JP2007273757A - Method of manufacturing coil component - Google Patents

Method of manufacturing coil component Download PDF

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JP2007273757A
JP2007273757A JP2006098113A JP2006098113A JP2007273757A JP 2007273757 A JP2007273757 A JP 2007273757A JP 2006098113 A JP2006098113 A JP 2006098113A JP 2006098113 A JP2006098113 A JP 2006098113A JP 2007273757 A JP2007273757 A JP 2007273757A
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winding
coil
portions
coil component
caulking
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JP4483820B2 (en
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Atsushi Shoji
淳 東海林
Sumio Takahashi
純雄 高橋
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TDK Corp
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TDK Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a coil component which minimizes a wasteful winding. <P>SOLUTION: The method of manufacturing a coil component comprises a terminal fitting arranging step of arraying first and second relaying lines 52, 62 for first coil components, and first and second relaying lines 52, 62 for the other coil components on a straight line parallel to the alignment direction of terminal fittings 4; a drum core mounting step of mounting drum cores 2 to terminal fittings 4; a coil line routing step of engaging a winding line 3 onto the first relaying line 52 of the first coil component, winding around the winding core, engaging it onto the second relaying line 62, engaging it onto the first relaying line 52 of the other coil component, and routing it as far as the second relaying line 62; first and second relaying line cutting step of cutting the line engaged to the first and second relaying lines 52, 62 at positions in the vicinity of the first and second relaying lines 52, 62; and first and second relaying line step of electrically connecting winding lines engaged to the first and second relaying lines 52, 62 to the first and second relaying lines 52, 62. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

本発明はコイル部品の製造方法に関し、特に複数のコイル部品を製造する方法に関する。   The present invention relates to a method for manufacturing a coil component, and more particularly to a method for manufacturing a plurality of coil components.

従来、電気回路等において、ノイズ除去のためにノイズフィルタ等のコイル部品が用いられている。このコイル部品は回路基板への実装性を高めるために、フェライト等のコアに巻回された巻線がコアに設けられた端子金具と継線されて構成されている。よってコイル部品は、端子金具を回路上の電極にハンダ等により接合して、回路上に容易に実装することが可能となっている。   Conventionally, a coil component such as a noise filter has been used to remove noise in an electric circuit or the like. In order to improve the mountability to the circuit board, the coil component is configured by connecting a winding wound around a core such as ferrite to a terminal fitting provided on the core. Therefore, the coil component can be easily mounted on the circuit by joining the terminal fitting to the electrode on the circuit with solder or the like.

コイル部品は、電気回路等に実装される前に、予め巻線が端子金具等に継線されている必要があり、この継線に係る構成としては特許文献1に示されるように、端子部に巻線を巻き付けて継線する構成が開示されている。   Before the coil component is mounted on an electric circuit or the like, the winding needs to be connected to a terminal fitting or the like in advance. As shown in Patent Document 1, a terminal portion is provided as a configuration related to this connection. A configuration is disclosed in which a winding is wound around and connected.

特許文献1に示されるコイル部品では、一度に複数のコイル部品を製造する際に、一筆書きで複数のコイル部品に引き回されて巻回することが可能となっている。
特開平10−22137号公報
In the coil component disclosed in Patent Document 1, when a plurality of coil components are manufactured at a time, the coil components can be drawn and wound around the plurality of coil components with a single stroke.
Japanese Patent Laid-Open No. 10-22137

しかし、特許文献一に示されるコイル部品では、その端子金具である金属片とからげ端子との位置関係から、一筆書きで巻線を引き回して巻回した場合に、一のコイル部品の巻線終了箇所から他のコイル部品の巻線開始箇所までの距離が長くなる。この場合に切断されて除去される巻線が多くなり、巻線の無駄が多大に発生していた。よって本発明は、巻線の無駄な部分を極力少なくしたコイル部品の製造方法を提供することを目的とする。   However, in the coil component shown in Patent Document 1, when the winding is drawn and drawn with a single stroke due to the positional relationship between the metal piece that is the terminal fitting and the tangled terminal, the winding of one coil component The distance from the end point to the winding start point of another coil component becomes longer. In this case, the windings that are cut and removed increase, and the windings are wasted. Therefore, an object of this invention is to provide the manufacturing method of the coil components which made the useless part of a coil | winding small as much as possible.

上記課題を解決するために、本発明は、柱状の巻芯部と巻芯部の両端に設けられた一対の鍔部とを有するドラムコアと、巻芯部に巻回され一端部と他端部とがドラムコア外に延出される巻線と、一対の鍔部の一方に設けられて一端部が継線される第一端子金具及び他端が継線される第二端子金具とを備え、第一端子金具には一端部を継線する第一継線部が設けられ、第二端子金具には他端部を継線する第二継線部が設けられたコイル部品を複数製造する方法を提供する。この製造方法では、一のコイル部品に係る一組の第一端子金具及び第二端子金具と、他のコイル部品に係る一組の第一端子金具及び第二端子金具とを一直線上に整列させると共に、一のコイル部品に係る第二継線部と他のコイル部品に係る第一継線部とを、一直線と平行な直線上に配置する端子金具配置工程と各々の一組の第一端子金具及び第二端子金具に各々のドラムコアの一方の鍔部をそれぞれ装着するドラムコア装着工程と、巻線を一のコイル部品に係る第一継線部に掛止し、一のコイル部品に係る巻芯部に巻回し、一のコイル部品に係る第二継線部に掛止した後に、他のコイル部品に係る第一継線部に掛止し、他のコイル部品に係る巻芯部に巻回し、他のコイル部品に係る第二継線部に掛止する巻線引回工程とを備えており、更に、各々の第一継線部に掛止する巻線を各々の第一継線部近傍位置で切断する第一継線部巻線切断工程と、各々の第二継線部に掛止された巻線を各々の第二継線部近傍位置で切断する第二継線部巻線切断工程と、各々の第一継線部に掛止された巻線を第一継線部と電気的に接続する第一継線工程と、各々の第二継線部に掛止された巻線を第二継線部と電気的に接続する第二継線工程と、を同時に若しくは順序を入れ換えて行う切断・継線工程と、を備えている。   In order to solve the above problems, the present invention provides a drum core having a columnar core part and a pair of flanges provided at both ends of the core part, and one end part and the other end part wound around the core part. A winding extending outside the drum core, a first terminal fitting provided at one end of the pair of flanges, and a second terminal fitting connected at the other end, A method of manufacturing a plurality of coil components in which one terminal fitting is provided with a first connecting portion connecting one end portion and the second terminal fitting is provided with a second connecting portion connecting the other end portion. provide. In this manufacturing method, a set of first terminal fittings and second terminal fittings related to one coil component and a set of first terminal fittings and second terminal fittings related to other coil components are aligned on a straight line. In addition, a terminal fitting arrangement step for arranging the second connection portion related to one coil component and the first connection portion related to another coil component on a straight line parallel to a straight line, and a set of first terminals. A drum core mounting step of mounting one flange portion of each drum core on the metal fitting and the second terminal metal fitting, and a winding hooked to the first connecting portion related to one coil component, and winding related to the one coil component After winding on the core and hooking on the second connecting part relating to one coil component, hooking on the first connecting part relating to the other coil part and winding on the core part relating to the other coil part And a winding routing step for hooking on the second connection part relating to other coil parts, A first wire portion winding cutting step for cutting the windings that are hooked to the first connecting portions at positions near the first connecting portions, and the windings that are hooked to the respective second connecting portions. The second connecting portion winding cutting step for cutting the wire at a position in the vicinity of each second connecting portion, and electrically connecting the winding hooked to each first connecting portion to the first connecting portion. Cutting to be performed simultaneously or by changing the order of the first connecting step and the second connecting step of electrically connecting the windings hooked to the respective second connecting portions to the second connecting portion. -It has a connection process.

このような製造方法によると、隣り合う一のコイル部品と他のコイル部品との間において、一のコイル部品の巻回終了位置となる第二継線部と他のコイル部品の巻開始位置となる第一継線部との間の距離を、一のコイル部品と他のコイル部品との間の距離と等しい距離とすることができる。従って、一のコイル部品と他のコイル部品との間に位置する巻線の長さを最も短くすることができる。   According to such a manufacturing method, between the adjacent one coil component and another coil component, the second connecting portion that is the winding end position of the one coil component and the winding start position of the other coil component The distance between the first connecting line part and the first coil part can be equal to the distance between one coil part and another coil part. Therefore, the length of the winding positioned between one coil component and another coil component can be minimized.

上記の製造方法に係るコイル部品において、各々の第一継線部と各々の第二継線部とは、同一直線上に位置していることが好ましい。このような構成によると、各々のコイル部品において同一形状とすることができる。   In the coil component according to the above manufacturing method, it is preferable that each first connecting portion and each second connecting portion are positioned on the same straight line. According to such a structure, it can be made the same shape in each coil component.

また各々の第一継線部と各々の第二継線部とには、それぞれ第一巻線位置規制部と第二巻線位置規制部とが規定され、引回工程において各々の第一継線部に掛止された巻線は、各々の第一巻線位置規制部により各々の第一継線部に対する位置が規定され、各々の第二継線部に掛止された巻線は、各々の第二巻線位置規制部により各々の第二継線部に対する位置が規定されていることが好ましい。   Further, a first winding position restricting portion and a second winding position restricting portion are respectively defined for each first connecting portion and each second connecting portion, and each first connecting portion is defined in the routing step. The windings hooked to the wire portions are defined with respect to the respective first connecting portions by the respective first winding position restricting portions, and the windings hooked to the respective second connecting portions are It is preferable that the position with respect to each 2nd connection part is prescribed | regulated by each 2nd winding position control part.

このような製造方法及び製造方法に係るコイル部品によると、各端子金具に巻線位置規制部を有しているので、余計な治具を用いることなくコイル部品自体が備える構造で巻線の位置を規制することができる。よって巻線引回工程において、巻線位置規制部により継線部に対する巻回位置及びドラムコアに対する巻回位置を正確にして、巻線を配置することができる。   According to such a manufacturing method and the coil component according to the manufacturing method, since each terminal fitting has a winding position restricting portion, the position of the winding is provided in the structure provided by the coil component itself without using an extra jig. Can be regulated. Therefore, in the winding routing step, the winding position can be arranged with the winding position with respect to the connecting portion and the winding position with respect to the drum core being accurately determined by the winding position restricting portion.

また第一継線工程と第二継線工程とは、第一継線部巻線切断工程と第二継線部巻線切断工程とが行われた後に実施されることが好ましい。   Moreover, it is preferable that the first connecting step and the second connecting step are performed after the first connecting portion winding cutting step and the second connecting portion winding cutting step are performed.

このような製造方法によると、例えば溶接等により継線する場合に、既に余分な巻線が切断されて除去されているため、溶接玉が安定して形成される。   According to such a manufacturing method, for example, when connecting by welding or the like, an extra winding is already cut and removed, so that a weld ball is stably formed.

また各々の第一継線部は、巻線を狭持可能な第一カシメ部と、巻線の引回方向において第一カシメ部の下流側に位置する第二カシメ部とをそれぞれ有し、各々の第二継線部は、巻線を狭持可能な第三カシメ部と、巻線の引回方向において第三カシメ部の下流側に位置する第四カシメ部とをそれぞれ有し、第一カシメ部と、第二カシメ部で巻線を狭持すると共に第三カシメ部と第四カシメ部とで巻線を狭持した後に、第一カシメ部と、第四カシメ部とにおいて、第一継線工程と第二継線工程とがそれぞれ行われることが好ましい。   Each of the first connecting portions has a first caulking portion that can sandwich the winding, and a second caulking portion that is located downstream of the first caulking portion in the winding direction of the winding, Each of the second connecting portions includes a third caulking portion that can sandwich the winding, and a fourth caulking portion that is located on the downstream side of the third caulking portion in the winding direction of the winding. After pinching the winding with the first caulking part and the second caulking part and holding the winding with the third caulking part and the fourth caulking part, the first caulking part and the fourth caulking part It is preferable that a 1st connection process and a 2nd connection process are each performed.

このような構成によると、第二カシメ部及び第三カシメ部で巻線を保持した状態で、継線工程を行うことができる。よって継線工程時において、巻線が継線部より外れることが抑制され、安定して継線作業を行うことができる。   According to such a configuration, the connecting step can be performed in a state where the winding is held by the second caulking portion and the third caulking portion. Therefore, at the time of a connection process, it is suppressed that a coil | winding remove | deviates from a connection part, and a connection operation can be performed stably.

本発明の製造方法によれば、巻線の無駄な部分を極力省いてコイル部品を製造することができる。   According to the manufacturing method of the present invention, it is possible to manufacture a coil component while omitting a useless portion of the winding as much as possible.

以下、本発明の実施の形態によるコイル部品の製造方法について図1から図12に基づき説明する。先ず、本発明の製造方法で製造されるコイル部品について説明する。コイル部品1は、4mm四方程度の大きさであり、プリント配線基盤等にリフローハンダ付け等で面実装され、各種電子機器においてチョークコイルとして用いられる部品である。   Hereinafter, a method for manufacturing a coil component according to an embodiment of the present invention will be described with reference to FIGS. First, the coil component manufactured with the manufacturing method of this invention is demonstrated. The coil component 1 has a size of about 4 mm square, is surface-mounted on a printed wiring board by reflow soldering or the like, and is used as a choke coil in various electronic devices.

図1に示されるコイル部品1は、ドラムコア2と、巻線3と、端子金具4とから構成されている。ドラムコア2は、例えばNi−Zn系の磁性材料を基材として、図2に示されるように、巻芯部21と、一対の鍔部22、23とから構成されている。巻芯部21は略柱状に構成され、巻線3が巻回されている。一対の鍔部22、23はそれぞれ同形かつ略円板状で、巻芯部21の軸方向両端に一体に設けられている。巻芯部21と、一対の鍔部22、23とは同軸的に配置されている。また一方の鍔部である鍔部23には、後述の第一端子5と第二端子6とに対応する箇所に、図5に示されるように、接着剤塗布箇所23A、23Bが設けられている。   A coil component 1 shown in FIG. 1 includes a drum core 2, a winding 3, and a terminal fitting 4. As shown in FIG. 2, the drum core 2 includes, for example, a Ni—Zn-based magnetic material as a base material, and includes a core portion 21 and a pair of flange portions 22 and 23. The winding core 21 is formed in a substantially column shape, and the winding 3 is wound around it. The pair of flange portions 22 and 23 are respectively the same shape and substantially disk shape, and are integrally provided at both axial ends of the core portion 21. The core part 21 and the pair of flange parts 22 and 23 are arranged coaxially. Moreover, as shown in FIG. 5, adhesive application portions 23 </ b> A and 23 </ b> B are provided in a portion corresponding to a first terminal 5 and a second terminal 6, which will be described later, on the flange portion 23 that is one of the flange portions. Yes.

巻線3は銅線にウレタン被膜が施された被覆銅線から構成されており、巻芯部21に巻回されて一端部31及び他端部32で端子金具4(図1)に継線されている。   The winding 3 is made of a coated copper wire in which a urethane wire is applied to a copper wire. The winding 3 is wound around the core 21 and connected to the terminal fitting 4 (FIG. 1) at one end 31 and the other end 32. Has been.

端子金具4は、燐青銅等の銅合金を基材としており、図3に示されるように、第一端子5と第二端子6とから構成されている。また図4に示されるように、端子金具4は、後述のリードフレーム40として一体に板材を打ち抜き加工して構成されている。第一端子5と第二端子6とは、並列して配置され、その並列方向と直交する面において対称に構成されている。よって代表として第一端子5について説明する。   The terminal fitting 4 is made of a copper alloy such as phosphor bronze, and is composed of a first terminal 5 and a second terminal 6 as shown in FIG. As shown in FIG. 4, the terminal fitting 4 is formed by punching a plate material integrally as a lead frame 40 described later. The 1st terminal 5 and the 2nd terminal 6 are arrange | positioned in parallel, and are comprised symmetrically in the surface orthogonal to the parallel direction. Therefore, the first terminal 5 will be described as a representative.

第一端子5は第一実装部51と第一継線部52とから主に構成されている。第一実装部51は略長方形の板材より構成されており、その一面側(紙面において上側)がドラムコア2との接合箇所となり、他面側(紙面において下側)が図示せぬ回路基板との実装箇所になっている。この第一実装部51の長手方向の一端部に第一継線部52が設けられている。   The first terminal 5 is mainly composed of a first mounting part 51 and a first connection part 52. The first mounting portion 51 is made of a substantially rectangular plate, and one surface side (upper side in the paper surface) is a joining portion with the drum core 2, and the other surface side (lower side in the paper surface) is a circuit board (not shown) It is a mounting part. A first connecting portion 52 is provided at one end of the first mounting portion 51 in the longitudinal direction.

第一継線部52は、巻線3が未だ継線されていない状態で、第一実装部51の平面と平行となるように第一実装部51との間に屈曲箇所を経て第一実装部51の一面側に持ち上げられて設けられており、その外周部分に第一周縁52Aが規定されている。また第一継線部52は、第一巻線位置規制部52Bと、第二カシメ部である第一巻線保持部52Cと、第一カシメ部である第一電気的接合部52Dとを備えている。   The first connecting portion 52 is in a state where the winding 3 is not yet connected, and the first mounting portion 51 is bent between the first mounting portion 51 so as to be parallel to the plane of the first mounting portion 51. The first peripheral edge 52 </ b> A is defined on the outer peripheral portion of the part 51. The first connecting portion 52 includes a first winding position restricting portion 52B, a first winding holding portion 52C that is a second caulking portion, and a first electrical joint portion 52D that is a first caulking portion. ing.

第一巻線位置規制部52Bは、継線部屈曲箇所の近傍に位置する第一周縁52Aの一部から規定されており、この第一巻線位置規制部52Bを規定する第一周縁52Aの一部は、第一実装部51の長手方向と直交する方向に延びている。また第一巻線位置規制部52Bに係る第一周縁52Aの一部の、第一実装部51の長手方向と直交する方向の長さは、少なくとも巻線3(図2)の直径より大きくなるように構成されている。   The first winding position restricting portion 52B is defined from a part of the first peripheral edge 52A located in the vicinity of the connecting portion bending portion, and the first peripheral edge 52A that defines the first winding position restricting portion 52B is defined. A part of the first mounting portion 51 extends in a direction orthogonal to the longitudinal direction. Further, the length of a part of the first peripheral edge 52A related to the first winding position restricting portion 52B in the direction orthogonal to the longitudinal direction of the first mounting portion 51 is at least larger than the diameter of the winding 3 (FIG. 2). It is configured as follows.

第一巻線保持部52Cは、第一巻線位置規制部52Bを規定する第一周縁52Aの一部の近傍位置に設けられており、巻線3を保持可能な腕部を備えている。   The first winding holding part 52C is provided in the vicinity of a part of the first peripheral edge 52A that defines the first winding position restricting part 52B, and includes an arm part that can hold the winding 3.

第一電気的接合部52Dは、第一巻線位置規制部52Bに対して第一巻線保持部52Cよりも離間した位置に設けられている。故に第一巻線保持部52Cは、巻線3の経路上において第一電気的接合部52Dより巻芯部21(図2)における巻回部分側に位置している。第一電気的接合部52Dにおいても、第一巻線保持部52Cと同様の腕部を備えている。   The first electrical joint 52D is provided at a position farther from the first winding holding part 52C than the first winding position restricting part 52B. Therefore, the first winding holding part 52C is located on the winding part side in the core part 21 (FIG. 2) from the first electrical joint part 52D on the path of the winding 3. The first electrical joint 52D also includes the same arm as the first winding holding part 52C.

また第一実装部51において、短手方向の一端部であって、第一実装部51において反第二端子6側となる位置に一面側に向けて延出された一対の第一フィレット形成片53、53が設けられている。第一フィレット形成片53、53は、コイル部品1が図示せぬ回路基板に実装される際に、好適にフィレットが形成されるように設けられている。   Further, in the first mounting portion 51, a pair of first fillet forming pieces extending toward one surface at one end portion in the short direction and at the position on the side opposite to the second terminal 6 in the first mounting portion 51. 53, 53 are provided. The first fillet forming pieces 53 and 53 are provided so that a fillet is preferably formed when the coil component 1 is mounted on a circuit board (not shown).

第二端子6も第一端子5と同様に第二実装部61と、第二継線部62と、第二フィレット形成片63、63が設けられ、第二継線部62はその外周部分に第二周縁62Aが規定されると共に、第二巻線位置規制部62Bと、第三カシメ部である第二巻線保持部62Cと、第四カシメ部である第二電気的接合部62Dとを備えている。   Similarly to the first terminal 5, the second terminal 6 is also provided with a second mounting portion 61, a second connecting portion 62, and second fillet forming pieces 63, 63, and the second connecting portion 62 is provided on the outer peripheral portion thereof. While the second peripheral edge 62A is defined, the second winding position restricting portion 62B, the second winding holding portion 62C that is the third caulking portion, and the second electrical joint portion 62D that is the fourth caulking portion. I have.

この端子金具4を備えるリードフレーム40は、図4に示されるように、長手方向に延びるフレーム41を有している。フレーム41には複数の端子金具4が、第一端子5と第二端子6との整列方向がフレーム41の長手方向と略平行となるように設けられている。   As shown in FIG. 4, the lead frame 40 including the terminal fitting 4 has a frame 41 extending in the longitudinal direction. The frame 41 is provided with a plurality of terminal fittings 4 such that the alignment direction of the first terminal 5 and the second terminal 6 is substantially parallel to the longitudinal direction of the frame 41.

以下、上記構成のドラムコア2、巻線3、端子金具4からコイル部品1を製造する方法について説明する。先ず端子金具配置工程として、図4に示されるリードフレーム40を準備する。このリードフレーム40において、一の製造中のコイル部品1’に係る第一端子5及び第二端子6は、それぞれ第一実装部51及び第二実装部61の長手方向が略平行となり、第一継線部52及び第二継線部62の向きが同一となるように配置されている。また一の製造中のコイル部品1’に係る一組の第一端子5及び第二端子6と、隣り合う他の製造中のコイル部品1’に係る一組の第一端子5及び第二端子6とが一直線上に整列していると共に、一の製造中のコイル部品1’に係る第二継線部62と隣り合う他の製造中のコイル部品1’に係る第一継線部52とが、該一直線と平行な直線上に配置されている。また全ての端子金具4において、全ての第一継線部52と第二継線部62とは、同一直線上に位置している。   Hereinafter, a method for manufacturing the coil component 1 from the drum core 2, the winding 3, and the terminal fitting 4 configured as described above will be described. First, as a terminal fitting arrangement step, a lead frame 40 shown in FIG. 4 is prepared. In the lead frame 40, the first terminal 5 and the second terminal 6 relating to the coil component 1 ′ being manufactured are substantially parallel to each other in the longitudinal direction of the first mounting portion 51 and the second mounting portion 61, respectively. It arrange | positions so that the direction of the connection part 52 and the 2nd connection part 62 may become the same. In addition, a set of first terminal 5 and second terminal 6 related to one coil component 1 ′ being manufactured, and a pair of first terminal 5 and second terminal related to another adjacent coil component 1 ′ being manufactured. 6 are aligned in a straight line, and the second connection portion 62 relating to the other coil component 1 ′ being manufactured adjacent to the second connection portion 62 relating to the one coil component 1 ′ being manufactured, Are arranged on a straight line parallel to the straight line. Moreover, in all the terminal fittings 4, all the 1st connection parts 52 and the 2nd connection parts 62 are located on the same straight line.

上記リードフレーム40に対し、図5に示されるドラムコア2を取り付ける(ドラムコア装着工程)。具体的には、ドラムコア2の一方の鍔部23に設けられた接着剤塗布箇所23A、23Bが第一端子5の第一実装部51と、第二端子6の第二実装部61上に位置するように、ドラムコア2を配置する。第一端子5及び第二端子6は、フレーム41により、一体となっているため、ドラムコア2を配置する際に、接着剤塗布箇所23A、23Bと第一実装部51及び第二実装部61との間にずれが生じることが抑制され、精度良くドラムコア2を端子金具4上に配置することができる。   The drum core 2 shown in FIG. 5 is attached to the lead frame 40 (drum core mounting step). Specifically, adhesive application locations 23 </ b> A and 23 </ b> B provided on one flange 23 of the drum core 2 are positioned on the first mounting portion 51 of the first terminal 5 and the second mounting portion 61 of the second terminal 6. The drum core 2 is arranged as described above. Since the first terminal 5 and the second terminal 6 are integrated by the frame 41, when the drum core 2 is disposed, the adhesive application locations 23A and 23B, the first mounting portion 51, and the second mounting portion 61 Is prevented from occurring, and the drum core 2 can be placed on the terminal fitting 4 with high accuracy.

ドラムコア2において接着剤塗布箇所23A、23Bには接着剤が塗布されているため、図6に示されるようにリードフレーム40上にドラムコア2を配置した状態で接着剤が硬化し、ドラムコア2と端子金具4とが一体に固定される。   Since the adhesive is applied to the adhesive application portions 23A and 23B in the drum core 2, the adhesive is cured with the drum core 2 disposed on the lead frame 40 as shown in FIG. The metal fitting 4 is fixed integrally.

次に図8に示されるように、巻線3を引き回していく(巻線引回工程)。巻線3は、ノズル3Aから延出されて、図示せぬ固定部に固定された後に一の製造中のコイル部品1’にかかる第一継線部52に引き回される。具体的には巻線3が第一電気的接合部52D位置から第一継線部52の下面に配置され、第一巻線保持部52C側へと配線される。第一巻線保持部52Cを過ぎた巻線3は第一継線部52の上面側に配線され、第一巻線位置規制部52Bに掛止される。そしてドラムコア2の巻芯部21(図3)に向けて延出され巻芯部21に巻回される。   Next, as shown in FIG. 8, the winding 3 is routed (winding routing step). The winding 3 is extended from the nozzle 3A, fixed to a fixing portion (not shown), and then routed to the first connecting portion 52 of the coil component 1 'being manufactured. Specifically, the winding 3 is disposed on the lower surface of the first connecting portion 52 from the position of the first electrical joint portion 52D and wired to the first winding holding portion 52C side. The winding 3 that has passed the first winding holding portion 52C is wired on the upper surface side of the first connecting portion 52, and is hooked on the first winding position restricting portion 52B. And it extends toward the core part 21 (FIG. 3) of the drum core 2 and is wound around the core part 21.

第一巻線位置規制部52Bにおける第一周縁52Aの一部は、巻線3がドラムコア2の巻芯部21に向かって導出される方向と交差する方向である第一電気的接合部52Dから第一巻線保持部52Cに向かう方向に延びている。第一巻線位置規制部52Bにおいて巻線3は、第一巻線保持部52C近傍位置で第一継線部52の下面側から上面側へと配線されて第一周縁52Aの一部に掛止されて、巻芯部21側へと導出されるため、第一巻線位置規制部52Bの前後で巻線3が屈曲される。故に巻線3の屈曲部分が第一巻線位置規制部52Bに掛止され、巻線3の配置位置を規定することが可能となる。これにより巻線3の第一端子5に対するずれが防止され、故に巻線3の継線を確実にすることができる。     A part of the first peripheral edge 52A in the first winding position restricting portion 52B is from the first electrical joint portion 52D which is a direction intersecting the direction in which the winding 3 is led out toward the core portion 21 of the drum core 2. It extends in the direction toward the first winding holder 52C. In the first winding position restricting portion 52B, the winding 3 is wired from the lower surface side to the upper surface side of the first connecting portion 52 at a position in the vicinity of the first winding holding portion 52C and hooked on a part of the first peripheral edge 52A. The winding 3 is bent before and after the first winding position restricting portion 52B because it is stopped and led out toward the winding core portion 21 side. Therefore, the bent portion of the winding 3 is hooked on the first winding position restricting portion 52B, and the arrangement position of the winding 3 can be defined. Thereby, the shift | offset | difference with respect to the 1st terminal 5 of the coil | winding 3 is prevented, Therefore The connection of the coil | winding 3 can be ensured.

巻線3は図3に示されるように、巻芯部21に複数回巻回された後に、図4に示されるように、第二継線部62に向けて導出される。そして第二継線部62の上面側から第二巻線位置規制部62Bに掛止されて第二巻線保持部62C位置から第二継線部62の下面側へと引き回されて、第二電気的接合部62D側へと配線される。そして第二電気的接合部62Dの端部位置から第二継線部62外へと導出されて、一の製造中のコイル部品1’に係る巻線3の引き回しが終了し、隣り合う他の製造中のコイル部品1’に係る第一継線部52へと巻線3が引き回され、同様に配線される。   As shown in FIG. 3, the winding 3 is wound around the winding core portion 21 a plurality of times and then led out toward the second connecting portion 62 as shown in FIG. 4. And it is hooked by the 2nd winding position control part 62B from the upper surface side of the 2nd connection part 62, and is drawn around from the 2nd winding holding part 62C position to the lower surface side of the 2nd connection part 62, Wiring is made to the two electrical junction 62D side. And it is derived | led-out from the edge part position of 2nd electrical junction part 62D out of the 2nd connection part 62, the routing of the coil | winding 3 which concerns on one coil component 1 'in manufacture is complete | finished, The winding 3 is routed to the first connecting portion 52 related to the coil component 1 ′ being manufactured and wired in the same manner.

このように巻線3を引き回することにより、隣り合う一の製造中のコイル部品1’と他の製造中のコイル部品1’との間において、一の製造中のコイル部品1’に係る巻回終了位置となる第二継線部62と他の製造中のコイル部品1’に係る巻開始位置となる第一継線部52との間の巻線3の距離が、一の製造中のコイル部品1’と他の製造中のコイル部品1’との間の距離と等しい最短距離となる。従って、一の製造中のコイル部品1’と他の製造中のコイル部品1’との間に位置する巻線3の長さを最も短くすることができる。   By winding the winding 3 in this way, the coil component 1 ′ being manufactured is related between the adjacent coil component 1 ′ being manufactured and the coil component 1 ′ being manufactured. The distance of the winding 3 between the second connecting portion 62 that is the winding end position and the first connecting portion 52 that is the winding start position related to the other coil component 1 ′ being manufactured is one manufacturing. This is the shortest distance equal to the distance between the coil component 1 'and another coil component 1' being manufactured. Accordingly, the length of the winding 3 positioned between one coil part 1 'being manufactured and another coil part 1' being manufactured can be minimized.

また第一端子5、第二端子6にそれぞれ第一巻線位置規制部52B、第二巻線位置規制部62Bを有しているので、余計な治具を用いることなくコイル部品1自体が備える構造で巻線3の位置を規制することができる。よって巻線引回工程において、第一巻線位置規制部52B、第二巻線位置規制部62Bにより第一継線部52、第二継線部62に対する巻回位置及びドラムコア2に対する巻回位置を正確にして、巻線3を配置することができる。   Further, since the first terminal 5 and the second terminal 6 have the first winding position restricting portion 52B and the second winding position restricting portion 62B, respectively, the coil component 1 itself is provided without using an extra jig. The position of the winding 3 can be regulated by the structure. Accordingly, in the winding routing step, the winding position for the first connecting portion 52 and the second connecting portion 62 and the winding position for the drum core 2 by the first winding position restricting portion 52B and the second winding position restricting portion 62B. The winding 3 can be arranged with accuracy.

フレーム41に接続された端子金具4にかかる全ての第一継線部52及び第二継線部62に巻線3が引き回された後に、図9(a)に示されるように、第一電気的接合部52D、第一巻線保持部52C、第二巻線保持部62C、及び第二電気的接合部62Dがカシメられて、第一継線部52及び第二継線部62において巻線3が保持される。   After the windings 3 are routed around all the first connection parts 52 and the second connection parts 62 applied to the terminal fittings 4 connected to the frame 41, as shown in FIG. The electrical joint 52D, the first winding holding part 52C, the second winding holding part 62C, and the second electrical joining part 62D are caulked and wound at the first connecting part 52 and the second connecting part 62. Line 3 is retained.

この場合に第一巻線保持部52Cでは確実に巻線3を狭持して保持する必要があるが、第一電気的接合部52Dでは少なくとも巻線3が第一電気的接合部52Dにあればよい。第二継線部62においても同様である。   In this case, it is necessary to securely hold and hold the winding 3 in the first winding holding portion 52C. However, in the first electrical joining portion 52D, at least the winding 3 is placed in the first electrical joining portion 52D. That's fine. The same applies to the second connection portion 62.

巻線3が第一継線部52及び第二継線部62において保持された後に、図9(b)に示されるように、第一継線部52に掛止する巻線3を第一継線部52近傍位置で切断するとともに、第二継線部62に掛止された巻線3を第二継線部62近傍位置で切断する(第一継線部巻線切断工程、第二継線部巻線切断工程)。   After the winding 3 is held in the first connecting portion 52 and the second connecting portion 62, the winding 3 that is hooked on the first connecting portion 52 is set to the first connecting portion 52 as shown in FIG. 9B. While cutting at the position near the connecting portion 52, the winding 3 hooked on the second connecting portion 62 is cut at the position near the second connecting portion 62 (first connecting portion winding cutting step, second Connecting part winding cutting process).

巻線3が切断された状態で、図10に示されるように、アーク溶接器3Bにより溶接による継線を行う(第一継線工程、第二継線工程)。この場合に第一継線部52においては、第一電気的接合部52Dが溶融されて、巻線3(図9)と溶接される。第二継線部62においては、第二電気的接合部62Dが溶融されて、巻線3(図9)と溶接される。   In the state where the winding 3 is cut, as shown in FIG. 10, the arc welding device 3 </ b> B performs welding by welding (first connecting process, second connecting process). In this case, in the first connection portion 52, the first electrical joint portion 52D is melted and welded to the winding 3 (FIG. 9). In the second connecting portion 62, the second electrical joint portion 62D is melted and welded to the winding 3 (FIG. 9).

巻線3は、第一巻線保持部52C及び第二巻線保持部62C保持されているため、第一電気的接合部52D及び第二電気的接合部62Dを溶融したとしても、第一継線部52及び第二継線部62から巻線3が外れることが防がれている。よって継線工程時において、安定して継線作業を行うことができる。   Since the winding 3 is held by the first winding holding portion 52C and the second winding holding portion 62C, even if the first electrical joint 52D and the second electrical joint 62D are melted, the first joint The winding 3 is prevented from being detached from the wire portion 52 and the second connecting portion 62. Therefore, it is possible to stably perform the connecting work during the connecting process.

また継線工程は、不要な巻線3が切断された後に行われているため、第一電気的接合部52D及び第二電気的接合部62Dで保持される巻線3の量は略一定となっている。第一端子5及び第二端子6は対称な形状であるため、第一電気的接合部52Dと第二電気的接合部62Dとの大きさも略等しくなっている。よって継線工程により、第一電気的接合部52D及び第二電気的接合部62Dを溶接して形成される溶接玉は、図11に示されるように、略同一形状に安定して形成される。従って、溶接玉が大きくなって、コイル部品1の外殻に係る寸法が変化することが抑制される。   Further, since the connecting step is performed after the unnecessary winding 3 is cut, the amount of the winding 3 held by the first electrical joint 52D and the second electrical joint 62D is substantially constant. It has become. Since the 1st terminal 5 and the 2nd terminal 6 are symmetrical shapes, the magnitude | size of 1st electrical junction part 52D and 2nd electrical junction part 62D is also substantially equal. Therefore, the welding ball formed by welding the first electrical joint 52D and the second electrical joint 62D through the connecting step is stably formed in substantially the same shape as shown in FIG. . Therefore, it is suppressed that the welding ball becomes large and the dimension related to the outer shell of the coil component 1 changes.

そして図12に示されるように、フレーム41から端子金具4を切り離し、複数のコイル部品1が完成する。   Then, as shown in FIG. 12, the terminal fitting 4 is separated from the frame 41 to complete the plurality of coil components 1.

本発明によるコイル部品の製造方法は、上述した実施の形態に限定されず、特許請求の範囲に記載された範囲で種々の変形や改良が可能である。例えば本実施の形態では、第一端子5及び第二端子6が並んでいる一直線と平行な直線上に全ての第一継線部52、第二継線部62が並んでいるが、これに限らず、図13に示されるように、少なくとも隣り合う第一のコイル部品1’の第一継線部52と他のコイル部品1’の第二継線部62とが、第一端子5及び第二端子6が並んでいる一直線と平行な直線上にあればよい。   The method of manufacturing a coil component according to the present invention is not limited to the above-described embodiment, and various modifications and improvements can be made within the scope described in the claims. For example, in the present embodiment, all the first connection parts 52 and the second connection parts 62 are arranged on a straight line parallel to the straight line in which the first terminals 5 and the second terminals 6 are arranged. Not limited to this, as shown in FIG. 13, at least the first connection portion 52 of the first coil component 1 ′ and the second connection portion 62 of the other coil component 1 ′ are connected to the first terminal 5 and It suffices to be on a straight line parallel to the straight line on which the second terminals 6 are arranged.

このような構成であっても、隣り合う一の製造中のコイル部品1’と他の製造中のコイル部品1’との間において、一の製造中のコイル部品1’の巻回終了位置となる第二継線部62と他の製造中のコイル部品1’の巻開始位置となる第一継線部52との間の巻線3の距離が、一の製造中のコイル部品1’と他の製造中のコイル部品1’との間の距離と等しい距離となる。従って、一の製造中のコイル部品1’と他の製造中のコイル部品1’との間に位置する巻線3の長さを最も短くすることができる。   Even in such a configuration, the winding end position of one coil part 1 ′ being manufactured between one adjacent coil part 1 ′ being manufactured and another coil part 1 ′ being manufactured can be The distance of the winding 3 between the second connecting portion 62 and the first connecting portion 52 that is the winding start position of another coil component 1 ′ being manufactured is the same as that of the coil component 1 ′ being manufactured. The distance is equal to the distance between the coil part 1 ′ and the other coil part being manufactured. Accordingly, the length of the winding 3 positioned between one coil part 1 'being manufactured and another coil part 1' being manufactured can be minimized.

本発明の実施の形態に係るコイル部品の斜視図。The perspective view of the coil components which concern on embodiment of this invention. 本発明の実施の形態に係るコイル部品のコアと巻線を示す側面図。The side view which shows the core and coil | winding of the coil components which concern on embodiment of this invention. 本発明の実施の形態に係るコイル部品の端子金具に係る斜視図。The perspective view which concerns on the terminal metal fitting of the coil components which concerns on embodiment of this invention. 本発明の実施の形態に係るコイル部品の製造工程を示す図であって、リードフレームを示す斜視図。It is a figure which shows the manufacturing process of the coil components which concern on embodiment of this invention, Comprising: The perspective view which shows a lead frame. 本発明の実施の形態に係るコイル部品の製造工程を示す図であって、ドラムコアを示す斜視図。It is a figure which shows the manufacturing process of the coil components which concern on embodiment of this invention, Comprising: The perspective view which shows a drum core. 本発明の実施の形態に係るコイル部品の製造工程を示す図であって、ドラムコアをリードフレームに固定した状態を示す斜視図。It is a figure which shows the manufacturing process of the coil components which concern on embodiment of this invention, Comprising: The perspective view which shows the state which fixed the drum core to the lead frame. 本発明の実施の形態に係るコイル部品の製造工程を示す図であって、リードフレームから連結部を取り外した状態を示す斜視図。It is a figure which shows the manufacturing process of the coil components which concern on embodiment of this invention, Comprising: The perspective view which shows the state which removed the connection part from the lead frame. 本発明の実施の形態に係るコイル部品の製造工程を示す図であって、巻線引回工程を示す斜視図。It is a figure which shows the manufacturing process of the coil components which concern on embodiment of this invention, Comprising: The perspective view which shows a coil | winding routing process. 本発明の実施の形態に係るコイル部品の製造工程を示す図であって、巻線がカシメられた状態を示す部分斜視図。It is a figure which shows the manufacturing process of the coil components which concern on embodiment of this invention, Comprising: The partial perspective view which shows the state by which the winding was crimped. 本発明の実施の形態に係るコイル部品の製造工程を示す図であって、巻線切断工程を示す部分斜視図。It is a figure which shows the manufacturing process of the coil components which concern on embodiment of this invention, Comprising: The partial perspective view which shows a coil | winding cutting process. 本発明の実施の形態に係るコイル部品の製造工程を示す図であって、継線工程を示す斜視図。It is a figure which shows the manufacturing process of the coil components which concern on embodiment of this invention, Comprising: The perspective view which shows a connection process. 本発明の実施の形態に係るコイル部品の製造工程を示す図であって、継線工程後の状態を示す斜視図。It is a figure which shows the manufacturing process of the coil components which concern on embodiment of this invention, Comprising: The perspective view which shows the state after a connection process. 本発明の実施の形態に係るコイル部品の製造工程を示す図であって、コイル部品が完成した状態を示す斜視図。It is a figure which shows the manufacturing process of the coil component which concerns on embodiment of this invention, Comprising: The perspective view which shows the state which the coil component was completed. 本発明の実施の形態の変形例に係る巻線引き回工程を示す図。The figure which shows the coil | winding routing process which concerns on the modification of embodiment of this invention.

符号の説明Explanation of symbols

1、1'・・コイル部品 2・・ドラムコア 3・・巻線 3A・・ノズル
3B・・アーク溶接器 31・・一端部 32・・他端部 4・・端子金具
5・・第一端子 6・・第二端子 21・・巻芯部 22・・鍔部 23・・鍔部
23A、23B・・接着剤塗布箇所 40・・リードフレーム 41・・フレーム
51・・第一実装部 52・・第一継線部 52A・・第一周縁
52B・・第一巻線位置規制部 52C・・第一巻線保持部
52D・・第一電気的接合部 53・・第一フィレット形成片 61・・第二実装部
62・・第二継線部 62A・・第二周縁 62B・・第二巻線位置規制部
62C・・第二巻線保持部 62D・・第二電気的接合部
63・・第二フィレット形成片
1, 1 ', coil part 2, drum core 3, winding 3A, nozzle 3B, arc welder 31, one end 32, other end 4, terminal fitting 5, first terminal 6 ..Second terminal 21..Core part 22..Hook 23..Hook 23A, 23B..Adhesive application point 40..Lead frame 41..Frame 51..First mounting part 52 .. First connecting portion 52A, First peripheral edge 52B, First winding position restricting portion 52C, First winding holding portion 52D, First electrical joint 53, First fillet forming piece 61, First Two mounting parts 62, second connecting part 62A, second peripheral edge 62B, second winding position restricting part 62C, second winding holding part 62D, second electrical joint 63, second Fillet forming piece

Claims (5)

柱状の巻芯部と該巻芯部の両端に設けられた一対の鍔部とを有するドラムコアと、該巻芯部に巻回され一端部と他端部とが該ドラムコア外に延出される巻線と、一対の該鍔部の一方に設けられて該一端部が継線される第一端子金具及び該他端が継線される第二端子金具とを備え、該第一端子金具には該一端部を継線する第一継線部が設けられ、該第二端子金具には該他端部を継線する第二継線部が設けられたコイル部品を複数製造する方法であって、
一のコイル部品に係る一組の第一端子金具及び第二端子金具と、他のコイル部品に係る一組の第一端子金具及び第二端子金具とを一直線上に整列させると共に、一の該コイル部品に係る第二継線部と他の該コイル部品に係る第一継線部とを、該一直線と平行な直線上に配置する端子金具配置工程と、
各々の一組の該第一端子金具及び該第二端子金具に各々のドラムコアの一方の該鍔部をそれぞれ装着するドラムコア装着工程と、
該巻線を一のコイル部品に係る第一継線部に掛止し、一のコイル部品に係る巻芯部に巻回し、一のコイル部品に係る該第二継線部に掛止した後に、他のコイル部品に係る該第一継線部に掛止し、他のコイル部品に係る巻芯部に巻回し、他のコイル部品に係る第二継線部に掛止する巻線引回工程と、
各々の第一継線部に掛止する該巻線を各々の該第一継線部近傍位置で切断する第一継線部巻線切断工程と、各々の第二継線部に掛止された該巻線を各々の該第二継線部近傍位置で切断する第二継線部巻線切断工程と、各々の該第一継線部に掛止された該巻線を該第一継線部と電気的に接続する第一継線工程と、各々の該第二継線部に掛止された該巻線を該第二継線部と電気的に接続する第二継線工程と、を同時に若しくは順序を入れ換えて行う切断・継線工程と、を備えることを特徴とするコイル部品の製造方法。
A drum core having a columnar core portion and a pair of flanges provided at both ends of the core portion, and a winding wound around the core portion and having one end and the other end extending outside the drum core A first terminal fitting provided on one of the pair of flanges and having one end thereof connected thereto, and a second terminal fitting provided with the other end thereof, the first terminal fitting comprising: A method of manufacturing a plurality of coil components in which a first connecting portion for connecting the one end portion is provided and a second connecting portion for connecting the other end portion is provided in the second terminal fitting. ,
A set of first terminal fittings and second terminal fittings related to one coil component and a set of first terminal fittings and second terminal fittings related to other coil components are aligned on a straight line, and A terminal fitting arrangement step of arranging the second connection portion relating to the coil component and the first connection portion relating to the other coil component on a straight line parallel to the straight line;
A drum core mounting step of mounting each of the flange portions of each of the drum cores to each set of the first terminal metal fitting and the second terminal metal fitting,
After the winding is hooked to the first connecting part related to one coil part, wound around the core part related to one coil part, and hooked to the second connecting part related to one coil part Winding routing that is hooked to the first connecting portion related to other coil components, wound to the core portion related to other coil components, and hooked to the second connecting portion related to other coil components Process,
A first wire portion winding cutting step for cutting the windings that are hooked to the respective first connecting portions at positions near the respective first connecting portions, and the hooks that are hooked to the respective second connecting portions. A second connecting portion winding cutting step for cutting the winding at a position in the vicinity of each of the second connecting portions, and the winding hooked on each of the first connecting portions. A first connecting step for electrically connecting the wire portions, and a second connecting step for electrically connecting the windings hooked to the second connecting portions to the second connecting portions, And a cutting and connecting step for performing the steps simultaneously or by changing the order.
各々の該第一継線部と各々の該第二継線部とは、同一直線上に位置していることを特徴とする請求項1に記載のコイル部品の製造方法。   2. The method of manufacturing a coil component according to claim 1, wherein each of the first connection portions and each of the second connection portions are located on the same straight line. 各々の該第一継線部と各々の該第二継線部とには、それぞれ第一巻線位置規制部と第二巻線位置規制部とが規定され、
該巻線引回工程において各々の該第一継線部に掛止された該巻線は、各々の該第一巻線位置規制部により各々の該第一継線部に対する位置が規定され、各々の該第二継線部に掛止された該巻線は、各々の該第二巻線位置規制部により各々の該第二継線部に対する位置が規定されていることを特徴とする請求項1または請求項2のいずれかに記載のコイル部品の製造方法。
Each of the first connection portion and each of the second connection portions is provided with a first winding position restricting portion and a second winding position restricting portion, respectively.
The windings that are hooked to the respective first connecting portions in the winding routing step are defined with respect to the respective first connecting portions by the respective first winding position restricting portions, The position of each of the windings hooked to each of the second connecting portions is defined with respect to each of the second connecting portions by each of the second winding position restricting portions. The manufacturing method of the coil component in any one of Claim 1 or Claim 2.
該第一継線工程と該第二継線工程とは、該第一継線部巻線切断工程と該第二継線部巻線切断工程とが行われた後に実施されることを特徴とする請求項1から請求項3のいずれか一に記載のコイル部品の製造方法。   The first connecting step and the second connecting step are performed after the first connecting portion winding cutting step and the second connecting portion winding cutting step are performed. The manufacturing method of the coil components as described in any one of Claims 1-3. 各々の該第一継線部は、該巻線を狭持可能な第一カシメ部と、該巻線の引回方向において該第一カシメ部の下流側に位置する第二カシメ部とをそれぞれ有し、
各々の該第二継線部は、該巻線を狭持可能な第三カシメ部と、該巻線の引回方向において該第三カシメ部の下流側に位置する第四カシメ部とをそれぞれ有し、
該第一カシメ部と、該第二カシメ部で該巻線を狭持すると共に該第三カシメ部と該第四カシメ部とで該巻線を狭持した後に、該第一カシメ部と、該第四カシメ部とにおいて、該第一継線工程と該第二継線工程とがそれぞれ行われることを特徴とする請求項4に記載のコイル部品の製造方法。
Each of the first connecting portions includes a first caulking portion that can sandwich the winding, and a second caulking portion that is located downstream of the first caulking portion in the winding direction of the winding. Have
Each of the second connecting portions includes a third caulking portion that can sandwich the winding, and a fourth caulking portion that is located downstream of the third caulking portion in the winding direction of the winding. Have
The first caulking part, the second caulking part and the second caulking part, and the third caulking part and the fourth caulking part, and the first caulking part, 5. The method of manufacturing a coil component according to claim 4, wherein the first connecting step and the second connecting step are respectively performed in the fourth caulking portion.
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