JP2008270309A - Coil winding nozzle and process for manufacturing small-sized coil using coil winding nozzle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil winding nozzle which can achieve cost reduction by enhancing productivity of a small-sized coil and can achieve mass production of highly reliable small-sized coil. <P>SOLUTION: A substantially columnar nozzle having a winding hole 4 for feeding out a coil winding 9 is provided with a D-cut region 7 produced by D-cutting the side face of the nozzle by a predetermined length from the distal end 6 in the axial direction. The D-cut region 7 reaches the inner surface of the winding hole 4 and R is formed at the outlet 4b of the winding hole 4 at the distal end 6 toward the outer circumference of the nozzle. Consequently, productivity of small-sized coil is enhanced and a highly reliable small-sized coil can be manufactured. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an improvement in a coil winding nozzle for winding a coil winding around a small coil used in an electronic circuit, and a method for manufacturing a small coil using the coil winding nozzle.

  Conventionally, a small SMD type coil using a magnetic material such as a ferrite material as a bobbin has been widely used in a power supply device such as a small electronic device typified by a mobile phone or a notebook personal computer, and various drive circuits. . Although this SMD type coil is manufactured by various methods, a manufacturing method is disclosed in which a coil winding is wound around a plurality of bobbins mounted on a collective circuit board in the manner of one-stroke writing (for example, a patent). Reference 1).

  Hereinafter, an outline of a conventional SMD type coil disclosed in Patent Document 1 and an outline of a conventional coil winding nozzle in which a coil winding is wound around a bobbin in order to manufacture the SMD type coil will be described. . In FIG. 13, 50 is a sectional view of a conventional SMD type coil. Reference numeral 51 denotes a circuit board made of a double-sided printed wiring board, and the wiring pattern 53 on the front surface and the wiring pattern 54 on the back surface are electrically connected to each other by a through hole 52 formed at each corner of the circuit board 51. Reference numeral 55 denotes a bobbin made of a magnetic material mounted on the circuit board 51, and has flange portions 55b having large diameters at both ends of a cylindrical core 55a.

  Reference numeral 56 denotes a coil winding wound around the winding core 55a. Winding terminals 56a and 56b at the beginning and end of winding of the coil winding 56 are respectively thermocompression-bonded or soldered to the wiring pattern 53 of the circuit board 51. It is attached. This conventional SMD type coil 50 is shown to be excellent in productivity by using a collective circuit board that can take a large number of circuit boards 51.

  Next, FIG. 14 shows an example of a conventional coil winding nozzle for manufacturing an SMD type coil. In FIG. 14, the conventional coil winding nozzle 60 is configured by a columnar nozzle attachment portion 61 having a large outer diameter and a nozzle small diameter portion 62 having a smaller outer diameter than the nozzle attachment portion 61. A winding hole 63 passes through the center of the coil winding nozzle 60. By attaching the nozzle attachment portion 61 of the coil winding nozzle 60 to a head portion of a winding machine (not shown), the coil winding nozzle 60 is incorporated into the winding machine.

  Here, by incorporating the coil winding nozzle 60 into the winding machine, the coil winding 56 fed out from the winding machine is inserted into the winding hole 63 as shown, and the coil winding 56 has a small nozzle diameter. It is fed out from the outlet 64 of the section 62. The coil winding nozzle 60 rotates around the bobbin 55 of the SMD type coil 50 described above, whereby the coil winding 56 can be wound around the bobbin 55.

  Next, FIG. 15 shows an example of the winding operation of the coil winding by the conventional coil winding nozzle 60. In FIG. 15, reference numeral 70 denotes a collective circuit board that takes a large number of circuit boards 51 that form the SMD type coil 50. A large number of bobbins 55 are mounted on the collective circuit board 70, and a coil winding nozzle 60 incorporated in a winding machine (not shown) rotates around the bobbin 55 while feeding out the coil winding 56. The coil winding 56 can be wound around 55.

Japanese Patent Laying-Open No. 2006-13054 (page 4, FIG. 7)

  However, since the nozzle small diameter portion 62 of the coil winding nozzle 60 enters the gap A of the bobbin 55 and winds the coil winding 56 as shown in FIG. 15, the bobbin mounted on the collective circuit board 70. Each gap A of 55 needs to be larger than the outer diameter of the nozzle small diameter portion 62. That is, if the gap A of the bobbin 55 is not sufficiently wider than the outer diameter of the nozzle small diameter portion 62 of the coil winding nozzle 60, the coil winding nozzle 60 can come into contact with the bobbin 55 to perform the winding operation. Absent. For this reason, the gap A between the bobbins 55 on the collective circuit board 70 needs to be maintained at a predetermined distance, and increasing the number of SMD type coils 50 that can be manufactured from a single collective circuit board 70 improves productivity. Have difficulty.

  Further, if the outer diameter of the nozzle small diameter portion 62 is reduced for the purpose of increasing the productivity by narrowing the gap between the bobbins 55 on the collective circuit board 70, the mechanical strength of the nozzle is lowered and the nozzle is easily deformed. As a result, there arise problems that the winding operation is unstable and the life of the nozzle is shortened. Similarly, when the outer diameter of the nozzle small diameter portion 62 is reduced, the R of the outlet 64 of the winding hole 63 is reduced, so that the coil winding 56 is bent sharply in the vicinity of the outlet 64, and as a result, the coil winding 56. As a result of the damage, there is a risk of cutting, and the reliability of the coil is lowered. Further, in order to reduce the outer diameter of the nozzle small diameter portion 62, precise processing is required, which leads to an increase in the cost of the coil winding nozzle.

  The object of the present invention is to solve the above-mentioned problems, improve the productivity of small coils, realize cost reduction, and realize a mass production of highly reliable small coils and a nozzle for coil winding. It is providing the manufacturing method of the small coil using this.

  In order to solve the above object, the coil winding nozzle and the method for manufacturing a small coil using the coil winding nozzle of the present invention employ the following configuration and manufacturing method.

  The nozzle for coil winding according to the present invention is a substantially cylindrical nozzle having a winding hole through which the coil winding is drawn, and the side surface of the nozzle is D along the axial direction by a predetermined length from the tip of the nozzle. A cut D-cut region is provided.

  As a result, since the tip of the coil winding nozzle is D-cut, the gap between the small coils mounted on the collective base can be narrowed, and the number of small coils to be taken per collective base is increased. Productivity can be improved and the cost of small coils can be reduced. In addition, the D-cut region 7 can reduce the thickness of the tip while keeping the outer diameter of the nozzle at a necessary strength, so that the mechanical strength of the nozzle can be sufficiently secured, and the processing is easy and the cost is reduced. It is possible to provide a cheap coil winding nozzle.

  In addition, the nozzle mounting portion having a thick outer diameter and the nozzle small diameter portion that forms the tip of the nozzle thinner than the nozzle mounting portion, and the D-cut region is formed in the nozzle small diameter portion. And

  Thereby, the nozzle for coil winding can be reliably attached to the winding machine using the nozzle attaching portion having a large outer diameter while maintaining sufficient mechanical strength. In addition, since the D-cut area is formed in the narrow nozzle part with a thin outer diameter, the gap between the small coils mounted on the assembly base can be narrowed, improving productivity and reducing the cost of the small coils. Can be realized.

  The D-cut region reaches the inner surface of the winding hole, and a part of the inner surface of the winding hole is exposed in the D-cut region.

  Thereby, since a part of inner surface of the winding hole is exposed in the D-cut region, the inner surface of the winding hole can be polished so that the coil winding can easily slide. As a result, the winding of the coil winding becomes smooth, the mechanical damage of the coil winding is reduced, the winding of the coil winding is surely performed, and a high-performance small coil can be manufactured.

  Further, the nozzle tip is formed with an outlet of a winding hole, and the outlet of the winding hole is formed with an R toward the outer periphery of the nozzle small diameter part.

  Thereby, since the coil winding drawn out from the tip of the coil winding nozzle is gently bent, the mechanical damage of the coil winding is reduced, and a small coil with excellent reliability can be manufactured. Further, since the damage to the coil winding is reduced, the winding speed of the nozzle can be increased, and the manufacturing cost can be reduced by reducing the man-hours in the coil manufacturing process.

  In the method for manufacturing a small coil using the coil winding nozzle of the present invention, a step of adhering an adhesive material to a collective base capable of taking a large number of bases on which terminal electrodes are formed, and a plurality of bobbins on the collective base Bobbin mounting process for mounting a coil winding, a coil winding process for continuously winding a coil winding on a bobbin mounted on a collective base using a coil winding nozzle, and a coil winding winding terminal A terminal processing step for joining the terminal electrode to the terminal electrode, a bobbin around which the collective base and the coil winding are wound is sealed with a sealing member, and a collective coil is formed. A cutting step of cutting into a coil.

  As a result, the small coil manufacturing method of the present invention can be manufactured in a lump using the assembly base, so that mass production of small coils with stable quality becomes possible. Further, since the coil winding is wound by the coil winding nozzle of the present invention, it is possible to provide a small coil with low cost and excellent reliability.

  Further, in the coil winding process, the coil winding nozzle is rotated so as to always face in the opposite direction with respect to the bobbin around which the D-cut region is wound.

  As a result, the gap between the small coils mounted on the assembly base can be narrowed, so the number of small coils per assembly base can be increased to improve productivity and reduce the cost of the small coils. I can do it.

  As described above, according to the present invention, the gap between the small coils mounted on the collective base can be narrowed, so that the productivity can be improved by increasing the number of small coils per collective base. Cost reduction. Further, the mechanical damage of the coil winding fed from the coil winding nozzle is reduced, and a small coil with excellent reliability can be provided.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a perspective view of a coil winding nozzle according to the present invention. FIG. 2A is a side view of the vicinity of the tip of the coil winding nozzle of the present invention. FIG. 2B is a top view of the vicinity of the tip of the coil winding nozzle of the present invention. FIG. 2C is a front view of the vicinity of the tip of the coil winding nozzle of the present invention. FIG. 3 is a perspective view for explaining the coil winding fed from the coil winding nozzle of the present invention. FIG. 4 is a flowchart of the manufacturing process for explaining the method for manufacturing a small coil according to the present invention. FIG. 5 is a perspective view for explaining the manufacturing process of the collective lead frame of the manufacturing method of the present invention. FIG. 6 is a perspective view for explaining a process of bonding an adhesive material to the assembly lead frame of the manufacturing method of the present invention.

  FIG. 7 is a perspective view for explaining a bobbin mounting process for mounting a plurality of bobbins on the collective lead frame of the manufacturing method of the present invention in a lump. FIG. 8 is a perspective view for explaining the coil winding step and the terminal processing step of the manufacturing method of the present invention. FIG. 9 is a top view for explaining the winding operation of the coil winding nozzle in the coil winding step of the manufacturing method of the present invention. FIG. 10 is a side view for explaining the winding operation of the coil winding nozzle in the coil winding step of the manufacturing method of the present invention. FIG. 11 is a perspective view for explaining a sealing process in which the assembly lead frame and bobbin of the manufacturing method of the present invention are sealed with a sealing member to form an assembly coil. FIG. 12A is a perspective view for explaining a cutting step of cutting the collective coil of the manufacturing method of the present invention into a single SMD type coil. FIG. 12B is a perspective view for explaining that a plurality of SMD type coils are completed by the cutting step of the manufacturing method of the present invention.

  First, the structure of the coil winding nozzle of the present invention will be described with reference to FIG. In FIG. 1, reference numeral 1 denotes a coil winding nozzle showing an example of the present invention. The coil winding nozzle 1 has a cylindrical shape made of metal, and is composed of a nozzle mounting portion 2 having a large outer diameter at the upper portion and a nozzle small diameter portion 3 having a smaller outer diameter as compared with the nozzle mounting portion 2 at the lower portion. . Reference numeral 4 shown by a broken line is a circular winding hole penetrating the center of the coil winding nozzle 1, and a coil winding 9 made of a copper wire or the like is inserted into the winding hole 4.

  Further, an insertion portion 5 is provided at the tip of the nozzle mounting portion 2, and the inlet 4 a of the winding hole 4 of the insertion portion 5 is arranged so that the coil winding 9 can be easily inserted into the coil winding nozzle 1. It has a structure in which the diameter of the winding hole 4 widens greatly. Here, the coil winding 9 inserted from the inlet 4 a of the insertion portion 5 reaches the nozzle small diameter portion 3 through the winding hole 4, and further from the tip portion 6, which is the tip of the nozzle small diameter portion 3, to the outside. It is paid out.

  Here, the nozzle mounting portion 2 of the coil winding nozzle 1 has, for example, a relatively thick cylindrical shape with an outer diameter of about 3 mm in order to be mounted on a head portion of a winding machine (not shown). Thus, since the coil winding nozzle 1 includes the nozzle mounting portion 2 having a large outer diameter, it can be reliably mounted to the head portion of the winding machine while maintaining sufficient mechanical strength.

  Further, the side surface of the nozzle small diameter portion 3 is formed with a D cut region 7 which is D cut along the axial direction of the coil winding nozzle 1 by a predetermined length from the tip end portion 6. By forming this D-cut region 7, the nozzle small diameter portion 3 can be made thinner and thinner than the actual outer diameter, so even if the gap between the small coils mounted on the assembly base described later is narrow, the nozzle small diameter The part 3 enters the gap, and the coil winding can be wound.

  The outlet 4 b of the winding hole 4 at the tip 6 is formed with an R toward the outer periphery of the nozzle small diameter portion 3. Since the coil winding 9 that is fed out is gently bent by the R of the outlet 4b of the winding hole 4, mechanical damage to the coil winding 9 can be prevented.

  Next, the configuration around the D-cut region, which is a feature of the coil winding nozzle of the present invention, will be described in detail with reference to FIGS. 2 (a) to 2 (c). Fig.2 (a) is a side view of the nozzle small diameter part 3 of the nozzle 1 for coil winding of this invention. In FIG. 2A, the D-cut region 7 is formed on the side surface of the nozzle small diameter portion 3 of the coil winding nozzle 1. Here, assuming that the outer diameter B of the nozzle small diameter portion 3 is 0.4 mm as an example, the nozzle small diameter portion 3 is scraped by the D-cut region 7, so that the thickness C of the tip portion 6 is 0 as an example. .27mm.

  That is, when the side surface of the nozzle small diameter portion 3 is D-cut, the thickness C of the tip portion 6 of the nozzle thin diameter portion 3 is 0.4 mm−0.27 mm = 0.13 mm. It can be made thinner than the diameter B. As described above, the provision of the D-cut region 7 makes it possible to make the thickness C of the tip portion 6 of the nozzle small diameter portion 3 thinner and thinner than the outer diameter B of the nozzle thin diameter portion 3.

  Since the coil winding nozzle of the present invention has such a feature, the outer diameter B of the nozzle small diameter portion 3 of the coil winding nozzle 1 can be reduced without extremely reducing the outer diameter B. The thickness C can be reduced to the required thickness. As described above, the coil winding nozzle according to the present invention forms the D-cut region 7 in the nozzle small diameter portion 3 while maintaining the outer diameter B of the nozzle thin diameter portion 3 at a necessary thickness. Since the thickness of the tip portion 6 can be reduced, the mechanical strength of the nozzle can be sufficiently ensured.

  However, in the conventional coil winding nozzle structure, if the outer diameter B of the nozzle small diameter portion 3 is set to 0.3 mm or less, for example, the mechanical strength of the nozzle is lowered and the nozzle is easily deformed. As a result, problems such as unstable winding operation and short life of the nozzle are likely to occur.

  Thus, by using the coil winding nozzle of the present invention, the gap between the small coils mounted on the assembly base can be narrowed, so the number of small coils to be taken per assembly base is increased. I can do it. Further, since the outer diameter of the nozzle small diameter portion 3 can be maintained at a necessary thickness, the mechanical strength is not lowered, problems such as nozzle deformation can be prevented, and the nozzle can be easily processed at a low cost. Can provide a cheap coil winding nozzle. In addition, the detail of the manufacturing method of the coil by the nozzle for coil winding of this invention is mentioned later.

  2A, the winding hole 4 indicated by a broken line is formed with an R toward the outer periphery of the nozzle small diameter portion 3 in the vicinity of the outlet 4b of the tip portion 6 as described above. Here, as described above, the outer diameter B of the nozzle small diameter portion 3 has a thickness necessary for strength. For example, the outer diameter B can be secured to 0.4 mm or more. The R formed at the outlet 4b of 4 can be formed relatively large. Therefore, the coil winding 9 fed out from the outlet 4b of the winding hole 4 is gently bent, and mechanical damage to the coil winding 9 can be prevented. Further, the D cut region 7 reaches the inner surface of the winding hole 4 as shown in the figure, and a part of the winding hole 4 is exposed to the outside in the D cut region.

  Next, FIG.2 (b) is a top view of the nozzle small diameter part 3 seen from the D-cut area | region 7 side of the nozzle 1 for coil winding of this invention. Here, since the D-cut region 7 reaches the inner surface of the winding hole 4, an exposed surface 7 a in which a part of the winding hole 4 is exposed to the outside is formed in the D-cut region 7. As a result, in the D-cut region 7, it becomes easy to perform polishing so that the coil winding 9 can slip through the inner surface of the winding hole 4. As a result, the coil winding 9 is smoothly drawn out, the mechanical damage of the coil winding 9 is reduced, and the winding of the coil winding 9 is surely performed to manufacture a high-performance small coil. I can do it.

  Also, the axial range of the D-cut region 7 is preferably about 1 mm from the tip 6 in consideration of the thickness of the small coil to be manufactured. Thereby, even if the outer diameter B of the nozzle small diameter part 3 is 0.4 mm, the thickness C in the range of about 1 mm from the tip part 6 can be reduced to 0.27 mm. Further, when the thickness of the small coil to be manufactured is 1 mm or more, the range of the D-cut region 7 may be lengthened according to the thickness.

  Next, FIG.2 (c) is a front view of the nozzle small diameter part 3 seen from the front-end | tip part 6 side of the nozzle 1 for coil winding of this invention. In FIG.2 (c), the nozzle small diameter part 3 is circular so that it may illustrate, and the circular winding hole 4 is formed in the center. As described above, the D-cut region 7 reaches the inner surface of the winding hole 4, and a part of the side surface of the winding hole 4 is exposed to the outside by the D-cut region 7. Moreover, it can be understood from this front view that the thickness C of the tip portion 6 cut by the D-cut region 7 is made thinner than the outer diameter B of the nozzle narrow diameter portion 3.

  Next, based on FIG. 3, the coil winding delivered from the coil winding nozzle of the present invention will be described. In FIG. 3, since the tip portion 6 of the nozzle small diameter portion 3 of the coil winding nozzle 1 has a large R formed at the outlet 4b of the winding hole 4 as described above, the coil winding fed out from the outlet 4b is performed. The line 9 can be gently bent along the R of the outlet 4b as shown. Thereby, mechanical damage to the coil winding 9 is reduced, and a small coil with excellent reliability can be manufactured. In addition, since damage to the coil winding is reduced, the winding speed of the nozzle can be increased, and the manufacturing cost can be reduced by reducing the number of steps in the coil manufacturing process.

  Next, an example of a method for manufacturing a small coil using the coil winding nozzle of the present invention will be described with reference to the drawings. As shown in the flowchart of FIG. 4, the small coil manufacturing method of the present invention includes a collective lead frame manufacturing process S1, an adhesive material bonding process S2, a bobbin mounting process S3, a coil winding process S4, a terminal processing process S5, a sealing process. Manufactured according to the order of steps S6 and S7. Hereafter, each manufacturing process is demonstrated based on drawing.

  First, the assembly lead frame manufacturing process S1 will be described with reference to FIG. In this embodiment, the small coil will be described as a surface mount type, that is, an SMD type coil. In FIG. 5, 10 is a collective lead frame as a collective base. In this collective lead frame 10, a number of lead frames 11 are arranged as a base on which SMD type coils are individually formed by pressing a thin metal material. The lead frame 11 includes a through-hole 13 in which a bobbin described later is mounted, a terminal electrode 14 that is electrically connected to the outside, and a bent portion that is provided around the through-hole 13 and forms a part of the terminal electrode 14. It is comprised by the parts 15a-15d. The arrangement of the assembly lead frame 10 is not limited, and may be a long reel, or an assembly lead frame obtained by cutting a long reel-shaped assembly lead frame into a certain length.

  Next, adhesive material bonding process S2 is demonstrated based on FIG. In FIG. 6, a sheet-like adhesive tape 16 as an adhesive material is bonded to the entire back surface of the assembly lead frame 10 by applying pressure in the direction of arrow E. Through this step, the adhesive surface 16 a of the adhesive tape 16 is exposed from the plurality of through holes 13 formed in the assembly lead frame 10.

  Next, the bobbin mounting step S3 will be described with reference to FIG. In FIG. 7, the plurality of bobbins 20 are aligned with a position of the through hole 13 of the assembly lead frame 10 by a tray (not shown), and the tray is moved in the direction of arrow F to move the inside of the through hole 13. Mounted on. That is, as described above, the adhesive surface 16a of the adhesive tape 16 is exposed on the bottom surface of the through hole 13, so that the bobbin 20 aligned by the tray is pressed in the direction of the arrow F, so that each bobbin 20 is fitted in the through-hole 13 to be in close contact with the adhesive surface 16 a and is fixed in the through-hole 13.

  Here, if the diameter of the through hole 13 is slightly smaller than the diameter of the bobbin 20 and the bobbin 20 is press-fitted into the through hole 13, the bobbin 20 is firmly bonded to the assembly lead frame 10, and the adhesive force of the adhesive tape 16 is increased. Even if it is somewhat weak, the bobbin 20 does not come off from the through hole 13. Further, the press-fitting of the bobbin 20 improves the positional accuracy of the bobbin 20 with respect to the collective lead frame 10, and the coil winding step S4, which is a subsequent step, can be performed smoothly.

  Further, if the diameter of the through hole 13 is slightly larger than the diameter of the bobbin 20 to provide a clearance, and the bobbin 20 is gently fitted into the through hole 13, the bobbin 20 can be gathered only by the adhesive force of the adhesive tape 16. The bobbin 20 can be fitted into the through hole 13 even if the alignment of the bobbin 20 with respect to the through hole 13 is not precise. Thereby, the tray for aligning the bobbins 20 can be designed roughly to some extent, and the bobbin mounting step S3 can be simplified. Accordingly, whether the bobbin 20 and the through hole 13 of the assembly lead frame 10 are to be press-fitted or loosely fitted may be selected according to product specifications and manufacturing process capability. The bobbin 20 has the same material and shape as the bobbin 55 shown in the conventional example.

  Next, the coil winding step S4 and the terminal processing step S5 will be described with reference to FIGS. In FIG. 8, the coil winding nozzle 1 of the present invention is attached to the head portion of a winding machine (not shown), and the coil winding nozzle 1 rotates in the direction of arrow G by the rotation of the head portion. Pull out line 9. As a result, the bobbin 20 mounted on the collective lead frame 10 is wound by the coil winding 9 fed out from the coil winding nozzle 1 to produce an SMD type coil.

  Here, the winding operation by the coil winding nozzle 1 will be described. First, the coil winding nozzle 1 is moved according to a program by a winding machine that moves in the X and Y directions, and after the coil winding 9 is wound around the bent portion 15b, the coil winding nozzle 1 rotates in the direction of the arrow G to rotate the core of the bobbin 20. After being wound around 21 and wound a predetermined number of times, it is wound around the bent portion 15a.

  Then, the coil winding nozzle 1 moves to the adjacent bobbin 20 and is wound around the corresponding bent portion 15b, wound around the core 21 of the bobbin 20, wound after a predetermined number of turns. It is tied to the part 15a. Thus, the coil winding process S4 of the large number of bobbins 20 arranged in the collective lead frame 10 is shortened by continuously performing the winding operation so that the coil winding nozzle 1 performs a single stroke according to the program. Can be done in time.

  Here, when the coil winding nozzle 1 winds the coil winding 9, the coil winding nozzle 1 enters a gap between the plurality of arranged bobbins 20 and rotates around the bobbin 20. Here, FIG. 9 shows the winding operation of the coil winding nozzle 1 and the bobbin positional relationship from above. In FIG. 9, the nozzle small diameter portion 3 of the coil winding nozzle 1 rotates around the bobbin 20 in the direction of arrow G as a winding operation. At this time, the D cut region 7 ( Rotate so that it is always in the opposite direction with respect to the bobbin 20.

  As a result, the D-cut region 7 of the nozzle small-diameter portion 3 faces the bobbins 20a to 20d disposed adjacent to the bobbin 20, so that the tip end portion having a thickness C reduced by the D-cut region 7 is obtained. Only 6 rotates into the gap between the bobbin 20 and the bobbins 20a to 20d.

  Here, FIG. 10 shows the positional relationship between the winding operation of the coil winding nozzle 1 and the bobbin from the side. In FIG. 10, the D-cut region 7 of the coil winding nozzle 1 is in the opposite direction with respect to the bobbin 20, and is opposed to the adjacent bobbin 20a. The part 6 enters the gap between the bobbin 20 and the bobbin 20a, and the winding operation is performed. For this reason, even if the clearance gap between the bobbin 20 and the bobbin 20a is narrow as shown in the figure, the nozzle small diameter portion 3 of the coil winding nozzle 1 does not contact the bobbin 20 and the bobbin 20a.

  As a result, the gap between the bobbins 20 can be narrowed to increase the number of SMD type coils to be taken per one assembly lead frame, so that productivity can be improved and the cost of the SMD type coils can be reduced. However, in the case of a conventional coil winding nozzle having no D cut region 7, the gap between the bobbins 20 must be larger than the outer diameter of the nozzle small diameter portion 3, so The number of SMD type coils cannot be increased.

  Next, returning to FIG. 8, after the coil winding step S4 is completed, terminal processing is performed by arc welding, soldering, or the like as terminal processing step S5 on the bent portions 15a and 15b in which the coil winding 9 is entangled. The winding terminals 9a and 9b of the coil winding 9 are securely coupled to the bent portions 15a and 15b.

  Next, sealing process S6 is demonstrated based on FIG. In FIG. 11, after the coil winding 9 is wound around all bobbins 20 mounted on the collective lead frame 10, the collective lead frame 10 is sealed with a sealing member 22 made of a liquid resin such as an epoxy material or a molded resin. The bobbin 20 around which the coil winding 9 is wound is resin-sealed. Thus, the collective coil 30 in which a large number of SMD type coils are assembled is completed.

  Thus, since the collective coil 30 is resin-sealed by the sealing member 22, an SMD type coil that is mechanically strong and excellent in weather resistance can be realized. Further, since the bent portions 15 a to 15 d formed on the collective lead frame 10 are bent in the direction of being embedded in the sealing member 22, the terminal electrode 14 formed by the collective lead frame 10 is connected to the sealing member 22. It is possible to realize a highly reliable SMD type coil. The sealing member 22 does not seal the back surface of the assembly lead frame 10 and is preferably sealed to the same height as the bobbin 20 or slightly lower than the bobbin 20.

  Next, a cutting step S7 for cutting the collective coil into a single SMD type coil will be described with reference to FIGS. 12 (a) and 12 (b). In FIG. 12A, the completed collective coil 30 is cut along a cutting line X, Y by a processing method such as dicing or punching.

  Next, FIG. 12B shows a state in which the collective coil 17 is cut by the cutting step S7 and a large number of single SMD type coils 31 are completed. As described above, according to the small coil manufacturing method of the present invention, a large number of small coils can be simultaneously manufactured by the collective base using the collective lead frame 10 or the like, so that mass production is possible. Small dimensional and characteristic variations of products and low cost small coils can be manufactured.

  Here, it will be described how much the number can be increased with a single assembly lead frame when the coil winding is wound using the coil winding nozzle of the present invention. As an example, 44 × 28 SMD type coils are arranged on one collective lead frame, and the outer diameter of one coil is 2 mm. Then, it is assumed that the individual gaps of the SMD type coils mounted on the collective lead frame can be reduced by 0.13 mm by using the coil winding nozzle 1 of this embodiment.

  Then, since there are 43 gaps between the 44 rows of SMD type coils in the longitudinal direction, a margin of 43 × 0.13 mm = 5.59 mm can be made in the longitudinal direction. Thereby, it is possible to add two rows of SMD type coils having an outer diameter of 2 mm with a margin. In addition, since there are 27 SMD coil gaps in 28 rows, a margin of 27 × 0.13 mm = 3.51 mm can be made. As a result, one row of SMD type coils having an outer diameter of 2 mm can be added with a margin. As a result, the number of collective lead frames per sheet can be increased by 100 or more.

  Note that the outer diameter B of the nozzle thin diameter portion 3 of the coil winding nozzle needs to be increased according to the thickness of the coil winding 9 to be used. For example, the outer diameter B of the nozzle thin diameter portion 3 is 1. In the case of 0.0 mm, the effect of increasing the number of pieces obtained by using the coil winding nozzle of the present invention is further increased.

  As described above, according to the present invention, since the number of collective lead frames per sheet can be increased, the productivity can be improved and the cost of the small coil can be reduced. Further, as described above, in the coil winding nozzle of the present invention, part of the winding hole 4 in the D-cut region 7 is exposed, so that the coil winding can easily slide on the inner surface of the winding hole 4. Can be polished. Thereby, mechanical damage of the coil winding 9 drawn out from the tip 6 of the coil winding nozzle is reduced, and the coil winding 9 is reliably wound, and a high-performance small coil is manufactured. I can do it.

  In addition, since the outlet 4b of the winding hole 4 of the tip 6 of the coil winding nozzle of the present invention has a large R toward the outer periphery, the coil fed out from the tip 6 of the coil winding nozzle The winding 9 is gently bent. As a result, mechanical damage to the coil winding 9 is reduced, and a small coil with excellent reliability can be manufactured. In addition, since the outer diameter B of the nozzle narrow diameter portion 3 can be designed to have a necessary strength, it is possible to prevent problems such as deformation of the nozzle, and the coil processing is easy and inexpensive for coil winding. A nozzle can be provided.

  In this embodiment, the collective lead frame is shown as an example of the collective base. However, the collective lead frame is not limited to the collective lead frame. For example, the collective circuit board as in the conventional example may be used as the collective base. good. In this case, if bobbins are arranged and mounted on the collective circuit board and the coil winding is wound by the coil winding nozzle of the present invention, mass production of small coils can be realized as in this embodiment. I can do it.

  Moreover, although the Example of this invention was demonstrated on the premise of the SMD type coil as a small coil, this invention is not limited to a SMD type coil, For example, it can apply also to a lead type coil. Moreover, although the embodiment of the present invention has been described as a method of manufacturing a small coil mounted with a single bobbin, the present invention is not limited to this form, and a plurality of bobbins can be obtained by arbitrarily changing the shape of the lead frame. It can be applied to the manufacturing method of the mounted multiple coils. Further, the present invention is not limited to coils, and can be applied to a method for manufacturing a composite electronic component in which another electronic component such as an IC chip is mounted on a lead frame together with a bobbin.

It is a perspective view of the nozzle for coil windings of the present invention. It is a side view near the front-end | tip of the nozzle for coil windings of this invention. It is a top view near the front-end | tip of the nozzle for coil windings of this invention. It is a front view near the front-end | tip of the nozzle for coil windings of this invention. It is a perspective view explaining the coil winding paid out from the nozzle for coil windings of the present invention. It is a flowchart of the manufacturing process explaining the manufacturing method of the small coil of this invention. It is a perspective view explaining the manufacturing process of the assembly lead frame of the manufacturing method of this invention. It is a perspective view explaining the process of bonding an adhesive material to the assembly lead frame of the manufacturing method of this invention. It is a perspective view explaining the bobbin mounting process which mounts a several bobbin collectively in the collective lead frame of the manufacturing method of this invention. It is a perspective view explaining the coil winding process and terminal processing process of the manufacturing method of this invention. It is a top view explaining winding operation | movement of the nozzle for coil winding in the coil winding process of the manufacturing method of this invention. It is a side view explaining winding operation | movement of the nozzle for coil winding in the coil winding process of the manufacturing method of this invention. It is a perspective view explaining the sealing process of forming the collective coil by sealing the collective lead frame and bobbin with the sealing member of the manufacturing method of the present invention. It is a perspective view explaining the cutting process which cuts the collective coil of the manufacturing method of the present invention into a single SMD type coil. It is a perspective view explaining that a plurality of SMD type coils are completed by the cutting process of the manufacturing method of the present invention. It is sectional drawing of the conventional SMD type coil. It is a side view which shows an example of the conventional nozzle for coil winding. It is explanatory drawing which shows an example of winding operation | movement of the coil winding by the conventional nozzle for coil winding.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Nozzle for coil winding 2 Nozzle attachment part 3 Nozzle narrow diameter part 4 Winding hole 4a Inlet 4b Outlet 5 Insertion part 6 Tip part 7 D cut area 9 Coil winding 10 Collective lead frame 11 Lead frame 13 Through hole 14 Terminal electrode 15a to 15d bent portion 16 adhesive tape 16a adhesive surface 20, 20a to 20d bobbin 21 core 22 sealing member 30 collective coil 31 SMD type coil

Claims (6)

A substantially cylindrical nozzle having a winding hole through which a coil winding is drawn,
A coil winding nozzle, characterized in that a side surface of the nozzle includes a D-cut region that is D-cut along the axial direction by a predetermined length from the tip of the nozzle.   A nozzle mounting portion having a large outer diameter and a nozzle small diameter portion that forms an end portion of the nozzle that is thinner than the nozzle mounting portion, and the D-cut region is formed in the nozzle small diameter portion. The nozzle for coil windings of Claim 1 characterized by these.   The coil winding according to claim 1 or 2, wherein the D-cut region reaches an inner surface of the winding hole, and a part of the inner surface of the winding hole is exposed in the D-cut region. Nozzle.   The tip of the nozzle is formed with an outlet of a winding hole, and the outlet of the winding hole is formed with an R toward the outer periphery of the small-diameter portion of the nozzle. 2. A nozzle for coil winding according to item 1. In the manufacturing method of the small coil using the nozzle for coil winding of any one of Claims 1 thru | or 4,
A process of fixing an adhesive to an assembly base that can take a large number of bases on which terminal electrodes are formed;
A bobbin mounting step of mounting a plurality of bobbins on the collective base in a lump;
A coil winding step of continuously winding a coil winding on the bobbin mounted on the assembly base using the coil winding nozzle;
A terminal processing step of coupling a winding terminal of the coil winding to the terminal electrode;
Sealing the bobbin around which the assembly base and the coil winding are wound with a sealing member, and forming an assembly coil;
A cutting step of cutting the collective coil into a single small coil;
The manufacturing method of the small coil characterized by the above-mentioned.   6. The coil winding step, wherein the coil winding nozzle is rotated so as to always face in an opposite direction with respect to the bobbin around which the D-cut region is wound. Manufacturing method for small coils.

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