 11b; 12a, 12b) which delimit the slot.
4. Magnetic coil as claimed in Claim 3, characterised in that the flanks (11a, 11b; 12a, 12b) of the slot (11, 12) are bent up.
5. Magnetic coil as claimed in Claim 1, characterised in that the connection tabs (7, 8) are provided on a connection tab support (9) which is retained on a magnet yoke (10) of the magnetic coil by means of snap hooks (15, 16).
6. Method of manufacturing a magnetic coil, characterised by the combination of the following method steps:

   the ends of a coil wire (2) of a coil body (1) are each wound automatically onto a contact pin (5, 6),

   in order to relieve the load on the wound coil wire (2) the contact pins (5, 6) are pressed deeper into the coil body (1),

   the coil wire (2) which is wound on is dip soldered,

   connection tabs (7, 8) are pushed onto the contact pins (5, 6) in such a way that on the one hand an electrical connection is ensured between the contact pin and the connection tab and on the other hand a relative movability of the connection tab (7, 8) in the longitudinal direction of the contact pin (5, 6) is ensured, and

   the magnetic coil is sheathed with plastic.
7. Method as claimed in Claim 6, characterised in that the coil wire (2) which is wound on is dip soldered in a solder bath with a temperature of more than 350°C, preferably more than 450°C.

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