JP2003115407A - Relay coil and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a new relay coil which is improved in strength of bonding between a terminal and a covered conductor and superior in heat resistance and vibration resistance, and to provide its manufacturing method. SOLUTION: A covered conductor 14 is composed of a core conductor 141 and a covering layer 142 covering the core conductor 141. The covered conductor 14 is wound on a bobbin 11, a terminal 13 is provided to each end 110 of the bobbin 11, and the covered conductor 14 is tied to the tip 130 of the terminal 13. The tip 130 of the terminal 13 is joined to the tip 140 of the covered conductor 14 through the intermediary of a molten ball 91 formed of silver solder 9 or lead-free solder for the formation of a relay coil.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a technical field of a relay coil used for load control, signal switching, etc. and a method of manufacturing the relay coil.

[0002]

2. Description of the Related Art Conventionally, in this type of relay coil, as shown in FIG. 9, terminal portions 13 are provided at both end portions 110 of a bobbin 11 on which a coated conductor 14 is wound, and a tip 13 of the terminal portion 13 is provided.
This is a structure in which the coated conductive wire 14 is twisted to 0. Further, the coated conductor wire 14 has a structure in which the core wire 141 is coated with a coating layer 142.

The terminal portion 13 of the relay coil 1 and the terminal portion 13
The tip 130 of the terminal portion 13 and the tip 14 of the covered conductor 14 are joined to the tip 130 of the covered conductor 14 which is twisted.
Solder 1 which was melted after applying flux to the joint with 0
It was dipped in a solder bath containing 0 and joined. For example, the one described in Japanese Patent Application Laid-Open No. 8-215836 is known.

However, the terminal portion 13 and the covered conductor 14
Since it is immersed in a high-temperature solder bath, the tip 140 of the coated conductive wire 14 is melted not only in the coating layer 142 but also in the core wire 141 during bonding. As a result, FIG.
As shown in FIG. 5, the tip 140 of the coated conductor wire 14 is thinned and is directly joined to the terminal portion 13 via the solder 10. Therefore, there is a problem that the joint strength between the terminal portion 13 and the covered conductor wire 14 is weak.

Further, since the above-mentioned joining is heat-treated in a high temperature solder bath, an oxide film 144 is formed between the melted solder 10 and the covered conductive wire 14 as shown in FIG.
The oxide film 144 serves as a protective wall, and the solder 10 and the coated conductor 1
4 is not physically joined. Therefore, for example, when the relay coil 1 is attached to a device that vibrates, there is a problem that the covered conductor wire 14 in the soldered portion is easily removed.

When the relay coil 1 is used for load control or the like in the engine room, the melting point of the solder is about 330 degrees, which is relatively low. There is also a problem that the coated conductor wire 14 at the attached portion is easily removed.

Further, at the moment when the flux applied to the joint is immersed in the high temperature solder bath, the solder becomes small particles on the surface of the solder bath and scatters in the air and adheres to the coil surface or bobbin surface as solder particles. However, as the relay coil becomes dirty, solder particles enter between the contacts inside the relay coil,
There is a problem that it may cause poor continuity.

[0008]

SUMMARY OF THE INVENTION The present invention has been made in response to such a situation, and a novel relay coil having an improved joint strength between a terminal portion and a coated conductor wire and excellent heat resistance and vibration resistance, and It is an object to provide a manufacturing method thereof.

Another object of the present invention is to provide a relay coil and a method of manufacturing the relay coil, in which dirt does not adhere to the relay coil even when the terminal portion and the covered conductor are joined together, thereby preventing defective conduction.

[0010]

[Means for Solving the Problems] In consideration of the above problems,
The relay coil and the manufacturing method thereof according to the present invention employ the following means.

That is, according to the first aspect of the present invention, in a relay coil in which a terminal portion is provided at an end of a bobbin wound with a coated wire, and the coated wire is twisted at a tip of the terminal portion, a core wire is provided from a tip of the coated wire. Is exposed, and the exposed portion of the core wire and the tip of the terminal portion are joined via silver solder.

According to this means, the terminal portion and the covered conductor are firmly joined. Further, the coating layer of the coated conductive wire is burned.

According to another aspect of the present invention, in a relay coil in which a terminal portion is provided at an end portion of a bobbin wound with a coated conductor wire, and the coated conductor wire is twisted at a tip of the terminal portion, a core wire is exposed from a tip end of the coated conductor wire. The exposed portion of the core wire and the tip of the terminal portion are joined together through lead-free solder.

With this means, the terminal portion and the covered conductor wire are firmly joined together. The coating layer of the coated conductor is burned in a relatively short time. It also contributes to environmental protection.

According to a third aspect of the present invention, in the relay coil according to the first or second aspect, the exposed portion of the core wire and the tip of the terminal portion are formed into a molten ball by silver solder or lead-free solder.

According to this means, the exposed portion of the core wire and the tip of the terminal portion are covered with silver solder or lead-free solder and joined. Conduction failure between the contacts inside the relay coil is avoided.

According to a fourth aspect of the present invention, there is provided the method of manufacturing a relay coil according to any one of the first to third aspects, wherein the tip of the terminal portion is installed downward, and the fine flame-shaped gas flame is directed toward the tip of the terminal portion. The coating layer at the tip of the coated wire is burned by a gas flame to expose the core wire, and at the same time the burned coating layer is blown away, and then the tip of the terminal part and the exposed portion of the core wire and the silver braze or lead-free solder are heated. It is characterized in that the tip of the terminal portion and the exposed portion of the core wire are covered with a molten sphere with molten silver solder or lead-free solder.

With this means, the tip of the terminal portion and the tip of the covered conductor are instantly heated. The burned coating layer is not attached to the relay coil, and the relay coil is prevented from becoming dirty.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment (1) of a relay coil of the present invention will be described below with reference to the drawings. 1 is an enlarged perspective view showing a relay coil of the embodiment (1), FIG. 2 is an enlarged view of a terminal portion of the relay coil of the embodiment (1), and FIG. 3 is a relay coil of the embodiment (1). FIG. 4 is a longitudinal sectional view of the terminal portion of the relay coil of the embodiment (1), and FIG. 5 is brazing for brazing the terminal portion of the relay coil of the embodiment (1). FIGS. 6 and 7 are enlarged perspective views showing the operation of the main part of the brazing device at the terminal portion of the relay coil of the embodiment (1), and FIG. 8 of the relay coil of the embodiment (1). It is a perspective view of completion of brazing in the terminal portion. It should be noted that the same symbols are given to those having the same meaning as in the conventional example, and detailed description thereof is omitted.

As shown in FIG. 1, the relay coil 1 is provided with terminal portions 13 at both end portions 110 of a bobbin 11 on which a coated conductor wire 14 having a core wire 141 coated with a coating layer 142 is wound. This is a configuration in which the covered conductive wire 14 is entangled at the tip 130, which is similar to the conventional example.

Further, the tip 130 of the terminal portion 13 and the tip 140 of the covered conductor 14 are generally configured by joining and forming a molten ball 91 with the silver braze 9.

Further, at the tip 130 of the terminal portion 13, a collecting portion 143 in which the covered conductor wires 14 are bundled after the tip 140 of the covered conductor wire 14 is wound around the peripheral surface 132 of the tip 130 of the terminal portion 13 to form a collecting portion 143. The peripheral surface 132 of the tip end 130 of the terminal portion 13 is joined to the peripheral surface 132 via the silver solder 9 to form a schematic structure.

The terminal portion 13 is a conductive member. The terminal portion 13 is made of, for example, a copper alloy, iron plating, or the like, is a terminal having a diameter of about 0.3 to 0.8 mm, and has, for example, a columnar L-shape. The terminal portion 13 is a bobbin end portion 110.
Is installed in the receiving portion 111 provided on the coil 12 side. Further, the tip end 130 of the terminal portion 13 is projected upward from the receiving portion 111, and the terminal end 133 of the terminal portion 13 is penetrated through both end portions 110 of the bobbin and is projected outward.

The terminal portion 13 extends along the peripheral surface 132 of the terminal portion 13 from the coil 12 and wraps the covered conductive wire 14 wound a plurality of times up to the tip 130 of the terminal portion 13.

The tip 130 of the terminal portion 13 has a tip surface 131.
Have.

The coated conductor 14 is a coated conductor having a small diameter,
For example, it is composed of an enamel wire or the like having a wire diameter of about 0.03 to 0.15 mm. Further, the coated conductor wire 14 has a structure in which the core wire 141 is coated with a coating layer 142.

The core wire 141 is a conductive wire made of copper, aluminum or the like. For example, the core 141 made of copper has a melting point of about 1000 degrees.

The coating layer 142 has a thinness of about 0.025-0.
It is an insulating film made of an insulating paint such as about 03 natural resin or synthetic resin. For example, the coating layer made of epoxy resin or polyurethane resin is easily melted at a temperature at which the solder is melted, and has a low heat resistance temperature.

The tip 140 of the coated conductive wire 14 is covered with the coating layer 14
Only the wire 2 is burnt and the core wire 141 is exposed. Therefore, the tip 140 of the coated conductive wire 14 is
It consists of only 41.

The gathering portion 143 in which the coated conductors 14 are bundled has a plurality of windings on the tip 130 of the terminal portion 13, and at least two windings of the coated conductors 14 are bundled on the peripheral surface 132 of the terminal portion 13.
The gathering portion 143 that bundles the coated conductive wires 14 is composed of only the core wire 141, like the tip portion 140 of the coated conductive wires 14.

The silver solder 9 is composed of a silver-copper alloy-based silver solder mixed with a flux having an antioxidant effect. The silver solder 9 forms a molten sphere 91.

The molten ball 91 is formed by the gathering portion 14 of the coated conductive wire 14.
3 as the starting point, the tip 130 of the terminal portion 13 and the covered conductor 14
Is formed by covering the tip 140 of the.

The inside of the silver solder 9 in which the molten balls 91 are formed will be described below.

FIG. 3 is a cross-sectional view of the tip surface 131 of the terminal portion 13. The tip 130 of the terminal portion 13 has a tip surface 1
It is joined to the molten silver solder 9 along the periphery of 31. Tip surface 1 of terminal portion 13 accompanying molten silver solder 9
There is no corrosion such as an oxide film on the periphery of 31. Further, the peripheral edge of the terminal portion 13 and the melted silver braze 9 are directly joined without forming a gap. Therefore, the tip end surface 131 and the peripheral surface 132 of the tip end 130 of the terminal portion 13 are firmly joined to the melted silver solder 9.

The tip 140 of the coated conductive wire 14 has a core wire 141.
The molten silver braze 9 is joined along the periphery of the.
The coating layer 142 is removed from the peripheral edge of the core wire 141.
Further, there is no corrosion due to the oxide film or the like of the core wire 141 due to the melted silver braze 9, and no gap is formed. Coated conductor 1
The tip 140 of No. 4 is directly joined with the molten silver braze 9.

Further, as shown in FIG. 4, the core wire 141 at the tip 140 of the coated conductive wire 14 is coated toward the center of the silver solder 9 forming the molten sphere 91 and without protruding from the molten sphere 91. The tip 140 of the coated conductive wire 14 is joined to the molten silver solder 9 without any gap.

Members of the tip 130 of the terminal portion 13 and the tip 140 of the covered conductor 14 are physically joined to each other through the molten silver brazing material 9. Silver solder 9 has a melting point temperature of about 700.
The degree is relatively high. The silver solder 9 is excellent in firmly joining members that require vibration resistance / heat resistance and high electrical conductivity. Therefore, the terminal portion 13 of the relay coil 1
It is very effective for joining. It is also applicable to minute in-vehicle relay coils.

The peripheral surface 132 of the terminal portion 13 which comes into contact with the collecting portion 143 of the coated conductive wire 14 is joined via the melted silver brazing material 9. The core wire 141 is exposed in the collecting portion 143 of the coated conductor wire 14. Therefore, the coated conductors 14 in the collecting portion 143 are entangled with each other through the silver solder 9 and are firmly joined to the peripheral surface 132 of the terminal portion 13.

In the coated conductive wire 14 near the gathering portion 143 of the coated conductive wire 14, the core wire 141 is exposed only in the portion in contact with the peripheral surface 132 of the terminal portion 13, and the molten silver braze 9 is formed.
It is joined to the peripheral surface 132 of the terminal portion 13 via.

Next, a manufacturing method for burning the coating layer 142 at the tip 140 of the coated conductor 14 and joining the tip 130 of the terminal portion 13 and the tip 140 of the coated conductor 14 will be described.

First, a brazing apparatus for achieving the above manufacturing method will be described.

As shown in FIG. 5, the brazing apparatus includes a holder 2 for installing the tip 130 of the terminal portion 13 of the relay coil 1 downward, a torch 3 for ejecting a fine flame-shaped gas flame F, and a hydrogen system. Gas supply system 4 for generating and supplying the gas to the torch 3, a moving mechanism 5 for adjusting the positional relationship between the tip 130 of the terminal portion 13 and the tip portion of the torch 3, the tip 130 of the terminal portion 13 and the tip of the torch 3. A camera 6 for measuring the position of the part, a brazing filler metal supply mechanism 7 for linearly advancing and retracting the silver brazing material 9 wound around a roller R, and a gas flame F of the torch 3 to shield the surroundings. It is composed of a blocking wall 8 and a controller (not shown).

The gas supply system 4 generates a hydrogen-based gas and supplies it to the torch 3. Hydrogen-oxygen gas generator 41 for generating hydrogen-oxygen gas, mixer 42 for mixing methyl alcohol vapor with hydrogen and oxygen generated by hydrogen-oxygen gas generator 41, torch 3, hydrogen-oxygen gas generator It is composed of a device 41 and a tube 43 connecting the mixing device 42.

The blocking wall 8 is composed of a ceramic cup 81 which is divided into two parts, a servo motor which drives the cup 81 to open and close, and the like. The cup 81 includes a ceiling wall 81 a that blocks the bobbin 11 of the relay coil 1 and the covered conductor 14, and a curved side wall 81 b that prevents uneven heating of the tip 130 of the terminal portion 13.

The brazing device is controlled by a controller composed of a sequencer that integrates various types.

Next, a method of manufacturing the relay coil 1 will be described based on the brazing device. Specifically, a method of joining the tip end 130 of the terminal portion 13 and the tip end 140 of the covered conductor 14 will be described.

The tip 130 of the terminal portion 13 of the relay coil 1
Is installed downward by the holder 2. As shown in FIG. 6, the tip end 130 of the terminal portion 13 has a circular hole 8 in the blocking wall 8.
2 is inserted downward, the torch 3 to the gas supply system 4
The gas flame F generated by is ejected.

First, the ejected gas flame F is connected to the terminal portion 13
The tip 130 is heated with heat. At the same time, the tip 140 of the coated conductive wire 14 and the collecting portion 143 are also heated. At this time, as shown in FIG. 6, since the temperature is preset to such a level that the silver brazing material 9 is melted, the tip 140 of the coated conductive wire 14 is set.
Then, the coating layer 142 in the collecting portion 143 is instantly burned. The burned coating layer 142 is blown off by the gas pressure of the gas flame F, and therefore does not adhere to the tip 130 of the terminal portion 13. Adhesion of coating burned dust to the relay coil 1 is reliably prevented.

The tip 140 of the coated conductor 14 and the collecting portion 143
Only the core wire 141 is exposed. Gas flame F is terminal 1
3 tip 130, covered conductor 14 tip 140, and assembly portion 1
The core wire 141 of 43 is instantly heated.

Further, since the positions of the tip 130 of the terminal portion 13 of the relay coil 1 and the tip of the torch 3 are fixed, and the portion other than the tip 130 of the terminal portion 13 is blocked by the blocking wall 8, the terminal portion 13 is formed. The tip 130 of the is heated pinpoint. Therefore, the collecting portion 143 of the coated conductor 14
It is surely heated starting from the heating point. The portions other than the tip 130 of the terminal portion 13 are not unnecessarily heated, and peeling, burning, melting, and the like of the coating layer of the portion other than the tip 140 and the collecting portion 143 of the coated conductive wire 14 are prevented.

Subsequently, the brazing material supply mechanism 7 linearly supplies the silver solder 9 to the tip 130 of the terminal portion 13 at a pinpoint. The approaching silver solder 9 has a tip 130 of the terminal portion 13.
And the tip 140 of the coated conductor wire 14 with the core wire 141 exposed.
Is heated with. Since the tip 130 of the terminal portion 13 and the tip 140 of the coated conductor 14 are heated by the gas flame F in advance, the silver braze 9 instantly reaches the melting point and is melted. Further, since the silver braze 9 is linearly supplied, the silver braze 9 is melted starting from the collecting portion 143 of the coated conductive wire 14. It should be noted that it is also applicable to a minute in-vehicle relay coil.

The molten silver solder 9 is gravitationally charged to the terminal portion 13.
Along the tip 130 of the. The silver solder 9 that has flowed down forms a molten ball 91 at the tip 130 of the terminal portion 13 due to surface tension. Further, since the silver braze 9 contains a flux having an antioxidant action in advance, the tip 140 of the coated conductive wire 14 and the tip 130 of the terminal portion 13 where the core wire 141 is exposed are prevented from being oxidized and wet. It is also useful for the formation of molten spheres of silver wax with the sexual effect. Therefore, the terminal portion 1
The tip 130 of No. 3 and the tip 140 of the coated conductive wire 14 are surely joined and brazed while being covered by the molten ball 91.
That is, as shown in FIG.
The silver solder 9 is melted in a pinpoint manner from 43, and the terminal portion 1
3, the peripheral surface 132, the tip surface 131, and the tip 1 of the coated conductor 14.
40 is reliably joined.

The formation of the molten balls 91 is photographed by the camera 6. This image information is transmitted to the controller, and the supply time (supply length) of the silver solder 9 is adjusted.

As described above, the tip 130 of the terminal portion 13 of the relay coil 1 and the tip 140 of the covered conductor 14 are securely joined by heating to the pinpoint using the brazing device.

Further, the gas flame injection surely burns the coating layer at the tip of the coated wire, and the burned coating layer is not attached to the relay coil.

Next, the embodiment (2) of the present invention will be described.

In the embodiment (2), the embodiment (1)
In the case of joining the tip of the terminal portion and the tip of the covered conductive wire by using lead-free solder instead of the silver solder 9 used in
The same apparatus and manufacturing method as those in the embodiment (1) are used.

That is, the tip of the terminal portion and the tip of the covered conductor are joined together via the lead-free solder in which molten balls are formed by gas flame injection.

The lead-free solder is composed of a tin-copper alloy-based lead-free solder, is preliminarily mixed with a flux, and has a wire shape with a diameter of about 0.5 mm, for example. The melting point of lead-free solder is about 300 degrees.

Since the lead-free solder is lower than the melting point temperature of the silver solder 9 used in the embodiment (1), the distance between the torch and the tip of the terminal portion is set beforehand when the gas flame injection is performed. It is set shorter than (1). This distance setting is controlled by the camera and controller to reach the melting temperature of the lead-free solder.

The tip of the terminal portion and the tip of the coated conductor are heated in advance by gas flame injection, and lead-free solder is pressed against the tip of the terminal portion to form a molten ball.

Since the lead-free solder has a lower melting temperature than the case where the silver solder 9 of the embodiment (1) is used, it is less damaged by heat, and it is possible to simplify the measures for preventing the surrounding wall or bobbin from being heated. To be done.

Next, the present invention will be described with reference to examples.

[0064]

[Example] The terminal portion 13 of the relay coil 1 has a diameter of 0.5.
mm phosphor bronze is used, and the coated conductor wire 14 has a wire diameter of 0.05.
The thickness of 0.0025 mm polyurethane resin was used for the copper wire of mm and its coating layer. Silver solder 9 has a diameter of 0.
3 mm silver wax was used.

By using the above-mentioned relay coil, the terminal portion and the coated conductor wire were securely joined via the silver solder.

Also, the silver solder formed molten spheres. In the coated lead wire inside the molten sphere, only the core wire in which the coating layer was burned was joined to the terminal via the silver solder.

[0067]

As described above, in the case of joining the terminal portion and the covered conductor according to the present invention, the joining strength is increased and the heat resistance is improved by joining through the silver braze or the lead-free solder forming the molten sphere.・ Has an excellent effect of being a relay coil that is resistant to vibration.

Further, since the coating layer of the coated conductor is surely burned and the burned coating layer is blown off, the relay coil is prevented from being contaminated and the conduction failure can be avoided.

[Brief description of drawings]

FIG. 1 is an enlarged perspective view showing a relay coil according to an embodiment (1).

FIG. 2 is an enlarged view of a terminal portion of the relay coil according to the embodiment (1).

FIG. 3 is a transverse sectional view of a terminal portion of the relay coil according to the embodiment (1).

FIG. 4 is a vertical cross-sectional view of a terminal portion of the relay coil according to the embodiment (1).

FIG. 5 is an explanatory diagram of a brazing device for brazing the terminal portion of the relay coil according to the embodiment (1).

FIG. 6 is an enlarged perspective view showing the operation of the main part of the brazing device at the terminal portion of the relay coil of the embodiment (1).

FIG. 7 is an enlarged perspective view showing a main part operation of the brazing device at the terminal portion of the relay coil according to the embodiment (1).

FIG. 8 is a perspective view showing the completion of brazing at the terminal portion of the relay coil according to the embodiment (1).

FIG. 9 is an enlarged perspective view showing a conventional relay coil.

FIG. 10 is an enlarged view of a terminal portion of a conventional relay coil.

[Explanation of symbols]

1 relay coil 11 bobbins 110 Both ends of bobbin 111 Receiver 12 coils 13 terminals 130 tip 131 Tip surface 132 circumference 133 end 14 coated conductor 140 tip 141 core wire 142 coating layer 143 Assembly Department 144 oxide film 2 holder 3 torch 4 gas supply system 41 Hydrogen oxygen gas generator 42 Mixing device 43 tubes 5 Moving mechanism 6 cameras 7 Brazing material supply mechanism R roller 8 barrier 81 cups 81a Sky wall 81b side wall 82 round hole 9 silver wax 91 molten sphere 10 Solder

Front page continuation (51) Int.Cl. ⁷ Identification code FI theme code (reference) // B23K 101: 34 B23K 101: 34

Claims (4)

[Claims] 1. A relay coil in which a terminal portion is provided at an end portion of a bobbin wound with a coated conductor wire, and the coated conductor wire is entangled at the tip of the terminal portion, and the core wire is exposed from the tip end of the coated conductor wire. The relay coil, wherein the exposed part of the and the tip of the terminal part are joined via silver solder. 2. A relay coil comprising a bobbin wound with a coated wire, a terminal portion provided at an end portion thereof, and the coated wire being entangled at a tip of the terminal portion, wherein the core wire is exposed from the tip of the coated wire. A relay coil characterized in that the exposed portion of and the end of the terminal portion are joined via lead-free solder. 3. A relay coil according to claim 1, wherein the exposed portion of the core wire and the tip of the terminal portion are formed into a molten ball by silver brazing or lead-free solder. 4. The method for manufacturing a relay coil according to claim 1, wherein the tip of the terminal portion is installed downward and a fine flame-shaped gas flame is jetted toward the tip of the terminal portion. ,
The coating layer at the tip of the coated conductor is burned by a gas flame to expose the core wire, and at the same time, the burned coating layer is blown off, and then the tip of the terminal portion and the exposed portion of the core wire and the silver solder or lead-free solder are heated and melted. A method for manufacturing a relay coil, characterized in that the tip of the terminal portion and the exposed portion of the core wire are covered with molten balls with silver solder or lead-free solder.