JP2010040706A - Thin-film coil and method of manufacturing the same, and power supply using thin-film coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the following problems: wiring mistakes, or the like possibly occur between a leading line from wiring and a terminal as the number of pieces of winding built into a conventional coil increases; and further soldering having high connection resistance has been performed to fix the leading line in the conventional coil. <P>SOLUTION: The leading line 14 from the wiring 26 is inserted into a radial groove 15 provided on a terminal block 13 and is further fixed by a line pressing section 16, and further is connected to terminals 12 provided at not less than one terminal of the terminal block 13 by welding, thus preventing wiring mistakes from occurring between the leading line 14 and the terminals 12 even if the number of pieces of built-in wiring 25 increases and hence improving reliability the connection to a metal wire 22 in a thin-type coil 11. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present application relates to a thin coil used for a power supply circuit of various electric products such as a thin display (for example, a wall-mounted liquid crystal television, a plasma television, an EL television, etc.) and a manufacturing method thereof. And chalk.

  As various electrical products become smaller and thinner, coil parts are required to be further reduced in size and thickness and to reduce mounting costs.

  FIG. 11 is a bottom view for explaining lead wire connection processing in a conventional coil. In FIG. 11, the conventional coil 1 is connected by winding a lead wire 2 extending from a winding around a terminal 3 via a groove 4. As such an example, Patent Document 1 is known.

  However, in such a conventional coil 1, since the lead wire 2 extending from the winding is manually wound one by one, the groove 4 at a predetermined position is selected from a large number of grooves 4, and the workability is improved. It is low and there is a possibility that a wiring mistake or the like occurs.

When a plurality of windings are to be incorporated in one conventional coil 1, a plurality of lead wires 2 extending from the plurality of windings are set (or inserted) into a plurality of grooves 4 one by one by hand. In addition, wiring mistakes are more likely to occur.
JP 2001-23833 A

  However, in the conventional coil 1 proposed in FIG. 11 and the like, a plurality of lead wires 2 extending from a plurality of windings are wound and fixed around a terminal 3 at a predetermined location via the groove 2 by one manual operation. As a result, a wiring mistake or the like may occur.

  In the present invention, particularly when a plurality of windings are incorporated in a thin coil, the lead wires 2 extending from the plurality of windings are accurately and automatically connected at high speed without any connection mistakes. It is possible to provide a thin coil, a manufacturing method thereof, and a power source using the same, which can be connected to each other inside the thin coil.

  In order to solve the above problems, the present invention includes a winding, a resin terminal block for holding the winding, and a metal terminal fixed so that a part of the terminal block is exposed at one end or more. A plurality of grooves are provided radially on the bottom surface of the terminal block, and a wire pressing portion is provided in a portion of the groove in the vicinity of the terminals and where the grooves are substantially parallel to each other. The lead wires from the windings are structurally separated from each other by disposing them in the grooves, and substantially all of the lead wires from the windings disposed in the grooves are disposed in the grooves. The thin coil is provided with a resistance welding portion at an exposed portion of the terminal from the terminal block.

  According to the present invention, connection mistakes in a thin coil can be reduced, and automatic, high-speed and high-reliability connection can be achieved. This makes it possible to reduce the cost and quality of a thin coil.

  Note that the drawings shown in the embodiments of the present invention are schematic views and do not show the positional relationship correctly in terms of dimensions.

(Embodiment 1)
The first embodiment of the present invention will be specifically described below with reference to FIGS.

  FIGS. 1A and 1B are respectively a perspective view of the back surface of the thin coil according to Embodiment 1 and an enlarged perspective view of a part thereof. FIGS. 1A and 1B are both perspective views showing a part of the thin coil, and only the necessary parts are not shown.

  In FIG. 1, 11 is a thin coil, 12 is a terminal, 13 is a terminal block, 14 is a lead wire, 15 is a groove, 16 is a wire holding portion, 17a and 17b are welded portions, and 18 is a hole. Note that the hole 18 in FIG. 1A corresponds to a second hole 24 in FIGS. 4A and 4B and FIGS. 5A and 5B described later.

  As shown in FIG. 1B, welding between the terminal 12 and the lead wire 14 may be performed at a portion protruding outward from the terminal block 13 as in the welded portion 17b, but as in the welded portion 17a. Alternatively, it may be performed inside the terminal block 13 (or in the groove 15). What is necessary is just to respond | correspond according to the use and purpose to be used. The welds 17a and 17b are both part of the exposed portion of the terminal 12.

  In FIG. 1, a terminal 12 protrudes from a resin terminal block 13 so as to be parallel to the bottom surface. By making the terminal 12 made of metal, the weldability can be improved and the strength as the terminal 12 can be maintained, and the welded portion 17 formed by welding the lead wire 14 can be formed thereon.

  1A and 1B, the grooves 15 are provided radially on the back side of the terminal block 13 of the thin coil 11. Then, the lead wires 14 extending from a plurality of windings (not shown) incorporated in the thin coil 11 are individually embedded one by one in the grooves 15 provided radially on the back side of the thin coil 11, It is connected to a terminal 12 fixed near the tip by a welded portion 17.

  As shown in FIGS. 1A and 1B, the lead wires 14 are individually inserted into the plurality of grooves 15 formed radially. By doing so, wiring mistakes and wiring mistakes do not occur.

  As described above, a winding (not shown), a resin terminal block 13 that holds the winding, and a metal plate that is fixed so that a part of the terminal block 13 is exposed at one end or more. A thin coil 11 comprising a terminal 12, wherein a plurality of grooves 15 are provided radially on the bottom surface of the terminal block 13, and the grooves 15 are substantially parallel to each other in the vicinity of the terminal 12 of the groove 15. The wire holding portion 16 is provided in the portion, and the lead wire 14 from the winding is disposed in the groove 15 so as to be structurally separated from each other, and the lead from the winding disposed in the groove 15 is provided. Almost all of the wire 14 is disposed in the groove 15, and the thin coil 11 is provided with a welded portion 17 on the exposed portion of the terminal 12 from the terminal block 13, thereby incorporating a plurality of windings. Even if it is a case, it is wiring of several lead wires 14 from this coil | winding Without causing the scan, etc., it is possible to accurately wiring. Further, by connecting the lead wire 14 and the terminal 12 by welding (preferably resistance welding), the connection resistance can be reduced and the reliability of the welded portion 17 can be increased. Moreover, the reliability and productivity of the thin coil 11 can be improved by performing automatic welding.

  It is not necessary to insert the lead wire 14 in all the grooves 15. By providing an extra number or number of grooves 15 in the terminal block 13, a plurality of types of thin coils (for example, differences in the number of built-in windings, etc.) can be obtained from the terminal block 13 formed from a single mold. 11 and can reduce the cost and productivity of the thin coil 11.

  The terminal 12 is a metal wire (for example, a metal wire 22 in FIG. 4 to be described later), and this metal wire has a flat portion at least at a part thereof. The weldability between the terminal 12) made of the metal wire and the lead wire 14 is improved. This is because at least the welding surface (or the surface in contact with the lead wire 14) of the terminal 12 (or the metal wire constituting the terminal 12) has a flat portion, so that it is possible to prevent the mutual lines from slipping. It is to become.

  The terminal 12 may be formed by punching a metal plate and insert-molded on a resin terminal block 13. By doing so, the productivity of the thin coil 11 is increased.

(Embodiment 2)
Next, as a second embodiment, an example of a method for manufacturing the thin coil 11 described in the first embodiment will be described.

  First, with reference to FIG. 2 to FIG. 3, a state in which the lead wires 14 are inserted into the radially provided grooves 15 on the back surface side of the thin coil 11, fixed with the wire pressing portions 16, and welded will be described.

  FIGS. 2A and 2B are perspective views for explaining how the lead wire 14 is inserted into the groove 15 provided on the back surface side of the thin coil 11 and fixed by the wire pressing portion 16.

  2 (A) and 2 (B), 19 is a dotted line, and in FIGS. 2 (A) and 2 (B), it means a virtual leader line 14. By providing an extra number of grooves 15 on the back surface of the terminal block 13 of the thin coil 11 in advance, one type of terminal block 13 can cope with the thin coil 11 having a different number of built-in windings. it can. Reference numeral 20 denotes an arrow. An arrow 20 indicates a direction in which, for example, the leader line 14 is bent substantially vertically and inserted into the groove 15.

  As shown in FIG. 2A, a plurality of lead wires 14 from a plurality of windings (not shown) are holes (not shown) provided in the terminal block 13. It is pulled out to the back side via the bottom). Thereafter, as shown by the arrow 20, the lead wire 14 is inserted into the groove 15.

  FIG. 2B is a perspective view showing a state in which the lead wire 14 inserted into the groove 15 is fixed by the line pressing portion 16. The line pressing part 16 in FIG. 2 (B) is a part where a part of the groove 15 is locally thinned, and is provided for fixing the lead wire 14.

  As shown in FIGS. 2A and 2B and FIGS. 1A and 1B, the wire pressing portion 16 has a plurality of radial grooves 15 provided on the back surface side of the thin coil 11 so that they are substantially parallel to each other. Provide in the part. Thus, by providing the line pressing part 16 in the vicinity of the terminal 12 provided at the tip of the groove 15 and where the plurality of grooves 15 are substantially parallel to each other, the lead wire 14 is accommodated in the groove 15. Can be ensured.

  In addition, by making the plurality of grooves 15 radial, an effect of facilitating automatic insertion of the lead wire 14 into the groove 15 by a rubber roller or the like can be obtained. By providing, a plurality of lead lines 14 can be fixed together.

  In addition, by fixing a part of the lead wire 14 with the wire pressing portion 16, workability in fixing the lead wire to the terminal 12 (for example, including temporary fixing before and after welding) is improved. Moreover, the wire pressing part 16 can reduce the thermal influence on the covering of the lead wire 14 by heat generated during welding, and it is easy to ensure the creepage distance and the insulation distance.

  In FIGS. 2A and 2B, it is needless to say that a variety of thin coils 11 can be handled by using the actual lead wire 14 in the portion shown in phantom as indicated by the dotted line 19.

  FIGS. 3A and 3B are perspective views for explaining the welded portion 17 provided on the terminal 12 and the lead wire 14. 3A and 3B, reference numeral 21 denotes an external connection portion. The external connection portion 21 is provided, for example, at one end of a metal wire constituting the terminal 12, and is a circuit board (not shown). It corresponds to a part for inserting into a mounting hole or the like provided in) and soldering.

  In FIG. 3 (B), the welded portion 17 formed in such a shape that the leader line 14 is strongly crushed is shown on the leader line 14, but the shape of the welded portion 17 is limited to this. There is no need to do. Further, a part of the lead wire 14 is fixed by a line pressing portion 16 provided in the groove 15.

  Next, it will be described in more detail with reference to FIGS.

  4A to 4C are cross-sectional views for explaining a state in which the terminal 12 is provided on the terminal block 13. 4A to 4C, 22 is a metal wire, 23 is a first hole, 24 is a second hole, and 25 is a C taper portion. The C taper portion 25 is a portion in which a R (phase) or a C surface (for example, an inclined slope) is provided at the corner of the connection portion between the second hole 24 and the groove 15. This is provided to prevent stress generation and springback of the lead wire 14 (not shown) set here.

  First, as shown in FIG. 4A, the metal wire 22 is inserted into the first hole 23 provided in the terminal block 13 as shown by the arrow 20. Thereafter, as shown in FIG. 4B, a part of the metal wire 22 is bent substantially vertically as shown by an arrow 20 to obtain a state shown in FIG. 4C, and one end of the metal wire 22 is connected to the external connection portion 21. The other end is used as a terminal 12.

  As shown in FIGS. 4A and 4B, when the metal wire 22 is inserted, the metal wire 22 is previously molded into an L shape (a shape having a portion bent substantially perpendicularly to the L shape). Alternatively, this may be outsert molding or insert molding. Further, instead of the metal wire 22, a predetermined metal plate may be punched out.

  A dotted line 19 in FIG. 4B and FIG. 5A and FIG. 5B, which will be described later, explains how the thickness of the cover of the lead wire 14 is adjusted by the depth of the groove 15, and details will be described later. This will be described with reference to FIG.

  FIGS. 5A and 5B are cross-sectional views illustrating how the lead wire 14 is inserted into the groove 15 provided in the terminal block 13. 5A and 5B, reference numeral 26 denotes a winding.

  As shown in FIG. 5A, the lead wire 14 from the winding 26 is inserted into the second hole 24 as shown by the arrow 20.

  FIG. 5B is a cross-sectional view for explaining how the lead wire 14 inserted into the second hole 24 is inserted into the groove 15. As shown by an arrow 20 in FIG. 5B, the lead wire 14 is set in the groove 15. 5A and 5B and the like, the line pressing portion 16 that fixes the lead wire 14 is not shown.

  FIG. 6 is a cross-sectional view illustrating a state in which the lead wire 14 is resistance-welded to the terminal 12 which is a part of the exposed portion of the metal wire 22. 6A and 6B, reference numeral 27 denotes a resistance welding apparatus. In FIG. 6, since the lead wire 14 is fixed so as to be substantially parallel to the terminal 12 by the wire pressing portion 16 (not shown), the welding workability by the resistance welding device 27 is improved. In addition, the arrow 20 in FIG. 6 shows the welding process by the resistance welding apparatus 27 typically.

  First, as shown in FIG. 6, when the lead wire 14 is bent substantially vertically, a C-plane taper portion 25 is provided at the connection portion between the bottom of the groove 15 and the second hole 24, thereby leading the lead wire 14. Prevents stress concentration and springback.

  Next, the effect by resistance welding is demonstrated using FIG. 7 (A)-(C).

  FIG. 7A is a cross-sectional view showing a state in which the lead wire 14 is fixed to the terminal 12 that is a part of the exposed portion of the metal wire 22, and FIG. 7B is a diagram of each portion when the resistance welding method is used. FIG. 7C is a diagram showing the temperature, and FIG. 7C is a diagram showing the temperature in each part when the conventional soldering method is used. 7A to 7C, reference numeral 28 denotes a temperature rising by the resistance welding method, and 29 denotes a temperature rising by the soldering method.

  7A to 7C, the dotted line 19a indicates the temperature (specifically, the temperature of the lead line 14) in each part of FIG. 7A. A dotted line 19b indicates the allowable temperature range of the lead line 14 coating. 7B and 7C, when the dotted line 19b is exceeded, there is a possibility that the covering of the lead wire 14 is thermally affected.

  7B and 7C, the Y axis is the temperature of the lead wire 14, and schematically shows the temperature (particularly the peak temperature) of the lead wire 14 by resistance welding or soldering.

  7B and 7C, the X axis indicates the distance from the welded portion 17.

  As shown in FIG. 7B, the temperature 28 that rises by the welding method becomes maximum near the welded portion 17, but is not particularly raised in other portions. This is because resistance welding is performed instantaneously as shown in FIG. For this reason, as shown in FIG. 7B, the thermal influence on the covering of the lead wire 14 shown by the dotted line 19b hardly occurs.

  FIG. 7C is a schematic diagram showing the influence of the temperature 29 that is increased by the conventional soldering method. 7C, the distance from the soldered portion corresponds to the case where the welded portion 17 in FIG. 7A is a soldered portion (not numbered).

  As shown in FIG. 7C, in the case of the soldering method, as shown by a temperature 29 rising by the soldering method in order to heat both the terminal 12 and the lead wire 14 by a soldering iron or the like for a certain period of time. It can be seen that the temperature rises to a considerable portion of the lead wire 14 (or to a position far away from the soldering portion). As a result, up to a significant portion of the leader line 14, the coating is thermally affected. As a result, the creepage distance and insulation distance obtained by covering the lead wire 14 change.

  On the other hand, as shown in FIG. 7B, in the case of the welding method, since the welding is completed instantaneously, the coating is hardly affected by heat, and the creepage distance and insulation obtained by the coating of the lead wire 14 are reduced. Since the distance does not change, the reliability of the thin coil 11 is increased.

  Next, an example of the structure of the line pressing portion 16 will be described with reference to FIG. FIG. 8 is a perspective view showing a state in which the lead wire 14 can be fixed so as to be substantially parallel to the terminal 12 by the line pressing portion 16. In addition, the wire holding | suppressing part 16 raises fixing strength using the elasticity of a coating | cover by fixing the coating | cover which is a part of the leader line 14. FIG.

  The line pressing part 16 in FIG. 8 is, for example, a part in which a part of the groove 15 is locally thinned, and is provided to fix the lead wire 14.

  As shown in FIGS. 1A and 1B and FIGS. 2A and 2B, the line pressing portion 16 is provided in a portion where the radial grooves 15 are substantially parallel to each other. That is, by providing the plurality of grooves 15 in the vicinity of the terminal 12 of the groove 15 and being substantially parallel to each other, the lead wire 14 can be reliably accommodated in the groove 15. Thus, automatic insertion of the lead wire 14 into the groove 15 by a rubber roller or the like is facilitated.

  Further, by fixing a part of the lead wire 14 with the wire pressing portion 16, there is no occurrence of glitches or the like during welding of the lead wire 14 to the terminal 12, so that the workability of welding is improved. Moreover, the heat dissipation effect by the wire pressing part 16 reduces the thermal influence on the coating of the lead wire 14 during welding.

  Next, the manner in which the lead wire 14 and the terminal 12 are fixed substantially in parallel will be described with reference to FIG.

  FIGS. 9A and 9B are cross-sectional views for explaining how the exposed portion of the metal wire 22 and the lead wire 14 are connected. 30 is a coating, 31 is a copper wire, and a coating 30 is formed around it. The coating 30 can be selected from reinforced insulation or three-layer insulation specifications depending on the application.

  FIG. 9B is a cross-sectional view showing a state in which the leader line 14 is set in a substantially straight line by using the step between the metal line 22 and the bottom of the groove 15 indicated by a dotted line 19 in FIG. 9A. FIG. In FIG. 9 (B), the lead wire 14 is comprised from the copper wire 31 and the coating | cover 30 formed in the circumference | surroundings. 9A is provided between the bottom portion and the metal wire 22, no step due to the thickness of the covering 30 is generated in the lead wire 14 set here. This is because the level difference indicated by the dotted line 19 is substantially the same as the thickness of the coating 30 formed on the copper wire 31. In this way, the terminal 12 and the copper wire 31 can be made substantially parallel, the lead wire 14 can be made the shortest distance, and unnecessary stress can be prevented.

  9A and 9B, by making the depth of the groove 15 deeper than the diameter (or outer shape) of the lead wire 14, the lead wire 14 is hardly exposed to the outside from the groove 15. Therefore, the depth of the groove 15 is 1.5 times or more, preferably 2 times or more, more preferably 3 times or more the diameter of the lead wire 14.

  As described above, the lead wire 14 is a coated conductive wire having the copper wire 31 and the coating 30, and the groove 15 having a structure in which the copper wire 31 is substantially linear is provided at least at a position adjacent to the terminal 12. Thus, the reliability of the thin coil 11 is increased. The portion adjacent to the terminal 12 is the vicinity of the root of the terminal 12 bent substantially vertically (for example, 5 mm or less from the root, preferably 10 mm or less).

  By making the copper wire 31 straight, unnecessary stress on the copper wire 31 can be prevented, and the lead wire 14 can be shortened (and the electrical resistance can be minimized).

  As described above, the winding 26, the resin terminal block 13 holding the winding 26, and the metal terminal 12 (or metal) fixed so that a part of the terminal block 13 is exposed to one or more ends. A thin coil 11 formed by punching a wire 22 or a metal plate), and a plurality of grooves 15 are provided radially on the bottom surface of the terminal block 13, and in the vicinity of the terminals 12 in the grooves 15. A second hole 24 having a C-tapered portion 25 in which a wire holding portion 16 is provided in a portion where the grooves 15 are parallel to each other and a lead wire 14 from the winding 26 is provided in the groove 15. A thin coil in which substantially all of the lead wire 14 is structurally separated by being disposed in the groove 15 and provided with a welded portion 17 made of resistance welding at the exposed portion of the terminal 12. 11 in the thin coil 11 Automation and self-alignment of the wiring and connection (self-harmonization) becomes possible, to prevent the wiring and wiring mistakes. The lead wire 14 is arranged in the groove 15 as much as possible, so that the lead wire 14 and an external circuit or the like provided in the vicinity thereof (for example, a circuit board may be provided on the bottom portion of the thin coil 11). Can be prevented, and long-term reliability is ensured. Further, the use of the wire pressing portion 16 also has an effect of making it difficult for the lead wire 14 to hang from the groove 15.

  The winding 26 and the core (not shown) may be fixed to the terminal block 13 by using a normal fixing method.

  In addition, the arrangement | positioning of several groove | channels 15 is made mutually radial, The automatic insertion property of the lead wire 14 to the groove | channel 15 is improved, and the thin coil 11 can be reduced in size. Further, as shown in FIGS. 1A and 1B and FIGS. 2A and 2B, the radially provided grooves 15 are divided into a plurality of pieces (for example, the grooves 15 are further radially arranged in the middle of the radially grooved 15). To improve the moldability of the groove 15 and the automatic insertion of the lead wire 14 into the groove 15.

  In addition, by embedding one lead wire 14 in each groove 15 one by one, the insulation and reliability between the plurality of lead wires 14 can be enhanced, and the reliability of the thin coil 11 is improved. .

  In addition, the lead wire 14 is a coated conductor composed of a copper wire 31 and a coating 30 formed around the copper wire 31, and has a structure in which the copper wire 31 is substantially linear at least at a position adjacent to the terminal 12. By forming the thin coil 11 provided with a groove 15 (for example, the portion indicated by the dotted line 19 in FIGS. 5A and 5B and the groove 15 having the structure described in FIGS. 9A and 9B). The reliability of the copper wire 31 can be increased, the wiring resistance of the copper wire 31 can be minimized, and the characteristics of the thin coil 11 can be improved.

  Further, the step of fixing the winding 26 and the metal terminal 12 to the resin terminal block 13 by insert molding or outsert molding, and the lead wire 14 from the winding 26 to the terminal block 13 A thin coil 11 having a step of inserting into the groove 15 provided, and a step of resistance welding the lead wire 14 to an exposed portion of the terminal 12 provided at an end of the groove 15 to provide a welded portion 17. The thin coil 11 can be stably manufactured by the manufacturing method.

(Embodiment 3)
Hereinafter, as a third embodiment of the present invention, an example of a power source using the thin coil 11 described in the first embodiment will be described with reference to FIG.

  FIGS. 10A and 10B are cross-sectional views illustrating an example of a power source using the thin coil 11 described in the first embodiment. Here, the power source includes not only AC-AC but also AC-DC, DC-DC, and the like. Various circuits (for example, a sustain circuit) including the thin coil 11 such as a choke coil are also examples of the power source.

  10A and 10B, reference numeral 32 denotes a circuit board, for example, a double-sided board or a multi-layer board in which a copper foil is bonded to a glass epoxy resin. In addition, the copper foil in the circuit board 32 and various electronic components (for example, a semiconductor is a square chip resistor, an electrolytic capacitor, etc.) mounted on this are not shown in figure.

  Reference numeral 33 denotes an opening. For example, the thin coil 11 can be mounted at a low height by inserting a protruding portion of the thin coil 11 (for example, a thick portion in which a plurality of windings 26, cores, and the like are incorporated). It becomes.

  Reference numeral 34 denotes a connection hole, and the connection hole 34 is a hole formed in the circuit board 32. For example, the external connection portion 21 of the thin coil 11 of the present invention is inserted and electrically connected. By performing copper plating (or through-hole plating) or the like inside the connection hole 34, the stability of mutual electrical or physical connection is enhanced.

  Reference numeral 35 denotes a power source, which includes at least the thin coil 11 and the circuit board 32. 10A and 10B, in order to reduce the thickness of the power source 35, an electrolytic capacitor or the like which is a large component is laid down so as to be substantially parallel to the circuit board 32, or a rectangle formed on the circuit board 32. It is carried out in the hole. However, there are various shapes of holes in the circuit board 32 as described above (including not only a small round hole for inserting a lead wire, but also a large deformed hole of several centimeters square for inserting a plurality of electrolytic capacitors). The problem is that the mechanical strength of the circuit board 32 itself decreases as the thickness of the circuit board 32 increases.

  FIG. 10B is a cross-sectional view showing an example of a power source 35 in which the thin coil 11 is mounted on the circuit board 32 shown in FIG. As shown in FIG. 10B, by mounting the thin coil 11 of the present invention, the circuit board 32 can be reinforced, and the power source 35 can be thinned and thinned (and wall mounted). .

  A thin coil 11 comprising a winding 26, a resin terminal block 13 that holds the winding 26, and a metal terminal 12 that is fixed so that a part of the terminal block 13 is exposed at one or more ends. A plurality of grooves 15 are provided radially on the bottom surface of the terminal block 13, and a line pressing portion 16 is provided in the vicinity of the terminals 12 of the grooves 15 where the grooves 12 are parallel to each other. By arranging the lead wires 14 from the windings 26 in the grooves 15, these lead wires 14 are structurally separated from each other one by one and from the windings 26 arranged in the grooves 15. A thin coil 11 in which substantially all of the lead wire 14 is disposed in the groove 15 and a welding portion 17 made of a resistance welding portion is provided on the exposed portion of the terminal 15 and a part of the thin coil 11 are inserted. Hole (for example, the opening 33 or connection shown in FIGS. 10A and 10B) 34) having a circuit board 32, and a part of the terminal block 13 is fixed to the circuit board 32 so that the circuit board 32 is reinforced to provide a power source 35. It is possible to achieve both a reduction in the thickness of 35 and an increase in strength, contributing to the wall mounting of thin TVs and the like.

  A plurality of windings 26 and cores (not shown) incorporated in the thin coil 11 are located above the thin coil 11 (or above the terminal block 13), as shown in FIGS. The lead wire 14 from the winding 26 is fixed and provided on the back side of the thin coil 11 through a hole formed in the terminal block 13 (for example, the second hole 24 in FIGS. 5A and 5B). By storing in the groove 15, the thin coil 11 can be further thinned.

  As described above, in the present invention, the lead wire 14 from the winding 26 is inserted into the radial second groove 15 provided in the terminal block 13 and further fixed by the wire holding portion 16, thereby leading the lead wire 14. The necessary lead wires 14 are individually stored in the grooves 15 one by one without causing a wiring mistake between the terminal 12 and the terminal 12, and these are individually connected to the terminal 12 by the highly reliable welded portion 17. A thin coil 11 is proposed, and the cost is reduced by automatic production.

  As described above, the thin coil of the present invention, the manufacturing method thereof, and the power source using the same, even in the thin coil incorporating a plurality of windings, no connection mistakes or wiring mistakes between the windings occur. Since the terminal and the metal wire constituting the terminal can be reliably connected by resistance welding with excellent productivity and reliability, the cost and quality of the thin coil can be reduced.

(A) (B) is the perspective view of the back surface of the thin coil in Embodiment 1, respectively, and the perspective view which expanded the part Both (A) and (B) are perspective views for explaining a state in which a lead wire is inserted into a groove provided on the back surface side of the thin coil and fixed by a wire pressing portion. (A) (B) is a perspective view explaining the welding part provided in the terminal and the leader line together (A)-(C) is sectional drawing explaining a mode that a terminal is provided in a terminal block together (A) (B) is sectional drawing explaining a mode that a lead wire is inserted in the groove | channel provided in the terminal block together. Sectional drawing explaining a mode that a lead wire is resistance-welded to the terminal which is a part of exposed part of a metal wire (A) is sectional drawing which shows a mode that a lead wire is fixed to the terminal which is a part of exposed part of a metal wire, (B) is a figure which shows the temperature in each part at the time of using a resistance welding method, (C) Figure showing the temperature at each part when using the conventional soldering method The perspective view which shows a mode that a leader line can be fixed so that it may become substantially parallel with a terminal with a wire holding | suppressing part. (A) (B) is sectional drawing explaining a mode that an exposed part and leader line of a metal wire are connected together (A) (B) is sectional drawing which shows an example of the power supply using the thin coil demonstrated in Embodiment 1 together. Bottom view explaining lead wire connection processing in conventional coils

Explanation of symbols

DESCRIPTION OF SYMBOLS 11 Thin coil 12 Terminal 13 Terminal block 14 Lead wire 15 Groove 16 Wire holding part 17 Welding part 18 Hole 19 Dotted line 20 Arrow 21 External connection part 22 Metal wire 23 1st hole 24 2nd hole 25 C taper part 26 Winding 27 Resistance Welding Equipment 28 Temperature Raised by Welding Method 29 Temperature Raised by Soldering Method 30 Coating 31 Copper Wire 32 Circuit Board 33 Opening 34 Connection Hole 35 Power Supply

Claims (8)

A thin coil comprising a winding, a resin terminal block for holding the winding, and a metal terminal fixed so that a part of the terminal block is exposed at least one end of the terminal block,
A plurality of grooves are provided radially on the bottom surface of the terminal block,
In the vicinity of the terminal of the groove and in a portion where the grooves are substantially parallel to each other, a line pressing portion is provided,
The lead wires from the windings are structurally separated from each other by disposing them in the grooves,
Almost all of the lead wires from the windings arranged in the groove are arranged in the groove,
The thin coil which provided the resistance welding part in the exposed part from the said terminal block of the said terminal. 2. The thin coil according to claim 1, wherein the terminal is a metal wire, and the metal wire has a flat portion at least at a part thereof. The thin coil according to claim 1, wherein the terminal is formed by punching a metal plate and is insert-molded on the terminal block. A thin coil comprising a winding, a resin terminal block for holding the winding, and a metal terminal fixed so that a part of the terminal block is exposed at least one end of the terminal block,
A plurality of grooves are provided radially on the bottom surface of the terminal block,
In the vicinity of the terminal of the groove and in a portion where the grooves are parallel to each other, a line pressing part is provided,
The lead wire from the winding is taken out through a hole having a C taper provided in the groove,
Structurally separated by disposing substantially all of the leader lines in the groove;
A thin coil provided with a resistance weld at the exposed portion of the terminal. The thin coil according to claim 4, wherein one lead wire is embedded in one groove. The thin coil according to claim 4, wherein the lead wire is a coated conductive wire, and the copper wire is provided with a groove having a substantially linear shape at least at a position adjacent to the terminal. Fixing the winding and the metal terminal to the resin terminal block;
Inserting a lead wire from the winding into a groove provided in the terminal block;
Resistance-welding the lead wire to the terminal provided at the end of the groove;
The manufacturing method of the thin coil which has. A thin coil comprising a winding, a resin terminal block for holding the winding, and a metal terminal fixed so that a part of the terminal block is exposed at least one end of the terminal block,
A plurality of grooves are provided radially on the bottom surface of the terminal block,
In the vicinity of the terminal of the groove and the part where the groove is parallel to each other, a line pressing part is provided,
By arranging the lead wires from the windings in the grooves, they are structurally separated from each other,
Almost all of the lead wires from the windings arranged in the groove are arranged in the groove,
A thin coil provided with a resistance weld on the exposed portion of the terminal;
A circuit board having a hole for inserting a part of the thin coil, and a power source comprising:
By fixing a part of the terminal block to the circuit board,
A power supply in which the circuit board is reinforced.

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