JP2005044846A - Distributed winding method, winding device, and coil part - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an automated distributed winding method which winds a pair of wires keeping them separate from each other by a constant space, never causes an insulation reduction and a short circuit to windings, and hardly causes variations in the electrical properties of the windings. <P>SOLUTION: In the automated distributed winding method, positioning pins 4A and 4B are located at the right and left side of the tip, a drum core 50 provided with a pair of slit grooves which are located on the one side of a flange and separated from each other by an isolating projection is held by a spindle chuck 1 which is equipped with lateral position correcting pins 6A and 6B that can be projected or retracted between the positioning pins 4A and 4B, and wires 60A and 60B are put through winding nozzles 11A and 11B and sunk into the slit grooves located on the winding start flange of the drum core 50. Thereafter, the spindle chuck 1 is rotated to carry out distributed winding keeping the wires 60A and 60B separate from each other by a prescribed space while the winding nozzles 11A and 11B are made to traverse in parallel with the rotating center axis of the spindle chuck 1. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a distributed winding method and apparatus for providing a pair of windings on a drum core with distributed winding (space winding), and a coil component, and more particularly to a common mode filter for suppressing common mode noise such as signal lines. Distributed winding method and apparatus, such as a small common mode filter, and coil components used for high-speed differential signal interfaces such as digital video interface, HDMI (High Definition Multimedia Interface), etc. About.
[0002]
[Prior art]
As an example of a conventional winding method around a drum core (winding core), there has been a winding method in which a pair wire is used to wind closely (see Patent Document 1 below).
[0003]
In addition, as an example of a conventional winding method around a drum core (winding core), there has been a winding method in which a plurality of wire rods are wound in parallel and in close contact (see Patent Documents 2 and 3 below).
[0004]
Furthermore, as an example of a conventional winding method to a drum core (winding core), a plurality of wire rods are wound as a pair in parallel and in close contact, and the wire rods are brought into proximity with each other even in the lead-out portion to increase the degree of coupling. There was an improved winding method (see Patent Document 4 below).
[0005]
[Patent Document 1] Japanese Patent Application Laid-Open No. 2002-110428
[Patent Document 2] Japanese Patent Laid-Open No. 2002-33228
[Patent Document 3] Japanese Patent Application Laid-Open No. 2002-8931
[Patent Document 4] Japanese Patent Application Laid-Open No. 2003-77730
[0006]
[Problems to be solved by the invention]
By the way, in the conventional common mode filter shown in Patent Documents 1 to 4, two wires are used. However, in the conventional winding method, two wires are closely arranged and wound, and the winding is performed. The curled portion was a winding method that diagonally or horizontally pulled out.
[0007]
In this case, when a pair of wound wires or one line and two lines of wire are pulled out to the connecting portion (on the electrode) through a groove formed in the flange portion of the drum core, the contact portion of the different line wire in the vicinity of the connecting portion Will exist. In addition, when the wire and core side electrode are connected by a method such as soldering, thermocompression bonding, laser or arc welding, ultrasonic bonding, etc., the wire that is an insulation coated conductor by contact of one line and two lines Deterioration of the insulation film occurs.
[0008]
For these reasons, when there is a contact between different line wires in the vicinity of the connecting portion as in the conventional structure, problems such as a breakdown voltage between lines and a decrease in insulation resistance occur.
[0009]
In addition, as a common winding method for winding a wire around a drum core, automatic winding is easy. However, if the wires are in close contact with each other, the line-to-line capacity increases and the cutoff frequency decreases. Occurs. In particular, in applications used for high-speed differential signal interfaces such as DVI and HDMI, space winding, that is, distributed winding is required to increase the cut-off frequency, but the distance between lines should be kept constant. It was difficult to automate the winding work.
[0010]
In addition, in order to avoid the problem of a decrease in withstand voltage and insulation resistance between lines, a pair of wires can be pulled out through different grooves formed in the flange portion of the drum core. It was difficult to automate.
[0011]
The present invention has been made in view of the above problems, and is suitable for transmission of a high-speed differential signal with a high cutoff frequency, and an automated distribution such as a common mode filter having a high breakdown voltage and high reliability. A first object is to provide a winding method and apparatus and a coil component obtained by the method.
[0012]
In addition, the present invention makes it possible to keep the distance between a pair of wires constant by overlapping the number of turns by controlling the wire-to-wire distance constant while applying the winding nozzle position and angle correction for each rotation of the spindle chuck. A second object of the present invention is to provide an automated distributed winding method and apparatus that prevents contact and prevents contact, does not cause insulation degradation and short-circuits, and has little variation in electrical characteristics, and a coil component obtained by the method. Objective.
[0013]
Other objects and novel features of the present invention will be clarified in embodiments described later.
[0014]
[Means for Solving the Problems]
In order to achieve the above object, the distributed winding method according to the first aspect of the present invention has positioning pins on the left and right of the tip portion, and the left and right positioning pins that can be projected and retracted between the left and right positioning pins. A drum core having a pair of slit grooves separated by a separating convex portion on one side surface of the collar portion is held by the spindle chuck,
A first step of passing a pair of wires through a pair of winding nozzles and hooking the pair of wires on the left and right positioning pins, respectively;
A second step of hooking the pair of wires to the left and right position correction pins which are in a protruding state, and sinking the pair of wires into a pair of slit grooves of a winding start side flange of the drum core;
A third step of fixing the pair of wires to the pair of electrodes provided on the winding start side flange by wire fixing means;
A fourth step of performing distributed winding by rotating the spindle chuck while traversing the pair of winding nozzles parallel to the rotation center axis of the spindle chuck to provide a predetermined interline distance between the pair of wires;
A fifth step of moving the pair of winding nozzles and pulling out the pair of wires from a pair of slit grooves in the winding end side flange of the drum core;
A sixth step of sequentially fixing the pair of wires to the pair of electrodes provided on the winding end side collar by wire fixing means is performed.
[0015]
The distributed winding method according to claim 2 of the present application is the distributed winding method according to claim 1, wherein the winding nozzle bracket having the pair of winding nozzles has a rotation center axis in a direction perpendicular to the rotation center axis of the spindle chuck. In the fourth step, each time the spindle chuck makes one rotation, the winding nozzle bracket is rotated by correction to maintain the distance between the lines constant.
[0016]
The distributed winding method according to claim 3 of the present application is the distributed winding method according to claim 1 or 2, wherein the drum core has an inclined concave surface that extends from the bottom of the slit groove to the electrode, and after the second step, the third step. Before performing the above, the pair of wires are hooked on the left and right positioning pins while the pair of wires are held by the wire pressing member so as not to be detached from the slit groove, and the left and right positioning pins are pulled in. The pair of wires are pulled in a direction perpendicular to the axial direction of the drum core, and further, the wires are pressed along the inclined concave surface by the line pressing member.
[0017]
In the distributed winding method according to the invention of claim 4 of the present application, in claim 3, after the fifth step, the pair of wires are pressed by the wire pressing member so as not to come off from the slit groove of the winding end side flange. In this state, the pair of wires are respectively hooked on left and right positioning pins on the winding end side provided separately from the spindle chuck so that the pair of wires are pulled in a direction perpendicular to the axial direction of the drum core, The sixth step is performed after the wire is pulled out along the inclined concave surface.
[0018]
The distributed winding method according to the invention of claim 5 is characterized in that, in claim 1, 2, 3 or 4, a heater chip is used as the wire fixing means, and the wire is thermocompression bonded to the electrode.
[0019]
The distributed winding device according to claim 6 of the present application has positioning pins on the left and right of the tip, and has left and right positioning pins that can be protruded and retracted between the left and right positioning pins, and holds the drum core. A rotating spindle chuck;
A winding nozzle bracket having a pair of winding nozzles each passing a pair of wires and having a rotation center axis in a direction perpendicular to the rotation center axis of the spindle chuck;
Wire fixing means for fixing a wire to an electrode provided on the flange portion of the drum core;
The left and right positioning pins can hook the pair of wires, and the left and right positioning pins can be hooked to the pair of wires in a protruding state and separated from one side surface of the winding core side of the drum core The pair of wires can be sunk by movement of the pair of winding nozzles into a pair of slit grooves separated by a convex for use,
The spindle chuck is rotated while traversing the pair of winding nozzles parallel to the rotation center axis of the spindle chuck, and distributed winding is performed by providing a predetermined line distance between the pair of wires. .
[0020]
A distributed winding device according to a seventh aspect of the present invention is characterized in that, in the sixth aspect, the wire winding device further includes a line pressing member that holds the pair of wires so as not to be detached from the slit groove.
[0021]
A distributed winding device according to an eighth aspect of the present invention is characterized in that, in the sixth or seventh aspect, the wire fixing means is a heater chip.
[0022]
The coil component according to the ninth aspect of the present invention is characterized in that the drum core is wound by the distributed winding method according to the first, second, third, fourth or fifth aspect.
[0023]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of a distributed winding method and apparatus and coil components according to the present invention will be described below with reference to the drawings.
[0024]
1 to 10 show an embodiment of a distributed winding method and apparatus according to the present invention, and FIGS. 11 to 14 show a common mode filter as a coil component produced by the distributed winding method and apparatus. However, FIG. 11 to FIG. 14 show the mounting surface side (bottom surface side) upward.
[0025]
Before explaining embodiments of the distributed winding method and apparatus in FIGS. 1 to 10, the core structure and winding structure of the common mode filter to be manufactured by the above method will be described with reference to FIGS. In these drawings, a drum core 50 formed of a magnetic material such as ferrite or a non-magnetic material such as ceramic has square flange portions 52 on both sides of a core portion 51. Electrodes 53 are formed at two locations on each square flange 52 of the drum core 50 by baking metal paste, metal plating, or the like. The electrode 53 has at least a lower surface electrode portion (user electrode portion) 53a located on the lower surface (mounting surface) which is one surface of the four side surfaces of the square flange 52 and an end surface electrode portion 53b located on the outer end surface. It is formed as follows. In the distributed winding method and apparatus to be described later, when the wire and the electrode 53 are connected by the heater chip, the uppermost layer of the electrode 53 is tin ( Sn) A plating layer (or solder plating layer) is provided relatively thick.
[0026]
In the lower surface 52a of the square flange portion 52 where the lower surface electrode portion 53a of the electrode 53 is located on both sides, the intermediate position in the width direction is a separation convex portion 54, and 2 separated by the separation convex portion 54 on both sides thereof. Two slit grooves (drawing grooves) 55 are formed in parallel to the drum core axis direction.
[0027]
A pair of wires, that is, a first wire 60 </ b> A and a second wire 60 </ b> B are wound around the core 51 of the drum core 50, and the pair of wires 60 </ b> A and 60 </ b> B after the winding are separated by the separation convex portion 2. The wire ends are respectively passed through the two slit grooves (drawing grooves) 55 (maintained in a separated state), and the wire terminals are connected to the lower surface electrode portion 53a of the electrode 53 by thermocompression bonding (electrically at the connection position J in FIG. 11). Connected). In order to facilitate the derivation of the ends of the wires 60A and 60B to the lower surface electrode portion 53a, an inclined concave surface 56 extending from the bottom surface of the slit groove 55 toward the flat surface of the lower surface electrode portion 53a is formed along the end surface of the rectangular flange. Has been.
[0028]
The pair of wires 60A and 60B are not closely wound in order to increase the cutoff frequency of the common mode filter (preferably to set the cutoff frequency to 6.5 GHz or more), and between the wires 60A and 60B as shown in FIG. The line-to-line capacity is reduced as a distributed winding (space winding) in which a line-to-line distance a is provided and a winding interval b is provided between the turns of the wire. Furthermore, the lead-out portions of the wires 60A and 60B are also set so as to be passed through the slit groove 55 and connected to the lower surface electrode portion 53a while maintaining a distance equal to or greater than the line-to-line distance a in order to reduce the line-to-line capacity. For this reason, it can be said that the width of the separation convex portion 54 is desirably equal to or greater than the distance a between the lines. In this case, it is preferable that each wire 60A, 60B uses a cement wire or the like having heat-fusibility to prevent the wire from being displaced.
[0029]
The product shape of the common mode filter produced here is 2012 type (length 2.0 mm, width 1.2 mm, height 1.2 mm) or 2520 type (length 2.5 mm, width 2.0 mm, height). In this case, the diameter of the wire used is 0.05 mm or less. In the case of 2012 and 2520 type products, the distance a between lines and the winding distance b are set to about several tens of μm.
[0030]
In the conventional common mode filter of FIG. 17, the wire 60A, 60B wound around the drum core 50 is in contact with the electrode 53 of the terminal near the connection processing part, so that the different line wire is in contact. When processing is performed by soldering, thermocompression bonding, laser or arc welding, ultrasonic bonding, etc., a short circuit occurs in the part where the wire insulation film has been thermally deteriorated, especially where the wire at the beginning and end of winding comes into contact. On the other hand, in the common mode filter shown in FIGS. 11 to 14, in the vicinity of the connection processing portion of the terminals of the wires 60 </ b> A and 60 </ b> B, it is located at an intermediate position of the rectangular flange portion 52. By forming the separation projection 54, the wires are separated from each other, and there is no portion where the wires of different lines are in contact with each other. It is absolutely no danger of short-circuiting, and the reliability is improved.
[0031]
In the present embodiment, a distributed winding method and apparatus will be described below by taking as an example the case of producing a common mode filter having the drum core structure and winding structure shown in FIGS.
[0032]
In FIG. 1 to FIG. 10, reference numeral 1 denotes a spindle chuck that holds (grips) the drum core 50, and includes a fixed side chuck member 2 and a movable side chuck member 3. The spindle chuck 1 rotates around the rotation center axis C1. A first height positioning pin 4A that regulates the height of the first wire 60A wound around the drum core 50 is fixed to the left end of the distal end portion of the movable chuck member 3, and the drum core 50 is fixed to the right end of the distal end portion of the fixed chuck member 2. A second height positioning pin 4B that regulates the height of the second wire 60B to be wound is fixed. As shown in the enlarged side view, the first and second height positioning pins 4A and 4B are formed with V-grooves 5 in which wires are engaged at fixed height positions on the outer peripheral surface.
[0033]
Position fixing lift pins 6A for first wire positioning (for position correction) and position correction lifting pins 6B for second wire positioning (for position correction) are provided on the side surface of the fixed chuck member 2 so as to protrude and retract. It has been. The position correction elevating pins 6A and 6B are lower than the V-groove 5 in the retracted state, and are high enough not to catch the wires 60A and 60B. In FIG. 1 to FIG. 9, the position correction lifting pins 6A and 6B are shown in black only when they are in the protruding state.
[0034]
A dummy pin 7 is fixed at a fixed position on the side surface of the fixed chuck member 2, and the first and second height positioning pins 4A and 4B and the dummy pin 7 have the position correction lifting pins 6A and 6B on the inside. Located at the apex of the surrounding equilateral triangle.
[0035]
The winding nozzle bracket 10 has a first winding nozzle 11A for feeding through the first wire 60A and a second winding nozzle 11B for feeding through the second wire 60B, and is perpendicular to the rotation center axis C1 of the spindle chuck 1. It can be rotated around the rotation center axis C2 in any direction. Further, it can move in the X direction (horizontal direction), Y (vertical direction) and Z direction (direction perpendicular to the paper surface) of FIG.
[0036]
The tip ends of the first and second wires 60A and 60B are clamped (held) by the discard wire clamp 12, and the wires 60A and 60B on the first and second winding nozzles 11A and 11B side are the wires shown in FIGS. It is clamped by a clamp 13.
[0037]
First, the winding nozzle bracket 10 moves from the winding start position (home position) in FIG. 1A toward the dummy pin 7 as shown in FIG. The first and second wires 60A and 60B are hooked on the dummy pin 7, and the winding nozzle bracket 10 moves in the direction of the first height positioning pin 4A at the left end of the spindle chuck 1 as shown in FIG. By rotating counterclockwise, the first wire 60A is hooked on the first height positioning pin 4A.
[0038]
Next, as shown in FIG. 1 (D), the winding nozzle bracket 10 moves in the direction of the first height positioning pin 4B at the right end of the spindle chuck 1, and 180 ° from FIG. 1 (C) to (E). By rotating to the right, the second wire 60B is hooked on the second height positioning pin 4B, and the state shown in FIG.
[0039]
In FIGS. 1A to 1E, the position correction lifting pins 6A and 6B are in a retracted state, but in FIG. 1F, the wires 60A and 60B protrude to a height at which they can be hooked and function as a wire positioning guide. It becomes like this. That is, until the first and second winding nozzles 11A and 11B move to the dotted line positions in FIG. 1F, the position correction lift pins 6A and 6B are in the retracted state, but thereafter the position correction lift pins 6A and 6B. Becomes a protruding position, and the first wire 60A is moved to the position correction lift pin 6A and the second wire 60B is moved to the position correction lift pin 6B by the movement of the first and second winding nozzles 11A and 11B and the rotation operation of the predetermined angle θ. Hook.
[0040]
Then, as shown in FIG. 2A, the winding nozzle bracket 10 is moved in the direction of the extension line of the rotation center axis C1 of the spindle chuck 1, whereby the first and second wires 60A and 60B are moved in the axial direction of the drum core 50. Can be pulled out substantially in parallel. At this time, the position correction raising / lowering pins 6A and the position correction raising / lowering pins 6B are positioned on the left and right sides of the rotation center axis C1 of the spindle chuck 1, and the arrangement pitch P of the slit grooves 55 for drawing out the wires of the drum core 50 in FIG. The first and second wires 60A and 60B can be pulled out at substantially the same arrangement pitch (in other words, the first and second wires 60A and 60B can be pulled out at a slightly larger wire interval than the width of the separation convex portion 54 between the slit grooves 55). . Accordingly, the wires 60A and 60B are not run on the separation convex portion 54 provided at the center of the square flange portion 52 of the drum core 50, and are drawn so that the wires 60A and 60B do not protrude from the slit groove 55. The wire can be pulled out by sinking 60B into the normal position of the slit groove 55.
[0041]
Thereafter, as shown in FIGS. 2 (B) and 10 (A), the wire pressing member 20 is lowered, and the wire 60A in the slit groove 55 for pulling out the wire of the drum core 50 at the first pressing portion 21, Hold 60B. And the position correction raising / lowering pins 6A and 6B descend | fall while the wire pressing by the wire pressing member 20 is continued as shown in FIG. 2C (the operation of sinking the wires 60A and 60B into the normal position of the slit groove 55). As a result, the wires 60A and 60B are disengaged from the position correction elevating pins 6A and 6B, and the first and second wires 60A and 60B are hooked on the first and second height positioning pins 4A and 4B, respectively, and open to the left and right. From this state, it is set so as to be introduced into the slit groove 55 of the drum core 50 (as shown in FIG. 14, a wire lead-out portion is formed by bending the wires 60A and 60B to an L-shaped right angle). At this time, since the tension generating means (tension arm or the like) for applying tension to the wire is provided in the wire supply path to the first and second winding nozzles 11A and 11B, the wires 60A and 60B do not sag. The first and second wires 60A and 60B are fed back from the first and second winding nozzles 11A and 11B. 2D, the first and second wires 60A and 60B are clamped by the wire clamp 13 on the front side of the first and second winding nozzles 11A and 11B.
[0042]
Then, the line pressing member 20 advances in the arrow direction (−Y direction) as shown in FIG. This operation is for preventing the wires 60A and 60B from rising together with the wire holding member 20, and the wire holding member 20 is not immediately raised but separated from the drum core 50 by this forward movement, and thereafter in FIG. 3 (B). The line pressing member 20 is raised and lowered after returning to the retracted position (+ Y direction) in FIG. 10C (however, the second pressing portion 22 of the line pressing member 20 in FIGS. 10C and 10D). Goes down). By these series of operations, the first pressing portion 21 of the line pressing member 20 is lifted off from the state of FIG. 10A, and instead the line pressing member 20 as shown in FIGS. 10C and 10D. The second pressing portion 22 descends and presses the wires 60 </ b> A and 60 </ b> B along the inclined concave surface 56 of the drum core 50. After that, as shown in FIG. 3D, the line pressing member 20 moves up and then moves backward.
[0043]
After the wire holding member 20 is retracted, as shown in FIG. 4A, the heater chip (HT) 25 moves onto the electrode 53 on the winding start side of the drum core 50 and descends, and the wires 60A and 60B are moved to the drum core 50. Insulation coating of wires 60A and 60B, which are copper wires such as urethane wires, are pressed and pressed against the electrode 53 on the side, and pulse-heated with a heater chip 25 (heating temperature 400 to 500 ° C.) in FIG. Then, a tin layer previously applied on the electrode 53 is melted and a copper wire portion is welded (thermal diffusion bonding is performed by temporary alloying of tin and copper by thermocompression bonding). After that, the clamp of the wire clamp 13 is released in FIG. 4 (C), the heater chip 25 moves in FIG. 4 (D), and the wires 60A and 60B of the excess terminal portions coming out from the drum core 50 are cut by a cutter (not shown). To do.
[0044]
After the wire is cut, the wire pressing member 20 descends again as shown in FIG. 10A and presses the wires 60A and 60B on the winding start (start) side. This is to prevent the wires 60A and 60B from coming off (not protruding) from the slit groove on the drum core side. In this state, the winding nozzle bracket 10 having the first and second winding nozzles 11A and 11B moves to the side (winding start position) of the drum core 50 as shown in FIG. Thereafter, the wire holding member 20 is separated (escaped) from the drum core 50, rotates the spindle chuck 1 in the state of FIG. 5D, and traverses the winding nozzle bracket 10 in the -Y direction to cause the first and second wires. As shown in FIG. 14, distributed winding (space winding) is performed between 60A and 60B with a predetermined line distance a. However, the rotation angle of the winding nozzle bracket 10 is corrected for each turn, and is set so that the distance a between lines in FIG. 14 is constant. The correction value of the rotation angle here is obtained by experiment. In addition, by setting the traverse amount of the winding nozzle bracket 10 to an appropriate value, the winding intervals b between the turns of the wire in FIG. 14 can be provided at equal intervals.
[0045]
FIG. 6A shows a winding end state by distributed winding (space winding), and then the line pressing member 20 descends as shown in FIGS. 6B and 10B, and the third pressing portion 23 thereof. In this state, the first and second winding nozzles 11A and 11B are controlled as shown in FIG. 6C by pressing the wires 60A and 60B on the winding end side to regulate the position (there is also an action to correct the correct position). The spindle chuck 1 moves on an extension line of the rotation center axis C1.
[0046]
Thereafter, as shown in FIG. 7A, the third and fourth height positioning pins 4C and 4D are positioned symmetrically with the first and second height positioning pins 4A and 4B on the spindle chuck 1 side with respect to the drum core 50. Appears (things provided on the device side protrude). The third and fourth height positioning pins 4C and 4D are also formed with V-grooves that engage the wires at fixed height positions on the outer peripheral surface (the same height positions as the pins 4A and 4B). Note that the third and fourth height positioning pins 4C and 4D do not necessarily have to be symmetrical with the first and second height positioning pins 4A and 4B. If it is in the direction.
[0047]
Then, by moving and rotating the first and second winding nozzles 11A and 11B in the order of FIGS. 7A and 7B (moving to the left and returning to the center), the first wire 60A is moved to the third height. Hook on the positioning pin 4C. Next, by moving and rotating the first and second winding nozzles 11A and 11B in the order of FIGS. 7C, 7D and 7E, the second wire 60B is moved to the right and then returned to the center. Hook on the fourth height positioning pin 4D.
[0048]
Thereafter, as shown in FIG. 8 (A), the first and second winding nozzles 11A and 11B move on the extension line of the rotation center axis C1 of the spindle chuck 1, and the wire clamp 13 as shown in FIG. 8 (B). The wires 60A and 60B are clamped, and in this wire clamped state, the wire pressing member 20 moves and rises as shown in FIG. 10C, and further moves into the retracted position as shown in FIG. 8C and 8D, as shown in FIGS. 10C and 10D, the second pressing portion 22 of the line pressing member 20 descends and the inclined concave surface 56 of the drum core 50 is lowered. It is preferable to perform an operation of pressing the wires 60A and 60B along the line.
[0049]
Then, as shown in FIG. 8 (E), the heater chip (HT) 25 moves on the electrode 53 on the winding end side of the drum core 50 and descends, and presses the wires 60A and 60B against the electrode 53 on the drum core 50 side and adds them. 9A, pulse-heated with the heater chip 25 in FIG. 9A, evaporate and remove the insulation coating of the wires 60A and 60B, which are insulation-coated copper wires such as urethane wire (cement wire) having heat-fusibility, Further, a tin layer preliminarily applied on the electrode 53 is melted and a copper wire portion is welded (thermal diffusion bonding is performed by temporary alloying of tin and copper by thermocompression bonding). Thereafter, the heater chip 25 moves in FIG. 9 (B), and the wires 60A and 60B of the excessive terminal portions coming out from the drum core 50 are cut by a cutter (not shown).
[0050]
Thereafter, the winding nozzle bracket 10 having the first and second winding nozzles 11A and 11B moves in the order of FIGS. 9C and 9D and returns to the home position. Although not shown, the movable chuck member 3 opens relative to the fixed chuck member 2 of the spindle chuck 1, and the drum core 50 shown in FIG.
[0051]
In the common mode filter thus obtained, the separation convex portion 54 is formed at the intermediate position of the rectangular flange portion 52 in the vicinity of the connection processing portion of the end of the wires 60A and 60B. Thus, since the wires 60A and 60B are separated from each other and there is no portion where the different line wires are in contact with each other, there is no risk of short-circuit between different lines, and the reliability is improved. FIG. 15 shows the breakdown voltage measurement results between the lines of the common mode filter of the conventional common mode filter (product without protrusions separating the wires in FIG. 17) and the common mode filter of this embodiment (product with protrusions). As can be seen from this measurement result, it was confirmed in terms of characteristics that the common mode filter manufactured according to the present embodiment has a 50% increase in line withstand voltage.
[0052]
According to this embodiment, the following effects can be obtained.
[0053]
(1) It has positioning pins on the left and right of the tip, and has left and right positioning pins that can be projected and retracted between the left and right positioning pins. A winding nozzle bracket having a pair of winding nozzles passed therethrough and having a rotation center axis in a direction perpendicular to the rotation center axis of the spindle chuck, and a wire fixed to an electrode provided on the flange portion of the drum core By using a distributed winding device provided with a heater chip as a wire fixing means, the distributed winding process of the pair of wires 60A and 60B to the core 51 of the drum core 50 is automated, and the wire terminals before and after the distributed winding The drawing and connecting process can be automated.
[0054]
(2) Each time the spindle chuck makes one rotation, the winding nozzle bracket can be rotated by correction to keep the distance a between the pair of wires 60A and 60B constant.
As a result, it is possible to realize a coil component such as a surface mount type common mode filter that minimizes variations in the electrical characteristics while minimizing variations in the distance a between the wire wires wound around the drum core 50.
[0055]
(3) The wire holding member 20 is used together with a spindle chuck having right and left positioning pins that have positioning pins on the left and right of the tip, and that protrudes and retracts between the left and right positioning pins, and ends of the wires 60A and 60B. In order to improve the reliability, the tangled portion of the connecting wire realizes L-shaped right-angle wire drawing (processing to bend at right angles from the groove along the inclined recess). In other words, the drum core 50 has an inclined concave surface extending from the bottom of the slit groove 55 to the electrode 53, and the left and right position correction pins in a state in which the pair of wires 60A and 60B are held by the line holding member 20 so as not to be detached from the slit groove. The pair of wires 60A and 60B are hooked on the left and right positioning pins, respectively, so that the pair of wires 60A and 60B are pulled in a direction perpendicular to the axial direction of the drum core 50. An operation of pressing the wire along the inclined concave surface is performed. Thereby, the reliability improvement of the connection part of wire 60A, 60B and the drum core side electrode 53 can be aimed at.
[0056]
(4) The joining portion between the wires 60A and 60B and the electrode 53 is mechanically and electrically formed by temporarily alloying the tin plating layer on the electrode surface and the wire core wire (copper wire) by pulse heat method thermocompression bonding. Connect securely. For this reason, the connecting process such as soldering or welding is unnecessary after the winding process, and the manufacturing process can be simplified.
[0057]
(5) By the distributed winding method and apparatus described in the present embodiment, a pair of wires 60A and 60B are provided on the core 51 of the magnetic or nonmagnetic drum core 50, and a distance a between the wires is provided; Winding as a distributed winding having a winding interval b between each turn of the wire, and separating each wire one by one through the slit groove by the separation convex portion 54, and pulling the wire terminal to the electrode Surface-mounting type with a high cut-off frequency and high reliability, with a high cut-off frequency (preferably 6.5 GHz or more), suitable for high-speed differential signal transmission such as digital video interface, HDMI, etc. Common mode filter can be realized.
[0058]
FIG. 16 is a modification of the drum core that can be used in the present embodiment, and shows a longitudinal section at the center position of the rectangular flange of the drum core. In this case, concave grooves 61 and 62 are formed as concave portions for positioning the pair of wires 60A and 60B. The wire 60A is the concave groove 61 and the wire 60B is positioned by the concave groove 62 and distributed to the core 51. Set to be wound. Thereby, since the inter-wire distance a and the winding interval b between the turns of the wire are accurately defined by the concave grooves 61 and 62, it is possible to reduce variation in electrical characteristics of each product.
[0059]
Other configurations are the same as those of the common mode filter of FIGS.
[0060]
Although the embodiments of the present invention have been described above, it will be obvious to those skilled in the art that the present invention is not limited to these embodiments, and various modifications and changes can be made within the scope of the claims.
[0061]
【The invention's effect】
As described above, according to the distributed winding method and apparatus according to the present invention, the process of applying distributed winding to the drum core and the connecting process can be automated, and the cutoff frequency is high, which is suitable for transmission of high-speed differential signals. Thus, coil components such as a common mode filter having high withstand voltage and high reliability can be efficiently produced.
[Brief description of the drawings]
FIG. 1 is a first explanatory view showing an embodiment of a distributed winding method and apparatus and a coil component according to the present invention.
FIG. 2 is a second explanatory diagram of the embodiment.
FIG. 3 is a third explanatory diagram of the embodiment.
FIG. 4 is a fourth explanatory diagram of the embodiment.
FIG. 5 is a fifth explanatory diagram of the embodiment;
FIG. 6 is a sixth explanatory diagram of the embodiment;
FIG. 7 is a seventh explanatory diagram of the embodiment;
FIG. 8 is an eighth explanatory diagram of the embodiment;
FIG. 9 is a ninth explanatory diagram of the embodiment;
FIG. 10 is an explanatory diagram of the configuration and operation of the wire pressing member used in the embodiment.
FIG. 11 is a bottom view of a common mode filter as a coil component manufactured by the distributed winding method and apparatus.
FIG. 12 is a side view of the common mode filter with the bottom side (mounting side) facing upward.
FIG. 13 is a perspective view with the bottom side (mounting surface side) of the common mode filter facing upward.
FIG. 14 is a partial bottom view showing the lead-out and connecting portion of the wire terminal of the common mode filter in an enlarged manner.
FIG. 15 is a graph showing the line-to-line withstand voltage of a conventional common mode filter having no separation projection on the flange portion of the drum core and the common mode filter obtained by the present embodiment.
FIG. 16 is a front sectional view showing a longitudinal section at a center position of a rectangular flange portion, which is a modified example of the drum core that can be used in the embodiment of the present invention.
FIG. 17 is a perspective view of a conventional common mode filter.
[Explanation of symbols]
1 Spindle chuck
2 Fixed side chuck member
3 Movable chuck member
4A, 4B Height positioning pin
5 V groove
6A, 6B Position correction lifting pins
7 Dummy pin
10 Winding nozzle bracket
11A, 11B Winding nozzle
12 Waste wire clamp
13 Wire clamp
20 Wire holding member
21 First holding part
22 Second holding part
23 Third presser part
25 Heater chip
50 drum cores
51 Core part
52 square buttocks
53 electrodes
54 Separation convex part
55 Slit groove
56 inclined concave surface
60A, 60B wire

Claims (9)

Using a spindle chuck that has positioning pins on the left and right of the tip, and left and right positioning pins that protrude and retract between the left and right positioning pins, it is separated by a separating convex on one side of the collar. A drum core having a pair of slit grooves is held by the spindle chuck,
A first step of passing a pair of wires through a pair of winding nozzles and hooking the pair of wires on the left and right positioning pins, respectively;
A second step of hooking the pair of wires to the left and right position correction pins which are in a protruding state, and sinking the pair of wires into a pair of slit grooves of a winding start side flange of the drum core;
A third step of fixing the pair of wires to the pair of electrodes provided on the winding start side flange by wire fixing means;
A fourth step of performing distributed winding by rotating the spindle chuck while traversing the pair of winding nozzles parallel to the rotation center axis of the spindle chuck to provide a predetermined interline distance between the pair of wires;
A fifth step of moving the pair of winding nozzles and pulling out the pair of wires from a pair of slit grooves in the winding end side flange of the drum core;
A distributed winding method characterized by sequentially performing a sixth step of fixing the pair of wires to the pair of electrodes provided on the winding end side flange by wire fixing means. The winding nozzle bracket having the pair of winding nozzles has a rotation center axis in a direction perpendicular to the rotation center axis of the spindle chuck, and the winding nozzle every time the spindle chuck rotates once in the fourth step. The distributed winding method according to claim 1, wherein the bracket is rotated by correction to keep the distance between the lines constant. The drum core has an inclined concave surface extending from the bottom of the slit groove to the electrode, and after the second step, before the third step, the pair of wires are prevented from being detached from the slit groove by a wire holding member. The left and right position correction pins are pulled in the pressed state, and the pair of wires are hooked on the left and right positioning pins so that the pair of wires are pulled in a direction perpendicular to the axial direction of the drum core, and The distributed winding method according to claim 1, wherein the wire is pressed along the inclined concave surface by the wire pressing member. After the fifth step, the right and left positioning of the winding end side provided separately from the spindle chuck in a state where the pair of wires are pressed by the wire pressing member so as not to be detached from the slit groove of the winding end side flange. Each of the pair of wires is hooked on a pin so that the pair of wires are pulled in a direction perpendicular to the axial direction of the drum core, and the wire is pulled out along the inclined concave surface. The distributed winding method according to claim 3 to be performed. The distributed winding method according to claim 1, 2, 3, or 4, wherein a heater chip is used as the wire fixing means, and the wire is thermocompression bonded to the electrode. A spindle chuck that has positioning pins on the left and right of the tip, and has left and right positioning pins that can be protruded and retracted between the left and right positioning pins, and rotates while holding the drum core;
A winding nozzle bracket having a pair of winding nozzles each passing a pair of wires and having a rotation center axis in a direction perpendicular to the rotation center axis of the spindle chuck;
Wire fixing means for fixing a wire to an electrode provided on the flange portion of the drum core;
The left and right positioning pins can hook the pair of wires, and the left and right positioning pins can be hooked to the pair of wires in a protruding state and separated from one side surface of the winding core side of the drum core The pair of wires can be sunk by movement of the pair of winding nozzles into a pair of slit grooves separated by a convex for use,
The distributed chucking is performed by rotating the spindle chuck while traversing the pair of winding nozzles in parallel with the rotation center axis of the spindle chuck, and providing a predetermined line distance between the pair of wires. Distributed winding device. The distributed winding apparatus according to claim 6, further comprising a wire pressing member that presses the pair of wires so as not to be detached from the slit groove. The distributed winding apparatus according to claim 6 or 7, wherein the wire fixing means is a heater chip. A coil component in which a drum core is wound by the distributed winding method according to claim 1, 2, 3, 4 or 5.

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