JP2007207788A - Manufacturing method of coil component, and cylindrical bobbin - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce a component cost and a manufacturing cost by using a temporary terminal which will be removed after finishing a winding work, instead of a grommet to loop a wind-starting lead and a wind-finishing lead around, and then replacing the temporary terminal with a pin terminal and soldering the pin terminal and the part of the lead looped around the temporary terminal. <P>SOLUTION: A pair of bobbin pieces 10 and 20 are engaged with each other in such a manner they can rotate with respect to a closed magnetic circuit core 60 to complete the cylindrical bobbin 1. The bobbin piece 10 is formed with a flange formed with the temporary terminals 30 and pin terminal insertion holes 31. When doing a winding work by rotating the cylindrical bobbin 1, the winding work is started after the wind-starting lead is looped around either of the temporary terminals. After finishing the winding work, the wind-finishing lead is looped around the other temporary terminal. Thereafter, the temporary terminals are replaced with the pin terminals inserted through the pin terminal insertion holes 31, and the pin terminal and the part of the lead looped around the temporary pin are soldered. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a coil part manufacturing method and a cylindrical bobbin that are suitable for coil parts used in various electronic devices, particularly coil parts that use a closed magnetic circuit core.

  In general, a closed magnetic circuit core such as a rectangular endless closed magnetic circuit core (so-called scalloped core) is used in applications such as HF band line filters. For this reason, a bobbin piece having a cylindrical bobbin divided into two parts Are connected to each other so as to be rotatable with respect to the closed magnetic path core to form a cylindrical bobbin, and this is rotated to perform winding of the coil. For example, as a known document, there is Patent Document 1 below.

In Japanese Patent Publication No. 4-42809, in this Patent Document 1, winding is performed after inserting a pin terminal into a collar portion of a bobbin before coil winding work. The pin terminal is moved with respect to the flange so that the amount of protrusion of the pin terminal at the end of the winding at the end of winding is increased to ensure the required amount of protrusion.

  However, since the manufacturing method is based on the premise that the pin terminal is inserted into the flange portion of the bobbin before the coil winding operation, the overall length of the pin terminal is limited, and the outer dimensions of the closed magnetic circuit core are to be reduced. In this case, since the gap between the bobbin and the core becomes small, there is a possibility that a necessary protrusion amount of the pin terminal cannot be secured.

  On the other hand, as another conventional technique, there is a manufacturing method in which an end for winding the lead at the beginning and end of winding of the bobbin is provided on the flange portion of the bobbin, and a pin terminal penetrating the end is provided after the winding work. . A conventional example of a coil component using this hook will be described with reference to FIG.

  As shown in FIGS. 10A and 10B, the cylindrical bobbin 70 can rotate the first bobbin piece 80 and the second bobbin piece 90 into a square endless closed magnetic circuit core 60 such as a ferrite core. They are mated together.

  The first bobbin piece 80 is integrally formed with flanges 81 and 82 at both ends and flanges 83 and 84 at the middle. Further, a rotation transmission gear 85 is formed at an axially intermediate position of the first bobbin piece 80. Further, as shown in FIGS. 10B and 10C, through holes 87 for inserting pin terminals parallel to the end surfaces (the ridge surfaces) of the flange portions 81 and 82 at both ends are formed in the flange portions 81 and 82. Yes. And the eyelet 86 is fixedly arrange | positioned at the opening part to the collar outer peripheral surface of the 1st through-hole 87 (two eyes are arrange | positioned at one collar part). Similarly, the second bobbin piece 90 is also integrally formed with flanges at both end portions and an intermediate portion, and a rotational transmission gear is formed at an intermediate position in the axial direction. Then, in the state where the first and second bobbin pieces 80 and 90 are combined, the cylindrical bobbin 70 having the flanges at both ends and the intermediate part and having the gears is obtained.

  With respect to such a cylindrical bobbin 70, as shown in FIG. 10C, the winding start lead 51 of the coil 50 is entangled with any one of the ends 86, and then the coil winding operation is started. After the wire work is completed, the coil winding end lead is entangled with another fitting 86, and then the pin terminal 88 is inserted into the through hole 87 so as to have an appropriate protruding amount using the through hole on the inner periphery of the fitting 86. The fitting 86, the pin terminal 88, and the lead binding portion are soldered.

  Since the coil component of the conventional example of FIG. 10 is used for fitting, the material cost and the number of parts increase, and further, a process required for fitting and fixing the fitting is necessary, and there is a problem that the manufacturing cost also increases.

  In view of the above points, the present invention uses a temporary terminal that can be removed after the end of winding work, instead of a hook that ties the winding start and end of winding of the coil, and uses the temporary terminal as a pin terminal. An object of the present invention is to provide a method of manufacturing a coil component that can reduce the component cost and the manufacturing cost by replacing and soldering the lead binding portion.

  Further, the present invention provides a cylindrical bobbin that can rationalize the manufacturing method of the coil component by having a temporary terminal that can be removed and removed after the end of the winding work instead of the fitting. One purpose.

  Other objects and novel features of the present invention will be clarified in embodiments described later.

In order to achieve the above object, a method of manufacturing a coil component according to the present invention includes a first and second bobbin pieces each having a shape obtained by dividing a cylindrical bobbin having flanges at least at both ends into a closed magnetic circuit core. In order to complete the cylindrical bobbin by fitting with each other so as to be rotatable with respect to each other, and rotating the cylindrical bobbin to wind the coil,
The first bobbin piece has a flange provided with a temporary terminal, and a first pin terminal insertion hole penetrating most of the flange and having one end closed by the temporary terminal. 2 bobbin pieces have a second pin terminal insertion hole communicating with the first pin terminal insertion hole,
Wrapping the coil winding start lead to one of the temporary terminals and then starting the coil winding work, and after the winding work is finished, winding the coil winding end lead to another temporary terminal; and
The temporary terminals are dropped by pin terminals inserted into first and second pin terminal insertion holes that are in communication with each other, and the pin is connected to the winding start lead winding portion and the winding end lead binding portion of the coil. Inserting a terminal;
And a step of soldering the pin terminal and the tie portion of the lead.

  In the method of manufacturing the coil component, the temporary terminal may be formed integrally with the flange portion of the first bobbin piece. Alternatively, the temporary terminal may be a separate product from the first bobbin piece.

  In the coil component manufacturing method, it is preferable that a tapered recess is formed on the outer peripheral surface of the flange where the temporary terminal is located, and the temporary terminal protrudes from the bottom of the tapered recess.

  The method for manufacturing a coil component may further include a step of pushing the base side of the temporary terminal into the first pin terminal insertion hole before the start of the winding work.

  In the coil component manufacturing method, it is preferable that a rotation transmission gear be formed on the first and second bobbin pieces.

A cylindrical bobbin according to the present invention includes a first bobbin piece and a second bobbin piece that are in a shape obtained by dividing a cylindrical bobbin having a flange at least at both ends into two parts, and are fitted to each other.
The first bobbin piece has a flange portion integrally formed with a temporary terminal, and a first pin terminal insertion hole penetrating most of the flange portion and closed at one end by the base portion of the temporary terminal. And
The second bobbin piece has a second pin terminal insertion hole communicating with the first pin terminal insertion hole.

  In the cylindrical bobbin, a tapered recess may be formed on the outer peripheral surface of the flange where the temporary terminal is located, and the temporary terminal may protrude from the bottom of the tapered recess.

  According to the method for manufacturing a coil component according to the present invention, a bobbin piece having a shape obtained by dividing the cylindrical bobbin into two is fitted to each other so as to be rotatable with respect to the closed magnetic path core, thereby completing the cylindrical bobbin. When winding the coil by rotating the cylindrical bobbin, the coil winding start lead and the winding end lead are entangled with the temporary terminal provided on the bobbin piece, and then the temporary terminal is dropped. Therefore, since the pin terminal is inserted into the lead tie portion instead of the pin terminal, it is possible to provide a manufacturing method that is not limited by the length of the pin terminal.

  In addition, in the conventional example that uses an eyelet, the trouble of attaching and fixing the eyelet is troublesome, and when the tubular bobbin is downsized and the thickness of the collar portion is reduced, the shape of the eyelet that can be attached is small. Therefore, since only pin terminals having a diameter smaller than the inner peripheral diameter of the eyelet can be used, there is a disadvantage that a pin terminal having a required diameter cannot be inserted. On the other hand, providing the temporary terminal on the collar portion of the bobbin piece is easier to work than attaching and fixing the eyelet, and the cost of the temporary terminal is low. In particular, when the temporary terminal is formed integrally with the bobbin piece, it is particularly advantageous in terms of workability and manufacturing cost.

  According to the cylindrical bobbin according to the present invention, since it has a split structure, the temporary bobbin can be fitted and mounted so as to be rotatable with respect to the closed magnetic circuit core, and has a flange portion integrally formed with the temporary terminal. Can be used to bind the coil winding start lead and the winding end lead and contribute to the rationalization of the coil component manufacturing method.

  Hereinafter, as a best mode for carrying out the present invention, a coil component manufacturing method and a cylindrical bobbin embodiment will be described with reference to the drawings.

  A first embodiment of a coil component manufacturing method and a cylindrical bobbin according to the present invention will be described with reference to FIGS.

  1 and 2 show a first bobbin piece 10 and a second bobbin piece 20 constituting a cylindrical bobbin 1, and a rectangular endless closed magnetic circuit core (so-called mouth shape core) 60 such as a ferrite core.

  The first bobbin piece 10 is integrally formed with flanges 11 and 12 at both ends of the semi-cylindrical portion, and flanges 13 and 14 at the middle. Further, a rotation transmission gear 15 is formed at an axially intermediate position of the first bobbin piece 10. Further, the temporary terminals 30 are integrally formed on the outer peripheral surfaces (bottom surfaces when the coil parts are completed) of the flange portions 11 and 12 at both ends, and most of the flange portions 11 and 12 are parallel to the flange surface (end surface). A first pin terminal insertion hole 31 is formed, one end of which is closed by the temporary terminal 30.

  As shown in the enlarged view of FIG. 1 and FIG. 5A, a tapered recess 33 is formed on the outer peripheral surface of the flanges 11 and 12 where the temporary terminal 30 is located, and the temporary terminal extends from the bottom of the tapered recess 33. It is set as the shape which 30 protrudes. Further, the first pin terminal insertion hole 31 is formed to a position close to the base portion of the temporary terminal 30, and the temporary terminal 30 is connected to the flange portions 11 and 12 by a very thin connecting portion 35.

  For example, when the first bobbin piece 10 is manufactured by injection molding of a thermoplastic resin, the temporary terminal 30 and the first pin terminal insertion hole 31 are simultaneously formed by injection molding together with each flange portion. It should be noted that a fitting concave portion 16 at both ends, a fitting convex portion 17 at an intermediate position, and a fitting concave portion 18 are integrally formed at the abutting portion of the first bobbin piece 10 with the second bobbin piece 20.

  Similarly, the second bobbin piece 20 is integrally formed with the flange portions 21 and 22 at both ends of the semi-cylindrical portion, the flange portions 23 and 24 at the intermediate portion, and the rotational transmission gear 25 at the intermediate position in the axial direction. Is formed. Further, as shown in FIG. 1 and FIG. 5A, the second pin terminal insertion hole 32 communicating with the first pin terminal insertion hole 31 has the flange portions 21 and 22 as the flange surface when combined with the first bobbin piece 10. It is formed so as to penetrate in parallel to. Furthermore, at the abutting portion of the second bobbin piece 20 to the first bobbin piece 10, the fitting convex part 26 fitted into the fitting concave part 16 on the first bobbin piece 10 side, the fitting convex part 17 at the intermediate position, and A fitting concave portion 27 and a fitting convex portion 28 which are respectively fitted to the concave portion 18 are integrally formed. The second bobbin piece 20 may be produced by resin molding in the same manner as the first bobbin piece 10.

  As shown in FIG. 3, prior to the coil winding operation, the first and second bobbin pieces 10, 20 are uneven at the butt portion so as to surround the linear magnetic path of the rectangular endless closed magnetic path core 60. By combining with the fitting structure, the cylindrical bobbin 1 having the flanges at both ends having the temporary terminals 30, the flanges at the intermediate part, and the rotation transmission gear is rotatably mounted on the closed magnetic path core 60. Will be.

  When winding the left and right (a pair of) coils simultaneously on such a cylindrical bobbin 1, for example, for the left coil, the winding start lead 51 is tied to one of the left temporary terminals 30 (front side). Then, for the right coil, the winding start lead 51 is entangled with one side (front side) of the right temporary terminal 30, and then the coil winding operation is started. That is, as shown in FIG. 3, in the state where the winding start leads 51 of the left and right coils are entangled with one of the left and right temporary terminals 30, the gears 15 and 25 are meshed with external gears on the rotational drive side to form the cylindrical bobbin 1. Rotate the to perform winding work. For the left coil, winding is performed in the order between the collars 11 and 21 and the collars 13 and 23, and then between the collars 13 and 23 and the gears 15 and 25. , 22 and the flanges 14 and 24, and then the windings in the order between the flanges 14 and 24 and the gears 15 and 25. Then, as shown in FIG. 4, after the winding work of the left and right coils 50 on the cylindrical bobbin 1 is completed, the winding end lead 52 of the left coil is tied to the other (back side) of the left temporary terminal 30 to The winding end lead 52 is entangled with the other side (back side) of the right temporary terminal 30 (assuming that the back side of the temporary terminal 30 in FIG. 4 is illustrated).

  Thereafter, the pin terminal 40 is inserted through the second pin terminal insertion hole 32 of the second bobbin piece 20 to the first pin terminal insertion hole 31 as shown in FIG. The base portion of the temporary terminal 30 penetrating the flange portion 55 is pushed up, the connection portion 35 of the temporary terminal base portion is broken, and the temporary terminal 30 is dropped and removed as shown in FIG. The pin terminal 40 is inserted into the binding portion 55 of the winding end lead and set so as to have a required protruding amount with respect to the flange portions 11 and 12. At this time, since there is a tapered recess 33, even if a flash is generated when the temporary terminal 30 is removed, the tangled portion 55 of the lead is not affected.

  Then, as shown in FIG. 5D, by soldering the pin terminal 40 and the tangled portion 55 of the lead, the coil component in a completed state shown in FIGS. 6 and 7 is obtained. Usually, the outer peripheral surface of the flange portion from which the pin terminal 40 protrudes is the bottom surface side when attached to the printed board.

  According to the first embodiment, the following effects can be obtained.

(1) The cylindrical bobbin 1 is completed by fitting the first and second bobbin pieces 10 and 20 having a shape obtained by dividing the cylindrical bobbin 1 into two so as to be rotatable with respect to the closed magnetic path core 60. When winding the coil 50 by rotating the cylindrical bobbin 1, the coil winding start lead 51 and the winding end lead 52 are entangled with the temporary terminal 30 provided integrally with the bobbin piece 10, After that, the temporary terminal 30 is dropped and replaced with the pin terminal 30, and the pin terminal 30 is inserted into the lead tie portion 55. Therefore, a manufacturing method that is not restricted by the length of the pin terminal 30 can be achieved. That is, it is possible to set the protruding length of the pin terminal 30 according to the application of the coil component such as the HF band line filter that preferably uses the closed magnetic circuit core.

(2) In the conventional example using the eyelet, the trouble of attaching and fixing the eyelet is troublesome, and there is a drawback that a pin terminal having a diameter smaller than the inner peripheral diameter of the eyelet is used. Are formed integrally with the flanges 11 and 12 of the bobbin piece 10 by resin molding, so that it is possible to reduce material costs, man-hours, and manufacturing costs.

(3) In the cylindrical bobbin 1, a tapered recess 33 is formed on the outer peripheral surface of the flanges 11 and 12 where the temporary terminal 30 is located, and the temporary terminal 30 protrudes from the bottom of the tapered recess 33. Even if a temporary flash occurs when the temporary terminal 30 is pushed up by the pin terminal 40 and dropped, the tangled portion 55 of the lead is not affected.

  FIG. 8 shows a main configuration of the second embodiment of the present invention. In this case, the point that the temporary terminal 30A is integrally molded with the flanges 11 and 12 at the end portions of the first bobbin piece 10 is the same as in the first embodiment, but the length of the temporary terminal 30A is slightly longer. Before starting the winding operation of the coil wound around the cylindrical bobbin, there is a step of pushing (inserting) the base side of the temporary terminal 30A into the first pin terminal insertion hole 31 as shown in FIG. Other configurations are the same as those of the first embodiment.

  After the step of FIG. 8A, the coil winding operation is performed using the temporary terminal 30A in the same manner as in the first embodiment. Thereafter, the pin terminal 40 is inserted to the first pin terminal insertion hole 31 through the second pin terminal insertion hole of the second bobbin piece as shown in FIG. 8 (B), and the temporary terminal 30 is inserted as shown in FIG. 8 (C). The pin terminal 40 is inserted into the binding portion 55 of the coil winding start and winding end leads. Thereafter, as shown in FIG. 8D, the pin terminal 40 and the lead binding portion 55 are soldered.

  In the second embodiment, a step of pushing the base side of the temporary terminal 30A into the first pin terminal insertion hole 31 is necessary. However, compared with the case where an eyelet that is a separate part is used, the initial temporary terminal 30A is used. However, since it is formed integrally with the collars 11 and 12, the workability at the time of manufacture is improved, and the cost of the parts of the fitting can be reduced.

  FIG. 9 shows a main configuration of the third embodiment of the present invention. In this case, a temporary terminal 30B, which is a separate product (separate part) such as a metal, is inserted into the first pin terminal insertion hole 31 which is a through hole formed in the flanges 11 and 12 at the end position of the first bobbin piece 10. It has the process of pushing in (inserting). That is, the length of the temporary terminal 30B is slightly longer, and before starting the winding operation of the coil wound around the cylindrical bobbin, the base side of the temporary terminal 30B is connected to the first pin terminal as shown in FIG. It is provided by being pushed into the insertion hole 31.

  After the step of FIG. 9A, the coil winding operation is performed using the temporary terminal 30B in the same manner as in the first embodiment. Then, the pin terminal 40 is inserted to the first pin terminal insertion hole 31 through the second pin terminal insertion hole of the second bobbin piece as shown in FIG. 9 (B), and the temporary terminal 30B is inserted as shown in FIG. 9 (C). The pin terminal 40 is inserted into the binding portion 55 of the coil winding start and winding end leads. Thereafter, as shown in FIG. 9D, the pin terminal 40 and the lead binding portion 55 are soldered.

  In the third embodiment, a step of pushing the temporary terminal 30B, which is a separate part, into the first pin terminal insertion hole 31 is necessary. However, as compared with the case where a fitting is used, a simple pin-shaped temporary terminal 30B is used. Cost is low, workability at the time of temporary terminal mounting is good, and workability can be improved.

  In each embodiment, the number of coils provided in the winding process on the cylindrical bobbin can be singular or plural depending on the application of the coil component (line filter, transformer, etc. using a closed magnetic circuit core). It is.

  In addition, the temporary terminal is dropped and removed after the coil winding work is finished, but the timing for inserting the pin terminal into the cylindrical bobbin may be after the coil winding work is finished, or the winding work It may be before the start. However, when the pin terminal is inserted before starting the winding work, the length of the pin terminal is restricted.

  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.

It is Embodiment 1 of this invention, Comprising: It is a decomposition | disassembly front view which shows the cylindrical bobbin which consists of a 1st and 2nd bobbin piece, and a closed magnetic circuit core. FIG. It is a front view at the time of the same winding start. It is a front view after the end of the winding. In Embodiment 1, it is explanatory drawing which shows the process of replacing a temporary terminal with a pin terminal. In Embodiment 1, it is a front view which shows the coil component of a completion state. It is the same side view. In Embodiment 2 of this invention, it is explanatory drawing which shows the process of replacing a temporary terminal with a pin terminal. In Embodiment 3 of this invention, it is explanatory drawing which shows the process of replacing a temporary terminal with a pin terminal. It is a prior art example using a hame, (A) is a front view, (B) is a side view, (C) is a principal part enlarged view.

Explanation of symbols

1,70 cylindrical bobbin 10,80 first bobbin piece 11-14, 21-24, 81-84 collar 15,25,85 gear
20, 90 Second bobbin piece 30, 30A, 30B Temporary terminal 31 First pin terminal insertion hole 32 Second pin terminal insertion hole 35 Connecting portion 40 Pin terminal 50 Coil 51 Winding start lead 52 Winding end lead 55 Tangled portion 60 Square shape Endless closed magnetic circuit core 86

Claims (8)

A cylindrical bobbin is completed by fitting the first and second bobbin pieces, which are formed by splitting a cylindrical bobbin having at least two flanges at both ends, into two pieces so as to be rotatable with respect to the closed magnetic path core. A coil part manufacturing method for winding a coil by rotating the cylindrical bobbin,
The first bobbin piece has a flange provided with a temporary terminal, and a first pin terminal insertion hole penetrating most of the flange and having one end closed by the temporary terminal. 2 bobbin pieces have a second pin terminal insertion hole communicating with the first pin terminal insertion hole,
Wrapping the coil winding start lead to one of the temporary terminals and then starting the coil winding work, and after the winding work is finished, winding the coil winding end lead to another temporary terminal; and
The temporary terminals are dropped by pin terminals inserted into first and second pin terminal insertion holes that are in communication with each other, and the pin is connected to the winding start lead winding portion and the winding end lead binding portion of the coil. Inserting a terminal;
And a step of soldering the pin terminal and the tie portion of the lead.   The method of manufacturing a coil component according to claim 1, wherein the temporary terminal is formed integrally with the flange portion.   The method of manufacturing a coil component according to claim 1, wherein the temporary terminal is a separate product from the first bobbin piece.   4. The method of manufacturing a coil component according to claim 1, wherein a tapered recess is formed on an outer peripheral surface of the flange where the temporary terminal is located, and the temporary terminal protrudes from a bottom of the tapered recess.   The method of manufacturing a coil component according to claim 1, 2, 3, or 4, further comprising a step of pushing the base side of the temporary terminal into the first pin terminal insertion hole before the start of the winding work.   6. The method of manufacturing a coil component according to claim 1, wherein a rotation transmission gear is formed on the first and second bobbin pieces. A cylindrical bobbin having at least both ends formed with a cylindrical bobbin that is divided into two, and includes first and second bobbin pieces that are fitted to each other;
The first bobbin piece has a flange portion integrally formed with a temporary terminal, and a first pin terminal insertion hole penetrating most of the flange portion and closed at one end by the base portion of the temporary terminal. And
The cylindrical bobbin, wherein the second bobbin piece has a second pin terminal insertion hole communicating with the first pin terminal insertion hole.   The cylindrical bobbin according to claim 7, wherein a tapered recess is formed on the outer peripheral surface of the flange where the temporary terminal is located, and the temporary terminal protrudes from the bottom of the tapered recess.

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