JP2011171381A - Coil member and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil member that facilitates attachment of a lead wire to a coil and has a simple structure, and is superior in flexibility; and to provide a method of manufacturing the same. <P>SOLUTION: The coil member includes: a coil body 2 comprising a conductor 5 and a bobbin 6 wound with the conductor 5; lead wires 12a, 12b electrically connecting with the conductor 5; a frame-shaped frame 3 supporting the coil body 2 and forming a magnetic circuit for magnetic flux generated by the coil body 2; two terminal parts 10a, 10b to which both ends of the conductor 5 are connected; connection plates 11a, 11b disposed inside openings 3a, 3b of a frame part of the frame 3 and having conductivity; and a support part 8 provided on the bobbin 6 and supporting one-end sides of the terminal parts 10a, 10b. Ends of the lead wires 12a, 12b and other-end sides of the terminal parts 10a, 10b are connected to the connection plates 11a, 11b, respectively; and the lead wires 12a, 12b and conductor 5 are electrically connected to each other through the connection plates 11a, 11b, respectively. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a coil member and a manufacturing method thereof.

  Conventionally, a coil formed by winding a conductive wire around an insulating bobbin is known. As a method for manufacturing this type of coil, the present inventor has proposed a method for manufacturing a coil that can simplify the process of connecting a lead wire and a conductive wire in particular (for example, Patent Document 1).

  In the manufacturing method of the coil member described in Patent Document 1, the manufacturing process of the coil member is simplified by connecting the conducting wire and the lead wire using a fixing member. Specifically, after a conductive rod-shaped terminal is press-fitted into a fixing member, a conductive wire is wound around the terminal, and a lead wire is inserted into the fixing member insertion hole from a direction opposite to the terminal press-fitting direction. In the fixing member, the lead wire and the lead wire are soldered via the terminal.

JP 2007-294647 A (Detailed description of the invention)

  However, in the method for manufacturing a coil member described in Patent Document 1, it is necessary to connect the conductive wire and the lead wire using solder inside the fixing member, which takes time and labor. In addition, since the lead wire and the lead wire are connected and integrated inside the fixing member, only the lead wire cannot be retrofitted, resulting in poor versatility.

  The present invention has been made in view of such problems, and an object of the present invention is to easily attach a lead wire to a coil, to have a simple structure, and to have excellent versatility, and a method for manufacturing the same. Is to provide.

  In order to solve the above problems, the present invention generates a coil body formed of a conducting wire and a bobbin around which the conducting wire is wound, a lead wire that conducts electricity to the conducting wire, and supports the coil body and is generated from the coil body. Provided on the bobbin, a frame-like frame that forms a magnetic circuit of magnetic flux, two terminal parts to which both ends of the conducting wire are connected, a conductive connecting plate arranged inside the opening of the frame of the frame A support portion that supports one end of the terminal portion, and connects the end portion of the lead wire and the other end of the terminal portion to the connection plate, and electrically connects the lead wire and the conductive wire via the connection plate. To do.

  In another aspect of the present invention, the connection plate is preferably housed in a fixed plate made of a non-conductive material and arranged so as to be parallel or substantially parallel to the opening surface of the frame of the frame.

  In another aspect of the present invention, it is preferable that the fixed plate has a curved surface portion having a curved surface having a shape corresponding to the outer peripheral surface of the conducting wire wound around the bobbin on the side facing the coil body.

  According to another aspect of the invention, the fixing plate is provided with a protruding portion that protrudes sideways, and the protruding portion is formed so as to be fitted into the hole provided in the frame from the inside of the frame. It is preferable that

  In another aspect of the invention, the connection plate is formed with a first connection portion to which an end portion of the lead wire is connected and a second connection portion to which the other end of the terminal portion is connected. preferable.

  According to another aspect of the invention, the first connection portion and the second connection portion are cut at a pair of opposing sides of a rectangular or substantially rectangular region, and the region is orthogonal to the plane of the connection plate. The end of the lead wire is connected to the first connecting portion in a state where the end of the lead wire is inserted into the inside of the first connecting portion extruded in the arch shape, and is connected to the terminal. It is preferable that the other end of the part is connected to the second connection part in a state of being inserted into the second connection part extruded in an arch shape.

  According to another aspect of the invention, the terminal portion has a pin shape, and the support portion has an insertion hole such that a direction perpendicular to or substantially perpendicular to the axial direction of the coil body is a depth direction. One end of the terminal portion is inserted into the insertion hole and is supported so as to be rotatable with respect to the support portion, and the other end of the terminal portion is present at a position away from the rotation shaft. It is preferable to be electrically connected to the connecting portion.

  According to another aspect of the invention, the terminal portion has an elongated plate shape, and a hole portion penetrating in the thickness direction is formed on one end side of the terminal portion, and the hole portion is provided in the support portion. It is preferable that one end of the terminal portion is supported by the support portion and the other end of the terminal portion is electrically connected to the connection plate by being fitted into the convex portion.

  According to another aspect of the invention, the terminal portion includes a press-fit portion that is press-fitted into the support portion, and a contact portion that is disposed below the connection plate and is in surface contact or line contact with the connection plate. The terminal part is supported by the support part by press-fitting the part into the recess provided in the support part, and the terminal board is connected to the connection board by the contact part contacting the lower surface of the connection board. Is preferred.

  In another invention, a coil body formed of a conducting wire and a bobbin around which the conducting wire is wound, and a magnetic flux generated from the coil body while supporting the coil body in close contact with both axial end surfaces of the coil body. A frame-like frame forming the magnetic circuit, two terminal pins to which both ends of the conductive wire are connected, and an arch shape in a direction perpendicular to the plane, arranged above the coil body in the frame of the frame In the manufacturing method of the coil member having the connection plate having the connection portion pushed out to the end and the support portion having the insertion hole into which one end of the terminal pin is inserted, one end of each terminal pin is inserted into the insertion hole of the support portion A terminal pin inserting step, a terminal pin bending step of bending the other end of the terminal pin in a direction perpendicular to one end of the terminal pin, a winding step of winding a conducting wire around a bobbin to form a coil body, and a connecting plate Terminal pin A terminal pin press-fitting step in which the other end of the terminal pin is press-fitted into the connection portion of the connection plate, and the connection plate is moved together with the other end of the terminal pin around the one end of the terminal pin inserted into the insertion hole. A first disposing step of rotating and disposing the connecting plate on the coil body.

  In another invention, a coil body formed of a conducting wire and a bobbin around which the conducting wire is wound, and a magnetic flux generated from the coil body while supporting the coil body in close contact with both axial end surfaces of the coil body. A frame-like frame forming the magnetic circuit, two terminal plates having an elongated flat plate shape in which both ends of the conductive wire are connected and a hole is formed at one end thereof, and the coil body in the frame of the frame A coil member having a connection plate having a connection portion disposed above and extruded in an arch shape in a direction orthogonal to the plane, and a support portion having a convex portion that fits into a hole portion of the terminal plate In the manufacturing method, a fitting process in which one end of each terminal board is fitted into the convex portion of the support part, a terminal board bending process in which the other end side of the terminal board is bent in a direction perpendicular to the one end, and a conducting wire is wound around the bobbin. Winding process for coil body The terminal plate is pressed toward the other end of the terminal plate, and the other end of the terminal plate is press-fitted into the connecting portion of the connection plate, and the bent portion of the terminal plate bent in the terminal plate bending step is coiled. A second disposing step of folding back toward the body side and disposing the connecting plate on the coil body.

  In another invention, a coil body formed of a conducting wire and a bobbin around which the conducting wire is wound, and a magnetic flux generated from the coil body while supporting the coil body in close contact with both axial end surfaces of the coil body. A frame-like frame forming the magnetic circuit, two plate-shaped terminal plates having both press-fit portions and contact portions connected to the press-fit portions, and coils in the frame of the frame. In a manufacturing method of a coil member having a connection plate disposed above a body and a support portion having a recess into which a press-fit portion of a terminal plate is fitted, the press-fit portion of each terminal plate is placed in the recess of the support portion. A second terminal plate fitting step of fitting, a winding step of winding a conductive wire around a bobbin to form a coil body, and a second terminal plate bending step of bending the contact portion of the terminal plate so as to be inclined obliquely upward with respect to the press-fit portion And the lower side of the connection plate So as to contact, in which a third arrangement step of arranging the connecting plate on the coil member while pressing the connecting plate above the contact portion.

  According to the present invention, it is easy to attach a lead wire to a coil, and it is possible to provide a coil member having a simple structure and excellent versatility, and a method for manufacturing the same.

It is a perspective view of the coil member which concerns on the 1st Embodiment of this invention. It is a top view of the coil member which concerns on the 1st Embodiment of this invention. It is a perspective view of the bobbin and flame | frame used for the coil member shown in FIG. It is a figure which shows the structure of the stationary plate in FIG. 1, The upper stage is the top view, The middle stage is the front view which looked at the figure of the upper stage from the arrow A direction, The lower stage is the arrow B direction. It is the side view seen from. It is a perspective view which shows the structure of the connection board in FIG. It is a perspective view which shows the state which connected the terminal pin and the front-end | tip of a lead wire to the connection board in FIG. It is a flowchart of the manufacturing method of the coil member which concerns on the 1st Embodiment of this invention. It is a top view for demonstrating the terminal pin insertion process shown in FIG. It is a top view which shows the state in which the terminal pin was inserted in the insertion hole. It is a front view which shows the state after the winding process shown in FIG. It is a front view for demonstrating the terminal pin press-fit process shown in FIG. It is a front view which shows the state after the terminal pin press-fit process shown in FIG. FIG. 8 is a side view showing a state after the fixing plate arranging step shown in FIG. 7. It is a top view of the coil member which concerns on the 2nd Embodiment of this invention. It is a top view which shows the structure of the terminal board in FIG. 14, and a support part. It is a flowchart of the manufacturing method of the coil member which concerns on the 2nd Embodiment of this invention. It is a side view for demonstrating the state after the fitting process shown in FIG. It is a side view which shows the state which bent the terminal board and tied the front-end | tip part and rear-end part of conducting wire to this terminal board. It is a figure for demonstrating the terminal board press-fit process shown in FIG. It is a side view which shows the state after the 2nd fixing plate arrangement | positioning process shown in FIG. It is a top view of the coil member which concerns on the 3rd Embodiment of this invention. It is the schematic of the coil member seen from the arrow C direction in FIG. The upper stage is a plan view of a state in which the terminal plate is arranged on the support part in FIG. The lower row is a side view of the terminal board. It is a top view of the fixed board in FIG. It is a flowchart of the manufacturing method of the coil member which concerns on the 3rd Embodiment of this invention. It is a figure for demonstrating the 2nd terminal board press-fit process shown in FIG. It is a figure which shows the state after the winding process shown in FIG. It is a figure which shows the state after the 2nd terminal board bending process shown in FIG. It is a figure which shows the state after the 3rd stationary plate arrangement | positioning process shown in FIG.

Hereinafter, a coil member and a manufacturing method thereof according to a first embodiment of the present invention will be described with reference to the drawings. In the following description (common to each embodiment), FIGS. 1 to 6, 8 to 15, the arrow _{X 1} direction shown in FIGS. 17 to 24 and FIGS. 26 to 29 before, arrow the X ₂ direction behind the arrow _{Y 1} direction left, arrow _{Y 2} direction to the right, respectively define a lower and upper and arrow _{Z 2} direction arrow _{Z 1} direction.

(First embodiment)
FIG. 1 is a perspective view of a coil member 1 according to a first embodiment of the present invention. FIG. 2 is a plan view of the coil member 1 according to the first embodiment of the present invention.

  As shown in FIGS. 1 and 2, the coil member 1 includes a coil body 2, a frame-like frame 3 that covers the front and rear and the left and right of the coil body 2, and a fixing plate 4 that is held in the frame 3. And have. The coil body 2 includes a conducting wire 5, a bobbin 6 around which the conducting wire 5 is wound, and an exterior tape 7 that covers the outer peripheral side of the conducting wire 5. The conducting wire 5 is a covered wire formed by covering a conductive wire such as copper with an insulating film. As shown in FIG. 2, the bobbin 6 includes a trunk portion 6a around which the conducting wire 5 is wound, a front collar portion 6b provided at the front end of the trunk portion 6a, and a rear collar portion provided at the rear end of the trunk portion 6a. 6c and a support portion 8 provided at the upper end of the front flange portion 6b. The leading end portion 5a of the conducting wire 5 is drawn out from the gap between the front flange portion 6b and the exterior tape 7, and is connected to the terminal pin 10a pivotally supported by the support portion 8, and the trailing end portion 5b of the conducting wire 5 is connected to the front flange portion 6b. Is pulled out from the gap between the outer cover tape 7 and the terminal pin 10 b that is pivotally supported by the support portion 8.

  The exterior tape 7 is a thin tape formed of an insulating material (for example, an insulating cloth). The exterior tape 7 is wound so as to cover the entire conductor 5 wound around the body portion 6 a constituting the bobbin 6. The exterior tape 7 functions to prevent an electrical short circuit between the conductor 5 and a member outside the coil body 2. The frame 3 supports the bobbin 6 in close contact with the front flange portion 6b and the rear flange portion 6c provided at both ends in the axial direction of the bobbin 6, and forms a magnetic circuit of magnetic flux generated from the coil body 2.

  As shown in FIG. 2, the frame 3 has a frame shape, and the top and bottom thereof are open. Therefore, in a state where the coil body 2 is disposed in the frame 3, a first opening 3a described later opens upward. As described above, one end of the terminal pins 10 a and 10 b is pivotally supported on the support portion 8. The other ends of the terminal pins 10 a and 10 b are connected to connection plates 11 a and 11 b arranged inside the fixed plate 4. That is, the terminal pins 10 a and 10 b are disposed between the fixed plate 4 and the support portion 8. The terminal pins 10a and 10b have a form in which cylindrical stainless steel (wire) is bent. As described above, the terminal pins 10a and 10b include the front end portion 5a and the rear end portion 5b of the conducting wire 5, respectively. Are connected to each other. In addition, lead wires 12a and 12b for supplying power from the outside are connected to the connection plates 11a and 11b.

  FIG. 3 is a perspective view of the bobbin 6 and the frame 3.

  The frame 3 is composed of a thin plate member made of a magnetic material. As shown in FIG. 3, the frame 3 and a first frame 3c formed in a flat plate shape, and a concave from the rear to the front as viewed from above and below in FIG. The second frame 3d is formed in a shape. The first frame 3c and the second frame 3d are caulked and fixed by caulking the caulking portion W. The frame 3 includes a protruding engagement portion Y including a caulking portion W and a notch Z of the second frame 3d with which the protruding engagement portion Y engages. As a result of this fixing, the frame 3 has a frame shape, and a first opening 3a and a second opening 3b having square opening surfaces are formed above and below the frame 3 shown in FIG. . The first frame 3c is provided with a large-diameter frame hole 3e into which the plunger main body can be inserted, and a small-diameter frame hole that supports the movement of the plunger is provided at a portion facing the first frame 3c of the second frame 3d. 3f is provided. Further, holes 3g and 3g for fixing the fixing plate 4 are provided in a pair of wall portions standing on the left and right in the second frame 3d so as to face each other. Further, a notch portion 3h is formed at the front upper end portion of the second frame 3d formed in a concave shape by notching the center portion in the left-right direction of the upper end portion downward.

  As shown in FIG. 3, the bobbin 6 is a flanged cylindrical member in which an insertion hole 6 d through which the plunger is inserted is formed. As described above, the bobbin 6 includes a cylindrical body portion 6a, a square plate-shaped front flange portion 6b formed at the front end portion in the axial direction of the body portion 6a, and an axial rear end portion of the body portion 6a. A square plate-like rear collar portion 6c formed in the portion is provided. And the support part 8 by which the terminal pins 10a and 10b to which the front-end | tip part 5a and the rear-end part 5b of the conducting wire 5 are connected is provided in the upper end of the front collar part 6b. As shown in FIGS. 1 to 3, the support portion 8 includes a substrate portion 8 a having a plate shape, a left convex portion 8 b protruding upward from the left end of the substrate portion 8 a, and a right end of the substrate portion 8 a. It has the right convex part 8c which protrudes upwards, and the central convex part 8d which protrudes upwards from the center of the board | substrate part 8a. Further, grooves 8e that are notched in a concave shape along the left-right direction are formed on the upper surfaces of the left convex portion 8b and the right convex portion 8c. Furthermore, insertion holes 8f and 8f are formed on both the left and right sides of the central projection 8d from the left and right end faces toward the inner side in the left-right direction (see FIGS. 2 and 3). The insertion holes 8 f and 8 f are formed so that the depth direction of the holes is a direction perpendicular to the axial direction of the coil 2. One ends of the terminal pins 10 a and 10 b are inserted into the insertion holes 8 f and 8 f and are pivotally supported by the support portion 8.

  Here, the body part 6a, the front collar part 6b, the rear collar part 6c, and the support part 8 are integrally formed of an insulating resin material. The conductor 5 is wound around the body 6a of the bobbin 6, and the coil body 2 in which the entire wound conductor 5 is covered with the exterior tape 7 is accommodated in the frame 3 in the direction of the arrow shown in FIG. When the terminal pins 10a and 10b to which the front end portion 5a and the rear end portion 5b of the conductive wire 5 are connected are supported by the support portion 8 and connected to the fixed plate 4, the coil member 1 is obtained. At this time, the support portion 8 enters the cutout portion 3h of the frame 3 and is engaged with the cutout portion 3h.

  4 is a diagram showing the configuration of the fixing plate 4 in FIG. 1. The upper part is a plan view thereof, the middle part is a front view of the upper part viewed from the direction of arrow A, and the lower part is a diagram of the middle part. It is the side view which looked at from arrow B direction.

  As shown in the upper part of FIG. 4, the fixing plate 4 includes a crosspiece 16 that has a rectangular shape that is long in the left-right direction, and a rectangular portion 15 that is provided from the center of the crosspiece 16 toward the front. It has a substantially T-shaped plate shape. Inside the fixed plate 4, a pair of connection plates 11a and 11b are disposed. As shown in FIG. 1 and the like, the fixing plate 4 is disposed in the frame 3 in a form of being placed above the coil body 2. Specifically, the fixed plate 4 includes a rectangular portion 15 having a rectangular shape provided at the center in the left-right direction, and a crosspiece 16 extending outward from the left and right ends of the rectangular portion 15 in the left-right direction. , 16. As shown in the middle of FIG. 4, the crosspieces 16, 16 have side plate portions 17, 17 whose thickness increases toward the lower side as they go outward in the left-right direction. Projections 18, 18 projecting outward in the left-right direction in a substantially hemispherical form are provided on the side surfaces of the side plate portions 17, 17. The protrusions 18 and 18 are fitted into the holes 3g and 3g formed in the frame 3 when the fixing plate 4 is disposed in the frame 3 so that the fixing plate 4 is fixed to the frame 3. Fix it. The portions other than the connection plates 11a and 11b in the fixed plate 4 are made of, for example, a non-conductive material typified by an insulating resin material.

  As shown in FIG. 4, the rectangular portion 15 is formed with a pair of storage portions 19 and 19 for storing the connection plates 11 a and 11 b. The storage portions 19 are opened in a rectangular shape on the front end side of the rectangular portion 15. Connection plates 11a and 11b are arranged inside the storage portions 19 and 19 so as to be inserted from the front end side.

  Further, a curved surface portion 23 having a curved surface 22 formed in a curved shape toward the upper side is provided below the rectangular portion 15. The curved surface 22 has a curvature corresponding to the winding diameter of the outermost conductive wire 5 wound around the bobbin 6. For this reason, when the fixing plate 4 is disposed above the coil body 2, the curved surface 22 contacts the exterior tape 7 of the coil body 2 over the entire surface. Therefore, the fixed plate 4 disposed above the coil body 2 can maintain a stable state. Further, as shown in the lower part of FIG. 4, the curved surface portion 23 is formed in a substantially central region of the rectangular portion 15 in the front-rear direction. That is, the curved surface portion 23 is formed with a predetermined width dimension in a region in front of the crosspiece portion 16 when viewed from the lateral direction.

  FIG. 5 is a perspective view showing the configuration of the connection plates 11a and 11b. FIG. 6 is a perspective view showing a state in which the terminal pins 10a and 10b and the tips of the lead wires 12a and 12b are connected to the connection plates 11a and 11b.

  As shown in FIG. 5, the connection plates 11 a and 11 b are substantially rectangular plate members having a symmetrical shape on the left and right. The connection plates 11a and 11b are formed from a metal plate such as copper or iron. A total of four connection portions 24a to 24d for electrically connecting the terminal pin 10a and the lead wire 12a are formed on the connection plate 11a. The connection plate 11b is also formed with a total of four connection portions 25a to 25d for electrically connecting the terminal pins 10b and the lead wires 12b. The connection portion 24a is formed on the lower left side of the connection plate 11a. The connection portion 24 is formed by making a pair of upper and lower horizontal cuts in the connection plate 11a and pushing out a substantially rectangular region where the cuts are made in a curved shape (arch shape) downward. The other connecting portions 24b to 24d are provided with a pair of upper and lower horizontal cuts in the upper left, upper right and lower right of the connection plate 11a, and upward in a substantially rectangular region where the cuts are made. It is formed by extruding into a curved shape (arch shape). The connection parts 24c and 24d are formed to be slightly wider than the connection parts 24a and 24b. The connection portions 25a to 25d of the connection plate 11b are formed so as to be symmetrical with the connection portions 24a to 24d of the connection plate 11a. That is, the connecting portion 25a formed at the lower right of the connecting plate 11b is pushed downward in a curved shape (arch shape), and the other connecting portions 25b to 25d are pushed upward in a curved shape (arch shape). It is. Regarding the width dimension, the connecting portions 25c and 25d are formed to be slightly wider than the connecting portions 25a and 25b.

  As described above, the terminal pins 10a and the lead wires 12a are connected to the connection plate 11a. The terminal pin 10a is inserted from the front of the connection plate 11a so as to pass the upper side of the connection part 24a and the lower side of the connection part 24b. Specifically, the terminal pin 10a is inserted from the lower front side of the connection plate 11a so as to pass through the upper side of the connection portion 24a and then pass through the lower side of the connection portion 24b to the upper side of the connection plate 11a. That is, the connection parts 24a and 24b are formed as second connection parts. The lead wire 12a is inserted from the upper front side of the connection plate 11a so as to pass through the lower side of the connection part 24c and the lower side of the connection part 24d. That is, the connection parts 24c and 24d are formed as first connection parts. Then, in a state where the lead wire 12a is inserted into the connection portions 24c and 24d, the connection portions 24c and 24d are caulked downward (see FIG. 6). By this caulking, the lead wire 12a is securely connected to the connection plate 11a, and the lead wire 12a is prevented from coming off from the connection portions 24c and 24d. At this time, the lead wires 12a can be more effectively connected to the connection plate 11a by caulking the connection portions 24c and 24d while applying heat. Note that the connecting portions 24a and 24b into which the terminal pins 10a are inserted are not caulked.

  On the other hand, the terminal pin 10b and the lead wire 12b are connected to the connection plate 11b. As in the case of the terminal pin 10a, the terminal pin 10b is inserted from the lower front side of the connecting plate 11b so as to pass through the upper side of the connecting portion 25a and the lower side of the connecting portion 25b to the upper side of the connecting plate 11b. Similarly to the lead wire 12a, the lead wire 12b is also inserted from the upper front side of the connection plate 11b so as to pass through the lower side of the connection portion 25c and the lower side of the connection portion 25d. Then, the connecting portions 25c and 25d into which the lead wires 12b are inserted are caulked downward. At this time, the lead wires 12b can be more effectively connected to the connection plate 11b by caulking the connection portions 25c and 25d while applying heat. Note that the connecting portions 25a and 25b into which the terminal pins 10b are inserted are not caulked.

  2 and 4, the lower end of the terminal pin 10a connected to the connection plate 11a extends forward from a storage portion 19 formed on the left side of the fixing plate 4, and then bends to the right side. And inserted into an insertion hole 8 f formed in the support portion 8. On the other hand, the lower end of the terminal pin 10b connected to the connection plate 11b extends forward from a storage portion 19 formed on the right side of the fixed plate 4, and then bent to the left side to be formed on the support portion 8. Is inserted into the insertion hole 8f. Furthermore, the lead wires 12 a and 12 b connected to the connection plates 11 a and 11 b extend forward from the respective storage portions 19 formed on the left and right sides of the fixing plate 4, and Pulled out to the outside. Thus, the terminal pins 10a and 10b and the lead wires 12a and 12b are electrically connected to the connection plates 11a and 11b, respectively. For this reason, the terminal pin 10a and the lead wire 12a are electrically connected via the connection plate 11a, and the terminal pin 10b and the lead wire 12b are also electrically connected via the connection plate 11b. Furthermore, the front-end | tip part 5a and the rear-end part 5b of the conducting wire 5 are each connected to the terminal pins 10a and 10b. For this reason, the lead wire 12a is electrically connected to the conducting wire 5 via the connection plate 11a and the terminal pin 10a, and the lead wire 12b is also electrically connected to the conducting wire 5 via the connection plate 11b and the terminal pin 10b. ing.

  Next, the manufacturing method of the coil member 1 is demonstrated.

  FIG. 7 is a flowchart of the method for manufacturing the coil member 1. FIG. 8 is a plan view for explaining the terminal pin insertion step. FIG. 9 is a plan view showing a state in which the terminal pins 10a and 10b are inserted into the insertion holes 8f and 8f. FIG. 10 is a front view showing a state after the ticket turning process. FIG. 11 is a front view for explaining the terminal pin press-fitting step. FIG. 12 is a front view showing a state after the terminal pin press-fitting step. FIG. 13 is a side view showing a state after the fixing plate arranging step.

  First, as shown in the lower part of FIG. 6, the lead wire 12a is inserted into the connection portions 24c and 24d of the connection plate 11a, and the lead wire 12b is inserted into the connection portions 25c and 25d of the connection plate 11b. The lead wires 12a and 12b are electrically connected to the connecting plates 11a and 11b by caulking 24d, 25c and 25d while applying heat (lead wire connecting step P1). In this state, only the lead wires 12a and 12b are connected to the connection plates 11a and 11b, and the terminal pins 10a and 10b are not connected to the connection plates 11a and 11b.

  Next, as shown in FIG. 8, the terminal pins 10a and 10b are inserted along the respective grooves 8e and 8e formed in the left convex portion 8b and the right convex portion 8c from the outer side in the left-right direction of the support portion 8, respectively. Insert into the holes 8f, 8f (terminal pin insertion step P2). At this time, the terminal pins 10a and 10b are press-fitted into the insertion holes 8f and 8f. Note that the terminal pin insertion step P2 may be performed automatically by an insertion machine or manually.

  Next, as shown in FIGS. 9 and 10, the terminal pins 10a and 10b inserted into the insertion holes 8f and 8f are bent upward at a substantially right angle (terminal pin bending step P3).

  Then, the conducting wire 5 is wound around the bobbin 6 to manufacture the coil body 2 (winding step P4). In the winding process P4, the bobbin 6 to which the temporary fixing jig is attached is fixed to the fixing jig of the automatic winding machine, and the conductive wire 5 is wound around the body portion 6a of the bobbin 6. At this time, the bobbin 6 rotates together with the fixing jig. In this winding process P4, winding of the conducting wire 5 around the trunk portion 6a is automatically performed by an automatic winding machine. When the winding of the conducting wire 5 around the trunk portion 6a is completed, the bobbin 6 with the temporary fixing jig attached is removed from the fixing jig of the automatic winding machine. At this time, as shown in FIG. 10, the front end portion 5a and the rear end portion 5b of the conducting wire 5 wound around the bobbin 6 are pulled out from the front flange portion 6b of the bobbin 6, and the terminal pins 10a and 10b are bent. It is entangled near the part. All the winding process P4 is complete | finished above.

  Thereafter, dip soldering is performed on the front end portion 5a and the rear end portion 5b of the conducting wire 5 entangled with the terminal pins 10a and 10b (dip soldering process P5). Thereby, the front-end | tip part 5a and the rear-end part 5b of the conducting wire 5 are reliably fixed with respect to terminal pin 10a, 10b. Moreover, the exterior tape 7 is wound with an automatic machine so that the whole outer peripheral surface of the conducting wire 5 wound by the trunk | drum 6a may be covered.

  Then, as shown in FIG. 3, the bobbin 6 (coil body) is accommodated in the frame 3 in the direction of the arrow and fixed to the frame 3 (fixing step P6). In the fixing process P6, the frame 3 is fixed to the bobbin 6 by an automatic machine. These fixations may be performed manually.

  Next, as shown in FIG. 11, the fixing plate 4 is moved toward the bent terminal pins 10a and 10b. Then, the terminal pin 10a is passed through the left storage part 19 and press-fitted into the connection parts 24a and 24b, and the terminal pin 10b is passed through the right storage part 19 and press-fitted into the connection parts 25a and 25b (terminals). Pin press-fitting process P7). The terminal pin press-fitting process P7 is performed by an automatic press-fitting machine. In this state, the lead wires 12a and 12b and the terminal pins 10a and 10b are electrically connected via the connection plates 11a and 11b.

  Thereafter, in a state where the terminal pin press-fitting step P7 has been performed (see FIG. 12), the fixing plate 4 is rotated rearward around the terminal pins 10a and 10b inserted in the insertion holes 8f and 8f. Then, as shown in FIG. 13, the fixing plate 4 is disposed above the coil body 2 on the rear side of the support portion 8 so that the wide surface of the fixing plate 4 is along a direction parallel to the axial direction of the coil body 2. (Fixed plate arrangement step P8). At this time, the connection plates 11 a and 11 b arranged on the fixed plate 4 are also arranged in a direction parallel to the axial direction of the coil body 2. That is, the connection plates 11 a and 11 b are arranged in parallel or substantially parallel to the opening surface of the first opening 3 a of the frame 3. Further, when the fixing plate 4 is arranged above the coil body 2, the fixing plate 4 is fixed to the frame 3 by fitting the protrusions 18 and 18 of the fixing plate 4 into the holes 3 g and 3 g formed in the frame 3. Hold. The coil member 1 is manufactured through the above processes.

  In the coil member 1 according to the embodiment of the present invention, the terminal pins 10a, 10b and the lead wires 12a, 12b are electrically connected via the connection plates 11a, 11b arranged on the fixed plate 4. . For this reason, the electrical connection between the terminal pins 10a and 10b and the lead wires 12a and 12b can be reliably performed. Therefore, the electrical connection between the conductive wire 5 and the lead wires 12a and 12b can be reliably performed. Further, since the space above the conducting wire 5 formed inside the first opening 3a of the frame 3 is used to electrically connect the terminal pins 10a, 10b and the lead wires 12a, 12b, the space Can be used effectively, and the wiring structure can be simplified.

  In the coil member 1, the lead wires 12 a and 12 b are connected to a fixed plate 4 that is separate from the support portion 8. Therefore, the fixing plate 4 to which the lead wires 12a and 12b are connected in advance can be manufactured as a separate member, and the coil member 1 can be easily manufactured according to the needs of the user. Therefore, it is possible to reduce the cost and shorten the manufacturing time as compared with the case of manufacturing a lead wire with a connector.

  Moreover, in the coil member 1, since the support part 8 is united with the bobbin 6, for example, the bobbin 6 and the support part 8 can be mold-molded simultaneously, and manufacture becomes easy. In the fixing process P6, as shown in FIGS. 2 and 3, when the bobbin 6 is housed in the frame 3, the support portion 8 hits the frame 3, and the opening of the first opening 3a of the frame 3 is opened. The accommodation is completed in a state protruding from the surface. Therefore, the support part 8 functions as a stopper for the accommodation operation.

  In the coil member 1, the fixing plate 4 is lowered toward the terminal pins 10 a and 10 b bent vertically upward, and the connection portions 24 a and 24 b of the connection plates 11 a and 11 b arranged in the fixing plate 4. The terminal pins 10a and 10b are press-fitted into the connecting portions 25a and 25b. For this reason, it becomes easy to connect the terminal pins 10a and 10b to the connection plates 11a and 11b. Further, it is possible to automate the terminal pin insertion process P2, the terminal pin bending process P3, the winding process P4, and the dip soldering process P5, and it is possible to speed up the manufacturing work.

  In the coil member 1, the front end portion 5 a and the rear end portion 5 b of the conductive wire 5 connected to the terminal pins 10 a and 10 b are led out to the substrate portion 8 a of the support portion 8. For this reason, the opportunity that the front-end | tip part 5a and the rear-end part 5b of the conducting wire 5 contact with things other than the coil member 1 decreases. Therefore, the coil member 1 that is more difficult to be disconnected can be provided.

  In the coil member 1, one end of the terminal pins 10 a and 10 b bent at a right angle is inserted into the insertion holes 8 f and 8 f and is pivotally supported by the support portion 8. For this reason, after the other end side of the terminal pins 10a and 10b is press-fitted into the connection portions 24a and 24b of the fixing plate 4 by the terminal pin press-fitting step P7, the fixing plate 4 is fixed to the terminal pins 10a and 10b by the fixing plate arrangement step P8. It becomes possible to rotate around one end of the coil body 2 and arrange it above the coil body 2. Therefore, it is possible to electrically connect the terminal pins 10a and 10b and the lead wires 12a and 12b using the space above the conductive wire 5.

  In the coil member 1, a curved surface portion 23 is formed on the back side of the fixed plate 4. For this reason, it becomes possible to arrange | position the fixing plate 4 above the conducting wire 5 in the stable state. Further, when the fixing plate 4 is disposed above the conducting wire 5, the protrusion 18 provided on the fixing plate 4 is fitted into the hole 3 g. For this reason, it is possible to reliably hold the fixing plate 4 with respect to the frame 3.

(Second Embodiment)
Next, a coil member and a manufacturing method thereof according to the second embodiment of the present invention will be described with reference to the drawings. In the present embodiment, since only the configuration of the support portion and the terminal portion is different from that of the first embodiment, the different portions will be mainly described. Note that, in the coil member and the manufacturing method thereof according to the second embodiment, portions common to the first embodiment are denoted by the same reference numerals and description thereof is omitted or simplified.

  FIG. 14 is a plan view of the coil member 30 according to the second embodiment of the present invention. FIG. 15 is a plan view showing the configuration of the terminal boards 31a and 31b and the support portion 32 in FIG.

  As shown in FIG. 14, the coil member 30 includes a coil body 2, a frame-like frame 3 that covers the outer periphery of the coil body 2, and a fixing plate 4 that is held in the frame 3. The coil body 2 includes a conducting wire 5, a bobbin 6 around which the conducting wire 5 is wound, and an exterior tape 7 that covers the outer peripheral side of the conducting wire 5.

  In the present embodiment, a support portion 32 that holds one end of the terminal plates 31a and 31b to which the front end portion 5a and the rear end portion 5b of the conducting wire 5 are connected is provided at the upper end of the front flange portion 6b. As shown in FIG. 14, the support part 32 includes a board part 32a having a plate-like form, front and left and right outer edge parts of the board part 32a, and the board part 32a from the board part 32a to the left and right centers. A step 32b is provided so as to be higher by one step. By forming the stepped portion 32b, the support portion 32 is formed with flat portions 32c and 32c having a pair of flat surfaces on the left and right. From the left and right flat portions 32c and 32c, convex portions 33 and 33 having a substantially oval shape as viewed from above protrude upward. A hole 31d, which will be described later, of the front end portion 31c of the terminal plates 31a and 31b is fitted in the convex portion 33. The support part 32 is formed from an insulating resin material.

  As shown in FIGS. 14 and 15, the terminal plates 31 a and 31 b are elongated plate members arranged in a pair on the left and right. The front end portion 31c of the terminal plates 31a and 31b is formed with a substantially oval hole portion 31d having the same shape as the convex portion 33. The hole 31d penetrates the terminal plates 31a and 31b in the thickness direction (vertical direction). Further, on the side surface of the terminal plate 31a, 31b on the rear side of the hole portion 31d, a cutout portion 31e cut out in a curved shape toward the inside is formed. The front end 5a and the rear end 5b of the conducting wire 5 are entangled with the notch 31e. And the terminal boards 31a and 31b are arrange | positioned on the flat part 32c in the form that the convex part 33 fits in the hole part 31d. Further, the terminal plates 31 a and 31 b are firmly fixed to the support portion 32 by performing heat welding in a state where the convex portions 33 are fitted in the hole portions 31 d of the terminal plates 31 a and 31 b.

  The rear end portions of the terminal plates 31a and 31b are connected to the connection plates 11a and 11b arranged on the fixed plate 4 as in the case of the first embodiment. Since the terminal plates 31a and 31b are wider in the lateral direction than the terminal pins 10a and 10b, the width dimensions of the connecting portions 24a and 24b of the connecting plate 11a and the connecting portions 25a and 25b of the connecting plate 11b are the same as those in the first embodiment. It is formed larger than the shape. As in the case of the first embodiment, the terminal plate 31a is electrically connected to the connection plate 11a by being inserted into the connection portions 24a and 24b of the connection plate 11a. By being inserted into the connection portions 25a and 25b of the connection plate 11b, the connection plate 11b is electrically connected.

  Next, a method for manufacturing the coil member 30 will be described.

  FIG. 16 is a flowchart of the method for manufacturing the coil member 30. FIG. 17 is a side view for explaining the state after the fitting step. FIG. 18 is a side view showing a state in which the terminal plates 31a and 31b are bent and the leading end portion 5a and the trailing end portion 5b of the conductive wire 5 are bound to the terminal plates 31a and 31b. FIG. 19 is a diagram for explaining the terminal plate press-fitting step. FIG. 20 is a side view showing a state immediately after the second fixing plate arranging step is performed.

  First, as in the case of the first embodiment, the lead wires 12a and 12b are connected to the connection plates 11a and 11b by performing the lead wire connecting step P1. Then, as shown in FIG. 17, the convex part 33 is engage | inserted in the hole 31d of terminal board 31a, 31b, and each terminal board 31a, 31b is fixed to the support part 32 by thermocompression bonding (insertion process P10). Next, as shown in FIG. 18, the terminal plates 31a and 31b fixed to the support portion 32 are bent upward at a substantially right angle (terminal plate bending step P11).

  Then, the coil body 2 is manufactured by winding the conducting wire 5 around the bobbin 6 in the winding step P4. At this time, the front end portion 5a and the rear end portion 5b of the conducting wire 5 wound around the bobbin 6 are pulled out from the front flange portion 6b of the bobbin 6, and are entangled with the notch portion 31e. Next, dip soldering is performed on the front end portion 5a and the rear end portion 5b of the conducting wire 5 entangled with the terminal plates 31a and 31b (dip soldering process P5). Thereafter, the bobbin 6 (coil body) is accommodated in the frame 3 in the direction indicated by the arrow in FIG.

  Next, as shown in FIG. 19, the fixing plate 4 is moved toward the bent terminal plates 31a and 31b. Then, the terminal plate 31a is passed through the left storage portion 19 and pressed into the connection portions 24a and 24b, and the terminal plate 31b is passed through the right storage portion 19 and pressed into the connection portions 25a and 25b (terminals). Plate press-fitting step P12). The terminal board press-fitting process P12 is performed by an automatic press-fitting machine. In this state, the lead wires 12a and 12b and the terminal plates 31a and 31b are electrically connected via the connection plates 11a and 11b.

  Thereafter, the bent portions of the terminal plates 31a and 31b are folded back to the original state after the terminal plate press-fitting step P12. Then, as shown in FIG. 20, the fixing plate 4 is arranged above the coil body 2 on the rear side of the support portion 32 (second fixing plate arrangement step P13). At this time, the fixing plate 4 is held with respect to the frame 3 by fitting the protrusions 18 and 18 of the fixing plate 4 into the holes 3 g and 3 g formed in the frame 3. The coil member 30 is manufactured through the above processes.

  In the coil member 30 according to the embodiment of the present invention, the terminal plates 31a, 31b and the lead wires 12a, 12b are electrically connected via the connection plates 11a, 11b arranged on the fixed plate 4. . For this reason, the electrical connection between the terminal plates 31a and 31b and the lead wires 12a and 12b can be reliably performed. For this reason, the electrical connection between the conductive wire 5 and the lead wires 12a and 12b can be reliably performed. Further, since the terminal plates 31a and 31b are electrically connected to the lead wires 12a and 12b using the space above the conductor 5, the space can be used effectively and the wiring structure can be simplified. It becomes.

  In the coil member 30, the terminal plates 31 a and 31 b are fixed to the support portion 32 of the bobbin 6 by fitting the hole portion 31 d into the convex portion 33 and performing heat welding. Therefore, the terminal plates 31a and 31b can be fixed to the bobbin 6 with a simple method.

  The coil member 30 is configured to connect the fixed plate 4 containing the connection plates 11a and 11b to which the lead wires 12a and 12b are connected to the terminal plates 31a and 31b press-fitted to the bobbin 6 side. For this reason, if the fixing plate 4 to which the lead wires 12a and 12b are connected in advance is manufactured separately, the coil member 1 can be manufactured simply by connecting the fixing plate 4 to the bobbin 6 side. . Therefore, it is possible to reduce the cost and shorten the manufacturing time as compared with the case of manufacturing a lead wire with a connector.

  Moreover, in the coil member 30, since the terminal plates 31a and 31b have a plate shape, they are connected to the connection plates 11a and 11b with a large contact area. For this reason, the terminal plates 31a and 31b can be reliably held in the fixed plate 4, and the lead wires 12a and 12b and the conductive wire 5 can be more reliably electrically connected.

(Third embodiment)
Next, a coil member and a method for manufacturing the same according to a third embodiment of the present invention will be described with reference to the drawings. In the present embodiment, parts different from the first and second embodiments will be mainly described. Note that, in the coil member and the manufacturing method thereof according to the third embodiment, portions common to the first and second embodiments are denoted by the same reference numerals and description thereof is omitted or simplified.

  FIG. 21 is a plan view of a coil member 40 according to the third embodiment of the present invention. FIG. 22 is a schematic view of the coil member 40 as viewed from the direction indicated by arrow C in FIG. 23 is a plan view of a state in which the terminal plates 42a and 42b are arranged on the support portion 43 in FIG. The lower part of FIG. 23 is a side view of the terminal boards 42a and 42b in the upper part of FIG. 24 is a plan view of the fixing plate 41 in FIG.

  As shown in FIG. 21, the coil member 40 is held by the bobbin 6, the coil body 2, the frame-like frame 3 that covers the outer periphery of the coil body 2, the fixing plate 41 that is held in the frame of the frame 3. A pair of terminal plates 42a and 42b. The coil body 2 includes a conducting wire 5, a bobbin 6 around which the conducting wire 5 is wound, and an exterior tape 7 that covers the outer peripheral side of the conducting wire 5.

  In the present embodiment, a support portion 43 for press-fitting terminal plates 42a and 42b to which the front end portion 5a and the rear end portion 5b (see FIG. 23) of the conducting wire 5 are connected is provided at the upper end of the front flange portion 6b. It has been. Further, the support plate 43 holds the fixing plate 41 described above. Further, as shown in FIG. 24, connection plates 44 a and 44 b are attached to the back side of the fixed plate 41. As shown in FIG. 21, in a state where the fixing plate 41 is held by the support portion 43, the terminal plates 42a and 42b and the connection plates 44a and 44b are in contact with each other.

  As shown in the upper part of FIG. 21 to FIG. 23, the support portion 43 has a rectangular shape as viewed from above, and a pair of symmetrical recesses 45 a and 45 b on both the left and right sides of the support portion 43. Is formed. The recesses 45a and 45b are formed in regions D1 and D2 indicated by hatching in FIG. That is, the recesses 45a and 45b include a rectangular recess 45c having a rectangular shape, a square recess 45d formed so as to extend inward in the left-right direction from the rectangular recess 45c, and a rectangular recess 45c. It has a semicircular recess 45e that is located rearward and is formed in a substantially semicircular shape toward the outside in the left-right direction. Further, the rear side of the rectangular recess 45c is open. As shown in FIG. 23, terminal plates 42a and 42b are disposed in the recesses 45a and 45b.

  As shown in the upper part of FIG. 22 and FIG. 23, the region between the recesses 45a and 45b in the left-right direction is a protruding step 46 formed one step higher than the recesses 45a and 45b. The convex step portion 46 has a substantially H-shaped configuration having convex step portions 46b and 46b that are arranged in the front and rear direction and that are long in the left-right direction, and a convex step portion 46c that connects the convex step portions 46b and 46b arranged in the front and rear directions. is doing. Two projecting portions 47, 47 projecting upward are provided on both front and rear sides of the root portion of the square recess 45d. That is, the projecting portions 47 are formed so as to be adjacent to the four top portions 46a of the convex step portion 46 having a substantially H shape.

  In addition, a front wall portion 48 that is higher in height than the protruding step portion 46 and has the same height as the protruding portion 47 is provided in the front portion of the support portion 43. Further, a pair of locking portions 50, 50 projecting upward in a bowl shape are provided at both left and right ends of the support portion 43. Tapered surfaces 50a and 50a that are chamfered are formed on the inner surfaces of the locking portions 50 and 50 in the left-right direction (see FIG. 22). The support part 43 is formed from an insulating resin material.

  As shown in the upper part of FIG. 23, the terminal plates 42a and 42b are metal plate-like members arranged in a pair on the left and right. The terminal plates 42a and 42b have shapes corresponding to the recesses 45a and 45b. That is, the terminal plates 42a and 42b include a rectangular portion 42c having a rectangular shape, an extending portion 42d extending in a substantially rectangular shape from the rectangular portion 42c toward the inner side in the left-right direction, and the rectangular portion 42c. It has the contact part 42e extended in the substantially rectangular form toward back. The terminal plates 42a and 42b are held in the support portion 43 by being press-fitted into the recesses 45a and 45b, respectively. Specifically, the terminal plate 42a abuts the front and rear end portions on the right side of the rectangular portion 42c against the projecting portions 47 and 47, and the base portion of the extending portion 42d is narrowed from the front and rear sides by the projecting portions 47 and 47. It is press-fitted into the recess 45a in the form of holding. The terminal plate 42b has a configuration in which the left and right end portions of the rectangular portion 42c are brought into contact with the projecting portions 47 and 47, and the base portion of the extending portion 42d is sandwiched from the front and rear sides by the projecting portions 47 and 47. Then, it is press-fitted into the recess 45b in a form that is symmetrical to the terminal plate 42a. For this reason, the terminal plates 42a and 42b are attached in a state of being positioned in the support portion 43 using the protruding portions 47 and 47.

  The contact portion 42e is inclined obliquely upward at the elastic portion X shown in the lower part of FIG. As shown in the lower part of FIG. 23, the elastic part X is formed to be curved in an arc shape downward. That is, when a downward force is applied to the contact portion 42e, the contact portion 42e attempts to recover upward due to the spring property of the elastic portion X. Moreover, the front-end | tip part 5a and the rear-end part 5b of the conducting wire 5 are entangled with the extension part 42d of terminal board 42a, 42b.

  As shown in FIGS. 21 and 22, the fixing plate 41 is disposed above the support portion 43. The fixing plate 41 is fitted to the locking portions 50 and 50 of the support portion 43 so that the flange portions 51 and 51 provided so as to protrude upward at both left and right ends thereof are fitted to the support portion 43. Held. In this state, as shown in FIG. 22, the four projecting portions 47 and the front wall portion 48 are in contact with the lower surface of the fixing plate 41. For this reason, the fixing plate 41 is held with respect to the support part 43 without rattling. Further, in a state where the fixing plate 41 is held by the support portion 43, the contact portions 42e and 42e are in contact with the connection plates 44a and 44b attached to the back side of the fixing plate 41 as shown in FIG. That is, the terminal plates 42a and 42b and the connection plates 44a and 44b are in a conductive state. At this time, since the contact portions 42e and 42e have spring properties, when the contact portions 42e and 42e are pressed downward by the fixing plate 41, the downward force is applied to the contact portions 42e and 42e. On the contrary, an upward biasing force acts. For this reason, the contact state of the connection plates 44a and 44b and the connection plates 44a and 44b is reliably maintained. That is, by pressing the fixing plate 41 above the support portion 43, the contact portions 42e and 42e and the connection plates 44a and 44b are in contact with each other, and the terminal plates 42a and 42b and the connection plates 44a and 44b are electrically connected. It is set as such.

  As shown in FIG. 24, the fixing plate 41 has a substantially rectangular shape when viewed from above, and a pair of connection plates 44 a and 44 b having a symmetrical shape are attached to the back side of the fixing plate 41. Yes. The connecting plate 44a has a rectangular connecting portion 44c having a substantially rectangular shape and a rectangular extending portion 44d extending from the left rear of the rectangular connecting portion 44c toward the rear side. Further, similarly to the case of the first embodiment, the rectangular connection portion 44c of the connection plate 44a is formed so that connection portions 52a and 52b that are pushed and bent downward are aligned vertically. Yes. Then, the lead wire 12a is inserted into the connecting portions 52a and 52b, and the connecting portions 52a and 52b are caulked so that the lead wire 12a is electrically connected to the connecting plate 44a. The rectangular connecting portion 44c of the connecting plate 44b is also formed with connecting portions 52c and 52d so as to be symmetrical with the connecting plate 44a. By inserting the lead wire 12b into the connecting portions 52c and 52d, the lead wire is formed. 12b is electrically connected to the connection plate 44b. Note that portions of the fixing plate 41 other than the connection plates 44a and 44b are made of, for example, a nonconductive material typified by an insulating resin or the like.

  As shown in FIG. 22 and the like, on the back side of the fixed plate 41, connection plate storage portions 53a and 53b that are recessed upward are formed in a shape corresponding to the connection plates 44a and 44b. The connection plates 44a and 44b are fitted into the connection plate storage portions 53a and 53b by press-fitting from the back side of the fixed plate 41. Further, as described above, the left and right ends of the fixed plate 41 are provided with flange portions 51 and 51 that protrude upward along the front-rear direction. And as above-mentioned, this fixing | fixed board 41 is hold | maintained with respect to the support part 43 when this collar part 51 and 51 fits in the latching | locking parts 50 and 50 of the support part 43 along the front-back direction. . As described above, in a state where the fixing plate 41 is held with respect to the support portion 43, the contact portions 42e and 42e are urged upward by their own spring properties and contact the rectangular connection portions 44c and 44c of the connection plates 44a and 44b. (See FIG. 21). Specifically, the contact portions 42e and 42e are in contact with the left and right outer portions of the rectangular connection portion 44c where the connection portions 52a and 52b and the connection portions 52c and 52d are not formed in the connection plates 44a and 44b. .

  Next, the manufacturing method of the coil member 40 is demonstrated.

  FIG. 25 is a flowchart of the method for manufacturing the coil member 40. FIG. 26 is a diagram for explaining the second terminal plate press-fitting step. FIG. 27 is a diagram illustrating a state after the winding process. FIG. 28 is a diagram illustrating a state after the second terminal plate bending step. FIG. 29 is a diagram illustrating a state after the third fixing plate arranging step. The support portion 43 shown in FIGS. 26 to 29 corresponds to the cross section taken along the section line AA in FIG. 23, but hatching is omitted for easy understanding of the relationship between the terminal plates 42a and 42b and the support portion 43. is doing.

  First, as in the case of the first embodiment, the lead wires 12a and 12b are connected to the connecting portions 52a and 52b and the connecting portions 52c and 52d of the connecting plates 44a and 44b (second lead wire connecting step P21). Thereafter, the connection plates 44a and 44b to which the lead wires 12a and 12b are connected are press-fitted into the connection plate storage portions 53a and 53b of the fixed plate 41 from the back side (connection plate fitting step P22). Then, as shown in FIG. 24, the fixed plate 41 to which the connection plates 44a and 44b are attached is formed.

  Thereafter, as shown in FIG. 26, the terminal plates 42 a and 42 b in a state in which the extending portion 42 d and the contact portion 42 e are bent substantially vertically upward with respect to the rectangular portion 42 c are respectively formed into the concave portions 45 a and 45 b of the support portion 43. (2nd terminal board press-fit process P23). Specifically, as shown in FIG. 27, the rectangular portions 42c and 42c of the terminal plates 42a and 42b are press-fitted into the rectangular concave portions 45c and 45c of the concave portions 45a and 45b, respectively. More specifically, the rectangular portions 42c and 42c are press-fitted into the rectangular concave portions 45c and 45c so that the left and right inner sides of the rectangular portions 42c and 42c are brought into contact with the protruding portions 47 and 47. That is, the rectangular portions 42c and 42c function as press-fit portions for the terminal plates 42a and 42b, respectively.

  Next, the coil body 2 is manufactured by winding the conducting wire 5 around the bobbin 6 in the winding step P4. At this time, as shown in FIG. 27, the front end portion 5a and the rear end portion 5b of the conducting wire 5 wound around the bobbin 6 are drawn out from the front flange portion 6b of the bobbin 6, and are entangled with the extending portions 42d and 42d. . Next, dip soldering is performed to the front-end | tip part 5a and the rear-end part 5b of the conducting wire 5 entangled with the extension parts 42d and 42d (dip soldering process P5). Next, the extending portions 42d and 42d of the terminal plates 42a and 42b are bent in the horizontal direction from a state where the extending portions 42d and 42d are bent upward at a right angle, and the extending portions 42d and 42d are sandwiched by the two protruding portions 47 and 47. The contact portions 42e and 42e are bent toward the rear side in the elastic portion X, and the contact portions 42e and 42e are inclined obliquely upward toward the front side with respect to the horizontal direction. (Second terminal plate bending step P24). Thereafter, the bobbin 6 (coil body) is accommodated in the frame 3 in the direction indicated by the arrow in FIG.

  Next, the fixing plate 41 to which the connection plates 44a and 44b are attached is pushed from above the support portion 43 so as to be accommodated in the opening portion of the support portion 43, thereby fixing the fixing plate 41 above the support portion 43 and the coil body 2. (3rd fixed board arrangement | positioning process P25). At this time, since the chamfered tapered surfaces 50a and 50a are formed in the locking portions 50 and 50, when the fixing plate 41 is pushed in from above the support portion 43, the flange portions 51 and 51 are supported by the support portion 43. It fits in 43 latching | locking parts 50 and 50. FIG. As a result, the collar portions 51, 51 are engaged with the locking portions 50, 50, and the fixing plate 41 is held in a state of being accurately positioned with respect to the support portion 43. In this manner, the fixing plate 41 is positioned with respect to the support portion 43, whereby the terminal plates 42a and 42b and the connection plates 44a and 44b are brought into conduction. The coil member 40 is manufactured through the above processes.

  In the coil member 40 according to the embodiment of the present invention, the terminal plates 42a and 42b and the connection plates 44a and 44b can be electrically connected by surface contact or line contact. For this reason, it is possible to reliably perform electrical connection between the terminal plates 42a and 42b and the connection plates 44a and 44b. Accordingly, it is possible to reliably energize the lead wires 12a and 12b and the coil body 2 side, and to improve the reliability of electrical connection between the lead wires 12a and 12b and the coil body 2 side. It becomes possible.

  In the coil member 40, the terminal plates 42a and 42b are attached to the support portion 43 by a press-fitting method. The connection plates 44a and 44b are also attached to the connection plate storage portions 53a and 53b of the fixed plate 41 by a press-fitting method. As described above, the terminal plates 42a and 42b are incorporated into the support portion 43 and the connection plates 44a and 44b are incorporated into the fixed plate 41 by a press-fitting method in which the components are pressed in the vertical direction. Assembling work of the terminal plates 42a and 42b and the connection plates 44a and 44b can be automatically performed using a machine, and as a result, the manufacturing work can be speeded up.

  In the coil member 40, the fixing plate 41 is held with respect to the support portion 43 by engaging the flange portions 51, 51 with the locking portions 50, 50. For this reason, it is possible to hold the fixing plate 41 against the support portion 43 by an easy operation of press-fitting the fixing plate 41 from above the support portion 43. Further, since the terminal plates 42a and 42b and the connection plates 44a and 44b are incorporated in the support portion 43 and the fixing plate 41, respectively, by press-fitting methods, the terminal components can be stored compactly.

  As mentioned above, although each embodiment of this invention was described, this invention is not limited to the above-mentioned form, It can implement in the form variously deformed.

  In each of the above-described embodiments, the lead wires 12a and 12b are connected on the inner sides in the left and right directions of the connection plates 11a and 11b and the connection plates 44a and 44b, respectively, and the terminal pins 10a and 10b, the terminal plates 31a and 31b, and the terminal plate 42a. , 42b are connected on the outer side in the left-right direction of each of the connection plates 11a, 11b and the connection plates 44a, 44b. However, the present invention is not limited to such a connection form. For example, the lead wires 12a, 12b are connected to the connection plates. 11a and 11b and connection plates 44a and 44b are connected to each other on the outside in the left-right direction, and terminal pins 10a and 10b, terminal plates 31a and 31b, and terminal plates 42a and 42b are connected to connection plates 11a and 11b and connection plates 44a and 44b, respectively. Even if it is connected on the inner side in the left-right direction There.

  In the first and second embodiments described above, the connection portions 24a and 24b and the connection portions 25a and 25b in the connection plates 11a and 11b are provided in two along the front-rear direction. The number of connecting portions is not limited to two. For example, three or more of each may be provided, or one may be provided. Further, each of the connecting portions 24a and 24b is pushed and bent in the opposite direction of the front and back, but may be pushed and bent in one direction (same direction) of either the front and back. The connection portions 25a and 25b may be pushed and bent in one direction, either front or back.

  In the first and second embodiments described above, the curved surface portion 23 is provided on the lower side of the fixed plate 4, but the curved surface portion 23 may not be provided.

  In the first and second embodiments described above, the connection plates 11 a and 11 b are stored in the fixed plate 4 by inserting the connection plates 11 a and 11 b into the storage portions 19 and 19 from the front of the fixed plate 4. However, the method of housing the connection plates 11a and 11b in the fixed plate 4 is not limited to this method. For example, as in the third embodiment, the connection plates 11a and 11b are provided. The connection plates 11 a and 11 b may be accommodated in the fixed plate 4 by being press-fitted from the back side of the fixed plate 4. Further, in the third embodiment, the connection plates 44a and 44b are press-fitted from the back side of the fixed plate 41 and the connection plates 44a and 44b are accommodated in the fixed plate 41. As in the embodiment, the connection plates 44 a and 44 b may be accommodated in the fixed plate 41 by a method of inserting from the front.

  In the second embodiment, the terminal plates 31a and 31b are electrically connected by being inserted into the connection portions 24a and 24b and the connection portions 25a and 25b, respectively. It is not limited to the method. For example, as in the third embodiment, the connection plates 11a and 11b are arranged by press-fitting on the back side of the fixed plate 4, and the surface of the terminal plates 31a and 31b and the connection plate 11a, It is good also as a structure which makes the back surface of 11b surface-contact.

  In the third embodiment described above, the fixing plate 41 is fixed to the support portion 43 by fitting into the locking portion 50. However, the fixing method of the fixing plate 41 to the support portion 43 is the method concerned. For example, as in the first and second embodiments, protrusions projecting outward in the left-right direction are provided at the four front and rear corners of the left and right side surfaces of the fixing plate 41, and The fixing plate 41 may be held by the frame 3 by fitting the protruding portion into a hole provided in the frame 3.

  In the second embodiment described above, the flat terminal plates 31a and 31b are fixed to the support portion 32. However, in the vicinity of the notch portion 31e, the terminal plates 31a and 31b are bent in a substantially L shape in a side view. The terminal plates 31a and 31b may be fixed to the support portion 32, and then the winding step 4 and the terminal plate press-fitting step P12 may be performed. Moreover, you may make it perform the terminal board bending process P11 after the winding process P4.

  Moreover, in each above-mentioned embodiment, although the support parts 8,32,43 are set as the structure located in the front-end side of the flame | frame 3, it is not limited to such a structure, For example, A configuration may be adopted in which a notch 3 h is provided on the rear end side of the frame 3 and the support portions 8, 32, 43 are disposed on the rear end side of the frame 3.

DESCRIPTION OF SYMBOLS 1,30,40 ... Coil member 2 ... Coil body 3 ... Frame 3a ... 1st opening part (opening part)
3b ... second opening (opening)
3g ... hole 5 ... conducting wire 5a ... tip (corresponding to end)
5b ... Rear end (corresponding to end)
4, 41 ... fixed plate 8, 32, 43 ... support part 8f ... insertion hole 10a, 10b ... terminal pin (corresponding to terminal part)
11a, 11b ... connection plate 12a, 12b ... lead wire 18 ... projection 22 ... curved surface 23 ... curved surface 24c, 24d, 25c, 25d ... connection (corresponding to the first connection)
24a, 24b, 25a, 25b ... connection part (corresponding to the second connection part)
31a, 31b ... Terminal board (corresponding to the terminal part)
31d ... hole 33 ... convex 42a, 42b ... terminal plate (corresponding to terminal)
42c ... Press-fit part 42e ... Contact part 44a, 44b ... Connection plate

Claims (12)

A coil body formed of a conducting wire and a bobbin around which the conducting wire is wound;
A lead wire energized with the conducting wire;
A frame-like frame that supports the coil body and forms a magnetic circuit of magnetic flux generated from the coil body;
Two terminal portions to which both ends of the conducting wire are connected;
A conductive connecting plate disposed inside the frame opening of the frame;
A support part provided on the bobbin and supporting one end of the terminal part;
Have
A coil member characterized in that an end portion of the lead wire and the other end of the terminal portion are connected to the connection plate, and the lead wire and the conductive wire are electrically connected via the connection plate. The coil member according to claim 1,
The coil member, wherein the connection plate is housed in a fixed plate made of a non-conductive material, and is arranged so as to be parallel or substantially parallel to the opening surface of the frame of the frame. The coil member according to claim 2,
A coil member comprising a curved surface portion having a curved surface having a shape corresponding to an outer peripheral surface of the conducting wire wound around the bobbin on a side of the fixing plate facing the coil body. The coil member according to claim 2 or 3,
The fixing plate is provided with a projecting portion projecting sideways, and the projecting portion is formed so as to be fitted from the inside of the frame into a hole provided in the frame. Coil member. The coil member according to any one of claims 1 to 4,
The coil member, wherein the connection plate is formed with a first connection portion to which an end portion of the lead wire is connected and a second connection portion to which the other end of the terminal portion is connected. The coil member according to any one of claims 1 to 5,
The first connection portion and the second connection portion are cut in a pair of opposing sides of a rectangular or substantially rectangular region, and the region is arched in a direction perpendicular to the plane of the connection plate. The end portion of the lead wire is connected to the first connection portion in a state of being inserted into the first connection portion extruded in an arch shape, and the other end portions of the terminal portion. The coil member, wherein an end is connected to the second connection portion in a state of being inserted into the second connection portion pushed out in an arch shape. The coil member according to any one of claims 1 to 6,
The terminal portion has a pin shape, and the support portion is provided with an insertion hole such that a direction perpendicular to or substantially perpendicular to the axial direction of the coil body is a depth direction. One end is inserted into the insertion hole so as to be rotatable with respect to the support portion, and the other end of the terminal portion is located at a position off the rotation shaft, and is connected to the connection plate. A coil member that is electrically connected to the connecting portion. The coil member according to any one of claims 1 to 6,
The terminal portion has an elongated plate shape, and a hole portion penetrating in the thickness direction is formed on one end side of the terminal portion, and the hole portion fits into a convex portion provided in the support portion. Accordingly, one end of the terminal portion is supported by the support portion, and the other end of the terminal portion is electrically connected to the connection plate. The coil member according to any one of claims 1 to 6,
The terminal portion includes a press-fit portion that is press-fitted into the support portion, and a contact portion that is disposed below the connection plate and that makes surface contact or line contact with the connection plate, and the press-fit portion serves as the support portion. The terminal portion is supported by the support portion by press-fitting into a recessed portion provided, and the terminal plate is connected to the connection plate by the contact portion contacting the lower surface of the connection plate. A coil member characterized. A coil body formed of a conducting wire and a bobbin around which the conducting wire is wound;
A frame-shaped frame that supports the coil body in close contact with both axial end surfaces of the coil body and forms a magnetic circuit of magnetic flux generated from the coil body;
Two terminal pins to which both ends of the conducting wire are connected;
A connection plate disposed above the coil body in the frame of the frame and having a connection portion extruded in an arch shape in a direction perpendicular to the plane;
A support portion having an insertion hole into which one end of the terminal pin is inserted;
In the manufacturing method of the coil member having
A terminal pin insertion step of inserting one end of each terminal pin into the insertion hole of the support;
A terminal pin bending step of bending the other end of the terminal pin in a direction perpendicular to one end of the terminal pin;
A winding step of winding the conductive wire around the bobbin to form the coil body;
A terminal pin press-fitting step of moving the connection plate toward the other end of the terminal pin and press-fitting the other end of the terminal pin into the connection portion of the connection plate;
A first disposing step of rotating the connecting plate together with the other end of the terminal pin around the one end of the terminal pin inserted into the insertion hole to dispose the connecting plate on the coil body; ,
The manufacturing method of the coil member characterized by having. A coil body formed of a conducting wire and a bobbin around which the conducting wire is wound;
A frame-shaped frame that supports the coil body in close contact with both axial end surfaces of the coil body and forms a magnetic circuit of magnetic flux generated from the coil body;
Two terminal plates having an elongated flat plate shape in which both ends of the conducting wire are connected and a hole is formed at one end thereof;
A connection plate disposed above the coil body in the frame of the frame and having a connection portion extruded in an arch shape in a direction perpendicular to the plane;
A support portion having a convex portion that fits into the hole portion of the terminal plate;
In the manufacturing method of the coil member having
A fitting step of fitting one end of each terminal plate into the convex portion of the support;
A terminal plate bending step of bending the other end of the terminal plate in a direction perpendicular to the one end;
A winding step of winding the conductive wire around the bobbin to form the coil body;
A terminal plate press-fitting step of moving the connection plate toward the other end of the terminal plate and press-fitting the other end of the terminal plate into the connection portion of the connection plate;
A second disposing step of folding the bent portion of the terminal plate bent in the terminal plate bending step toward the coil body side, and disposing the connection plate on the coil body;
The manufacturing method of the coil member characterized by having. A coil body formed of a conducting wire and a bobbin around which the conducting wire is wound;
A frame-shaped frame that supports the coil body in close contact with both axial end surfaces of the coil body and forms a magnetic circuit of magnetic flux generated from the coil body;
Two terminal plates having a plate shape having both a press-fit portion and a contact portion connected to the press-fit portion, both ends of the conducting wire are connected,
A connecting plate disposed above the coil body within the frame;
A support portion having a recess into which the press-fit portion of the terminal plate is fitted;
In the manufacturing method of the coil member having
A second terminal plate fitting step for fitting the press-fitted portion of each terminal plate into the concave portion of the support portion;
A winding step of winding the conductive wire around the bobbin to form the coil body;
A second terminal plate bending step of bending the contact portion of the terminal plate so as to be inclined obliquely upward with respect to the press-fit portion;
A third arrangement step of arranging the connection plate on the coil member while pressing the connection plate above the contact portion such that the lower surface of the connection plate is in contact with the contact portion;
The manufacturing method of the coil member characterized by having.

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