JP2015012226A - Coil body and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil body configured so that the connection with a conductor is less likely to be divided, even if a tensile force acts on a lead wire, and to provide a manufacturing method therefor.SOLUTION: A coil body 1 has a lead wire attachment part 9 that is attached to a bobbin 2, and to which lead wires 100A, 100B, being connected with a conductor 3A, are attached. Lead wire insertion holes 10A, 10B into which the lead wires 100A, 100B are inserted, and a communication hole 11 crossing a part of the lead wire insertion holes 10A, 10B and communicating therewith are formed in the lead wire attachment part 9. An insertion member 12 is inserted into the communication hole 11, and in a state where the insertion member 12 is inserted into the communication hole 11, the intervals D1, D2 between the parts 16A, 16B facing the insertion member 12 on the inner peripheral surface of the lead wire insertion holes 10A, 10B and the insertion member 12 are narrower than the thickness W1, W2 of the lead wires 100A, 100B.

Description

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

  2. Description of the Related Art Conventionally, as disclosed in, for example, Patent Document 1, a coil body is known in which a conducting wire is wound around an insulating bobbin. In the coil body having such a configuration, the lead wire and the lead wire are fixed to each other by, for example, solder.

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

  However, when the lead wire is pulled, if the pulled force directly acts on the connecting portion between the lead wire and the lead wire, the lead wire and the lead wire are easily divided.

  Therefore, the present invention intends to provide a coil body having a configuration in which a connecting portion with a conducting wire is hardly divided even when a tensile force is applied to a lead wire, and a manufacturing method thereof.

  In order to solve the above-mentioned problems, the present invention provides a coil body in which a conducting wire is wound around a bobbin, and has a lead wire attachment portion attached to the bobbin and to which a lead wire connected to the conducting wire is attached. The lead wire insertion hole into which the lead wire is inserted, and a communication hole that intersects a part of the lead wire insertion hole and communicates with the lead wire insertion hole are formed, and an insertion member is inserted into the communication hole, In a state where the insertion member is inserted into the communication hole, the interval between the insertion member and the portion facing the insertion member on the inner peripheral surface of the lead wire insertion hole is narrower than the thickness of the lead wire.

  In addition to the above-described invention, in the coil body, the communication hole and the insertion member are orthogonal to the insertion direction of the lead wire into the lead wire insertion hole, with the cross-sectional shape orthogonal to the insertion direction of the insertion member into the communication hole. It is preferable that the long axis is arranged in an elliptical shape.

  In addition to the above-described invention, in the coil body, it is preferable that the insertion member is formed with a protrusion at a portion that comes into contact with the lead wire while being inserted into the communication hole.

  In addition to the above invention, in the coil body, it is preferable that the protruding portion of the insertion member has a pointed tip in a shape in a cross section perpendicular to the insertion direction of the insertion member into the communication hole.

  In addition to the above invention, in the coil body, the communication hole penetrates the lead wire mounting member, and the width of the both ends of the insertion member inserted into the communication hole is the inner circumference of the communication hole. It is preferable that a widened portion wider than the diameter is formed.

  Further, in addition to the above-described invention, in the coil body, the widened portion on the distal end side in the insertion direction of the insertion member into the communication hole of the widened portion has a lead wire insertion hole when the insertion member is inserted into the communication hole. It is preferable to arrange | position in the position which does not pass.

  In order to solve the above-mentioned problems, the present invention has a bobbin around which a conducting wire is wound, and a lead wire attaching portion to which a lead wire attached to the bobbin and connected to the conducting wire is attached. The lead wire insertion hole into which the lead wire is inserted, and a communication hole that intersects a part of the lead wire insertion hole and communicates with the lead wire insertion hole are formed. The insertion member is inserted into the communication hole, and the insertion member is In the method of manufacturing a coil body in which the distance between the insertion member and the portion facing the insertion member on the inner peripheral surface of the lead wire insertion hole in the state where it is inserted into the communication hole is narrower than the thickness of the lead wire, A winding connection part forming step for forming a winding connection part spirally wound around the part, a winding process for winding the conductive wire around the bobbin, and inserting the lead wire into the lead wire insertion hole, and the winding connection part A lead wire insertion process for inserting the end of the lead wire into And further comprising an end portion of the lead wire inserted in the winding connection part, and the soldering process to solder the winding connection part, and an insertion member insertion step of inserting the insertion member into the communicating hole.

  In addition to the above invention, in the method for manufacturing a coil body, the insertion member is preferably heated to a temperature equal to or higher than the softening temperature of the covering portion covering the lead wire before being inserted into the communication hole.

  According to the present invention, it is possible to provide a coil body having a configuration in which a connecting portion with a conductive wire is hardly divided even when a tensile force is applied to a lead wire, and a manufacturing method thereof.

It is a perspective view which shows the structure of the coil body which concerns on embodiment of this invention. It is a perspective view which shows the structure of the bobbin of the coil body shown in FIG. It is a figure which shows the structure of the cross section of the lead wire attaching part in the cutting line AA shown in FIG. The lead wire is not represented as a cross-sectional view for easy understanding of the drawing. It is a figure which shows the structure of the cross section of the lead wire attachment part in cutting property BB shown in FIG. 2, and has shown the state before an insertion member is inserted in a communicating hole. It is a figure which shows the structure of the cross section of the lead wire attachment part in cutting property BB shown in FIG. 2, and has shown the state by which the insertion member was inserted in the communicating hole. It is a figure which shows the structure of the cross section of the lead wire attachment part in the cutting line CC shown in FIG. 2, and has shown the state by which the insertion member is not inserted in the communicating hole. It is a flowchart which shows the manufacturing process of the coil body shown in FIG. It is a figure which shows the structure of the modification 1 of a coil body. It is a figure which shows the structure of the modification 2 of a coil body. It is a figure which shows the structure of the modification 3 of a coil body. It is a figure which shows the structure of the modification 4 of a coil body. It is a figure which shows the structure of the modification 5 of a coil body.

  Hereinafter, a coil body 1 and a manufacturing method thereof according to an embodiment of the present invention will be described with reference to the drawings. In the following description (common to each embodiment), the arrow X1 direction shown in each figure is the front (front side), the arrow X2 direction is the rear (rear side), and the arrow Y1 direction is the left (left side). The arrow Y2 direction is defined as the right side (right side), the arrow Z1 direction is defined as the upper side (upper side), and the arrow Z2 direction is defined as the lower side (lower side).

(Embodiment)
(Whole structure of the coil body 1)
FIG. 1 is a perspective view of a coil body 1 according to an embodiment of the present invention, and shows a state where two lead wires 100A and 100B are attached. As shown in FIG. 1, the coil body 1 includes a bobbin 2, a winding part 3 configured by winding a conducting wire 3 </ b> A around the bobbin 2, and a frame 4. The frame 4 presents a frame body that covers four sides (front and rear and left and right) of the bobbin 2 and the winding part 3 and is open in the vertical direction. The frame 4 is formed of a magnetic material such as iron, and supports the bobbin 2 and forms a magnetic circuit of magnetic flux generated from the winding portion 3.

  The conducting wire 3A is a covered wire formed by covering a conductive wire material such as copper with an insulating coating such as enamel, and the outer periphery of the winding portion 3 is covered with an insulating exterior tape 5 over the entire periphery. It has been broken. As shown in FIG. 3, a spiral connection portion 3BB is formed on one end side 3B of the conductive wire 3A, and the conductive wire 3A and the lead wire 100A are electrically connected to each other at the winding connection portion 3BB. It is connected to the. Moreover, as shown in FIG. 3, the winding connection part 3CC (refer FIG. 3) wound helically is formed also in the other end side 3C of 3 A of conducting wire, and conducting wire 3A is formed in this winding connection part 3CC. And the lead wire 100B are electrically connected. The portions of the winding connection portions 3BB and 3CC of the conducting wire 3A are stripped and the wire is exposed.

(Configuration of bobbin 2)
FIG. 2 is a perspective view showing the configuration of the bobbin 2. The bobbin 2 includes a trunk portion 6, a front collar portion 7 provided at a front end that is one end side of the trunk portion 6, a rear collar portion 8 provided at a rear end that is the other end side of the trunk portion 6, and a lead wire 100A. , 100B are attached to the lead wire attaching portion 9. The bobbin 2 is integrally formed of a resin such as LCP resin (liquid crystal polymer), PPS (polyphenylene sulfide), PBT (polybutylene terephthalate), or PET (polyethylene terephthalate) by molding or the like. Lead wire insertion holes 10 </ b> A and 10 </ b> B and a communication hole 11 are formed in the lead wire attachment portion 9, and an insertion member 12 is inserted into the communication hole 11.

  A conductor 3 </ b> A is wound around the trunk portion 6 as shown in FIG. 1, and the winding portion 3 is provided between the front collar portion 7 and the rear collar portion 8. Then, the bobbin 2 whose outer peripheral surface is covered with the exterior tape 5 is accommodated in the frame 4 from the opening above the frame 4. One end side 3 </ b> B of the winding part 3 is an end part on the winding start side of the conducting wire 3 </ b> A to the body part 6, and is drawn to the outside of the exterior tape 5 from between the front flange part 7 and the winding part 3. The other end side 3 </ b> C of the winding part 3 is an end part on the winding end side, and is drawn to the outside of the exterior tape 5 from between the outer peripheral surface of the wound part 3 and the exterior tape 5.

(Configuration of lead wire mounting portion 9)
The configuration of the lead wire attachment portion 9 will be described with reference to FIGS. FIG. 3 is a view showing a cross section of the lead wire attaching portion 9 along the cutting line AA shown in FIG. The lead wire is not represented as a cross-sectional view for easy understanding of the drawing. FIG. 4 is a view showing a cross section of the lead wire attachment portion 9 in the cutting property BB shown in FIG. 2 and shows a state before the insertion member 12 is inserted into the communication hole 11. FIG. 5 is a view showing a cross section of the lead wire attaching portion 9 in the cutability BB shown in FIG. 2, similarly to FIG. 4, and shows a state where the insertion member 12 is inserted into the communication hole 11. FIG. 6 is a view showing a cross section of the lead wire attaching portion 9 along the cutting line CC shown in FIG. 2, and shows a state where the insertion member 12 is not inserted into the communication hole 11.

  The lead wire attachment portion 9 has a rectangular shape whose cross section along the left-right direction and the up-down direction is flat in the up-down direction. Moreover, the shape of the lead wire attachment portion 9 in plan view is a trapezoid whose width in the left-right direction increases from the front to the rear. As shown in FIG. 2, the lead wire attaching portion 9 is provided at the upper end edge of the front collar portion 7 so as to protrude forward. Further, as shown in FIG. 1, the lead wire attachment portion 9 protrudes outside the frame 4 in a state where the bobbin 2 is accommodated in the frame 4.

  In the lead wire attachment portion 9, lead wire insertion holes 10 </ b> A and 10 </ b> B, a communication hole 11, and a recess 13 are formed. An insertion member 12 can be inserted into the communication hole 11.

  The lead wire insertion holes 10 </ b> A and 10 </ b> B are holes into which the lead wires 100 </ b> A and 100 </ b> B are inserted, and penetrate from the front end surface 14 of the lead wire attachment portion 9 to the recess front surface portion 13 </ b> A of the recess 13. That is, the lead wire insertion holes 10A and 10B are holes that penetrate the lead wire attachment portion 9 in the front-rear direction.

  The communication hole 11 is a hole that penetrates the upper surface 9A and the lower surface 9B of the lead wire attachment portion 9. The communication hole 11 is disposed at an intermediate position between the lead wire insertion hole 10A and the lead wire insertion hole 10B. The communication hole 11 has a cylindrical shape, and has a thickness that intersects the lead wire insertion hole 10A at the intersection 15A and also intersects the lead wire insertion hole 10B at the intersection 15B. The intersection 15A is a part of the lead wire insertion hole 10A, and the intersection 15B is also a part of the lead wire insertion hole 10B. That is, the lead wire insertion holes 10A and 10B and the communication hole 11 communicate with each other at the intersections 15A and 15B.

  An insertion member 12 is inserted into the communication hole 11. The insertion member 12 has a cylindrical shape, and has a thickness (diameter) that can be press-fitted into the communication hole 11 with respect to the inner peripheral diameter of the communication hole 11. The lead wire insertion holes 10A and 10B and the communication hole 11 communicate with each other at the intersections 15A and 15B. Therefore, when the insertion member 12 is inserted into the communication hole 11, a part of the insertion member 12 is disposed in the lead wire insertion holes 10A and 10B at the intersections 15A and 15B.

  As shown in FIG. 5, with the insertion member 12 inserted into the communication hole 11, the facing portion 16 </ b> A that is the portion facing the insertion member 12 on the inner circumferential surface of the lead wire insertion hole 10 </ b> A, and insertion of the inner circumferential surface The distance D1 from the member 12 is narrower than the thickness W1 (see FIG. 3) of the lead wire 100A. Further, in a state where the insertion member 12 is inserted into the communication hole 11, the distance between the facing portion 16 </ b> B that is a portion facing the insertion member 12 on the inner peripheral surface of the lead wire insertion hole 10 </ b> B and the insertion member 12 on the inner peripheral surface. D2 is narrower than the thickness W2 of the lead wire 100A (see FIG. 3).

  Therefore, as shown in FIG. 3, when the insertion member 12 is inserted into the communication hole 11 with the lead wire 100A inserted into the lead wire insertion hole 10A, the lead wire 100A is connected to the inner periphery of the lead wire insertion hole 10A. It is attached to the lead wire attachment portion 9 in a state of being sandwiched between the surface and the insertion member 12. In addition, with the lead wire 100B inserted into the lead wire insertion hole 10B, the insertion member 12 is inserted into the communication hole 11, so that the lead wire 100B has the inner peripheral surface of the lead wire insertion hole 10B and the insertion member 12. Are attached to the lead wire attachment portion 9 in a state of being sandwiched between the two.

  In this way, the lead wire 100A is sandwiched between the inner peripheral surface of the lead wire insertion hole 10A and the insertion member 12, so that even if a tensile force acts on the lead wire 100A forward, the lead wire 100A Becomes difficult to move. Similarly, even when the lead wire 100B is sandwiched between the inner peripheral surface of the lead wire insertion hole 10B and the insertion member 12, even if a tensile force acts on the lead wire 100B forward, the lead wire 100B becomes difficult to move.

  The covering portion 101 is removed from the ends of the lead wires 100A and 100B, and the core wire 102 is exposed. The core wire 102 is inserted into the spiral of the winding connection portions 3BB and 3CC, and the lead wires 100A and 100B and the conductive wire 3A are electrically connected by fixing the core wire 102 and the winding connection portions 3BB and 3CC with solder. Connected. Thus, since the core wire 102 and the winding connection portions 3BB and 3CC are only connected by solder, the core wire is applied when a force pulling the lead wires 100A and 100B forward acts on the lead wires 100A and 100B. The connection portion between 102 and the winding connection portions 3BB and 3CC is easily cut off.

  However, as described above, the lead wire attachment portion 9 can sandwich the lead wire 100A between the inner peripheral surface of the lead wire insertion hole 10A and the insertion member 12, and the lead wire 100B is also connected to the lead wire 100B. It can be sandwiched between the inner peripheral surface of the insertion hole 10 </ b> B and the insertion member 12. For this reason, even if a pulling force acts forward on the lead wires 100A and 100B, the lead wires 100A and 100B hardly move. Thus, even if a tensile force acts on the lead wires 100A and 100B forward, the lead wires 100A and 100B are made difficult to move, so that the connection portion between the core wire 102 and the winding connection portions 3BB and 3CC is formed. It can prevent being cut.

  The covering portion 101 of the lead wires 100A and 100B is formed of a resin that is easily deformed, such as polyvinyl chloride or polyethylene. Therefore, as shown in FIG. 3, the covering portion 101 of the lead wire 100 </ b> A is deformed by the insertion member 12, and the covering portion 101 is formed with a biting portion 103 </ b> A in which the insertion member 12 bites. Then, the lead wire 100 </ b> A is sandwiched between the inner peripheral surface of the lead wire insertion hole 10 </ b> A and the insertion member 12 in a state where the insertion member 12 bites into the covering portion 101.

  Similarly, for the lead wire 100 </ b> B, the covering portion 101 is deformed by the insertion member 12, and a biting portion 103 </ b> B in which the insertion member 12 bites is formed in the covering portion 101. The lead wire 100 </ b> B is sandwiched between the inner peripheral surface of the lead wire insertion hole 10 </ b> A and the insertion member 12 with the insertion member 12 biting into the covering portion 101.

  As described above, when the insertion member 12 bites into the covering portion 101 of the lead wires 100A and 100B, the biting portion is caught by the insertion member 12 when the lead wires 100A and 100B are about to move forward. Thereby, the lead wires 100A and 100B are further restricted from moving forward.

  The concave portion 13 is a concave portion that is formed in the central portion of the rear end portion of the lead wire attachment portion 9 and that is open upward and rearward. The front portion of the inner surface of the recess 13 is a recess front surface portion 13A, the lower portion of the inner surface of the recess 13 is a recess bottom portion 13B, and the left and right portions of the inner surface of the recess 13 are respectively The concave side surfaces 13C and 13C.

  As shown in FIG. 3, the core wire 102 of the lead wires 100 </ b> A and 100 </ b> B, the one end side 3 </ b> B (winding connection portion 3 </ b> BB), and the other end side 3 </ b> C (winding connection portion 3 </ b> CC) are disposed in the recess 13. . The recess 13 has a recess bottom surface portion 13B. That is, the frame 4 and the recess 13 are separated from each other by the recess bottom surface portion 13 </ b> B, and the frame 4 is not exposed to the recess 13. For this reason, it is possible to prevent a short circuit when the one end side 3B and the other end side 3C of the lead wires 100A, 100B or the conducting wire 3A are in contact with the frame 4.

(Main effects of this embodiment)
As described above, the coil body 1 around which the conducting wire 3A is wound around the bobbin 2 has the lead wire attaching portion 9 attached to the bobbin 2 and to which the lead wires 100A and 100B connected to the conducting wire 3A are attached. In the wire attachment portion 9, lead wire insertion holes 10A and 10B into which the lead wires 100A and 100B are inserted, and communication holes that intersect with part of the lead wire insertion holes 10A and 10B and communicate with the lead wire insertion holes 10A and 10B. 11, the insertion member 12 is inserted into the communication hole 11, and the insertion member 12 is inserted into the communication hole 11, and the portion facing the insertion member 12 on the inner peripheral surface of the lead wire insertion holes 10 </ b> A and 10 </ b> B. The distances D1 and D2 between the opposing portions 16A and 16B and the insertion member 12 are narrower than the thicknesses W1 and W2 of the lead wires 100A and 100B.

  By configuring the coil body 1 in this manner, the lead wires 100A and 100B can be attached to the lead wire attachment portion 9 with the spaces D1 and D2 being sandwiched therebetween. For this reason, even if the force pulling forward acts on lead wire 100A, 100B, lead wire 100A, 100B cannot move forward easily. That is, it is possible to prevent the connection portion between the lead wires 100A and 100B and the winding connection portions 3BB and 3CC from being disconnected when a force pulling forward acts on the lead wires 100A and 100B.

  Further, by configuring the coil body 1 in this way, the lead wires 100A and 100B can be sandwiched between the facing portions 16A and 16B and the insertion member 12, and the lead wires 100A and 100B can be easily connected to the lead wire mounting portion. 9 can be attached. For example, in the configuration of Patent Document 1, the lead wire is attached to the bobbin by fixing the lead wire to the terminal (pin) fixed to the bobbin with solder. That is, the attachment of the lead wire to the bobbin is via a terminal (pin), and the lead wire and the terminal have a complicated structure such as soldering. On the other hand, the coil body 1 has a configuration in which the lead wires 100A and 100B are attached to the lead wire attachment portion 9 by sandwiching the lead wires 100A and 100B between the facing portions 16A and 16B and the insertion member 12. That is, the configuration for attaching the lead wires 100A and 100B to the lead wire attaching portion 9 is simple, and therefore, the manufacture of the coil body 1 can be easily automated.

  Note that the shape of the lead wire attachment portion 9 in plan view is a trapezoid whose width in the left-right direction increases from the front to the rear. That is, the bobbin 2 is configured such that the area of the portion where the lead wire attaching portion 9 and the front collar portion 7 of the bobbin 2 are joined is larger than the area of the front end surface 14. For this reason, an increase in the size of the bobbin 2 is suppressed by reducing the width in the left-right direction toward the front end face 14 while making the joint between the front collar portion 7 and the lead wire attachment portion 9 strong.

(Manufacturing method of the coil body 1)
Next, the manufacturing method of the coil body 1 is demonstrated, referring FIG. FIG. 7 is a flowchart showing the coil body 1.

(Winding connection part formation process S1)
First, the winding connection part 3BB is formed on one end side of the conducting wire 3A (winding connection part forming step S1). In the winding connection part forming step S1, for example, a cylindrical pin (winding connection part forming jig pin) not shown as a jig is protruded from the front end face 14 side to the recess front part 13A side. It can be formed by inserting the lead wire insertion hole 10A into the lead wire insertion hole 10A and winding the one end side 3B of the conducting wire 3A around the winding connection portion forming jig pin.

(Wound part forming step S2)
Then, the conducting wire 3A is wound around the trunk portion 6 to form the winding portion 3 (winding portion forming step S2).

(Winding connection portion forming step S3)
And after formation of winding part 3 is completed, winding connection part 3CC is formed in the other end side of conducting wire 3A (winding connection part formation process S3). In the winding connection portion forming step S3, as in the winding connection portion forming step S1, a cylindrical pin (a winding connection portion forming jig pin) (not shown) is used as a jig from the front end face 14 side. It can be formed by inserting it into the lead wire insertion hole 10B so as to protrude to the concave front surface portion 13A side and winding the other end side 3C of the conducting wire 3A around the winding connection portion forming jig pin. In carrying out the winding connection portion forming step S3, the winding connection portion forming jig pin inserted into the lead wire insertion hole 10B may be inserted after the completion of the winding portion forming step S2. When the portion forming step S1 is performed, the winding connection portion forming jig pin may be inserted into the lead wire insertion hole 10A.

  An automatic winding machine can be used in the winding connection portion forming step S1, the winding portion forming step S2, and the winding connection portion forming step S3. In this case, with the automatic winding automatic machine, with the winding connection portion forming jig pin inserted into the lead wire insertion hole 10A and the lead wire insertion hole 10B, the winding connection portion forming step S1 and the winding The turn part forming step S2 and the winding connection part forming step S3 are sequentially performed.

(Jig pin removal step S4 for forming the winding connection part)
After the winding connection portion forming step S1, the winding portion forming step S2, and the winding connection portion forming step S3 are completed, the winding connection portion is inserted into the lead wire insertion hole 10A and the lead wire insertion hole 10B. The jig pin is moved forward, and the winding connection part forming jig pin is extracted from the lead wire insertion hole 10A and the lead wire insertion hole 10B (winding connection part forming jig pin extraction step S4).

  The diameter (thickness) of the outer periphery of the winding connection portion 3BB is smaller than the diameter of the inner periphery of the lead wire insertion hole 10A. When extracting the winding connection portion forming jig pin from the lead wire insertion hole 10A, the winding connection portion 3BB wound around the winding connection portion forming jig pin is also used together with the winding connection portion forming jig pin. Move forward. Since the diameter (thickness) of the outer periphery of the winding connection portion 3BB is smaller than the diameter of the inner periphery of the lead wire insertion hole 10A, the winding connection portion 3BB is inserted into the lead wire insertion hole 10A. And the movement to the front of winding connection part 3BB is restrict | limited by the elastic force etc. of conducting wire 3A in the state inserted in lead wire insertion hole 10A to some extent. For this reason, the winding connection part forming jig pin is pulled out from the lead wire insertion hole 10A with the winding connection part 3BB remaining in the lead wire insertion hole 10A.

  Similarly, the winding connection portion 3CC has an outer diameter (thickness) smaller than the inner diameter of the lead wire insertion hole 10B. Therefore, the winding connection portion forming jig pin is extracted from the lead wire insertion hole 10B with the winding connection portion 3CC remaining in the lead wire insertion hole 10B.

  In addition, in winding connection part formation process S1, the grade of the force which winds conducting wire 3A of the one end side 3B around the winding connection part formation jig | tool pin is winding connection in winding connection part formation jig | tool pin extraction process S4. The part forming jig pins are set to such an extent that they can be smoothly extracted from the winding connection part 3BB. Similarly, the degree of force for winding the lead wire 3A on the other end side 3C around the winding connection portion forming jig pin is also determined by the winding connection portion forming jig pin in the winding connection portion forming jig pin extraction step S4. It is set as the grade which can be smoothly extracted from winding connection part 3CC.

(Exterior tape winding step S5)
And the exterior tape 5 is wound around the outer periphery of the winding part 3, and the outer peripheral surface of the winding part 3 is covered with the exterior tape 5 (exterior tape winding process S5).

(Lead wire insertion step S6)
Next, the lead wire 100A is inserted into the lead wire insertion hole 10A, and the lead wire 100B is inserted into the lead wire insertion hole 10B (lead wire insertion step S6). The end portions of the lead wires 100A and 100B in the insertion direction are previously removed from the covering portion 101 and the core wire 102 is exposed.

  The diameter (thickness) of the winding connection part forming jig pin used in the winding connection part forming steps S <b> 1 and S <b> 3 is slightly larger than the diameter (thickness) of the core wire 102. Therefore, the diameter of the inner periphery of the winding part of the winding connection part 3BB and the winding connection part 3CC is formed to be slightly larger than the diameter of the core wire 102. Therefore, when the lead wire 100A is inserted into the lead wire insertion hole 10A, the core wire 102 can be inserted into the inner periphery of the winding connection portion 3BB. Further, when the lead wire 100B is also inserted into the lead wire insertion hole 10B, the core wire 102 can be inserted into the inner periphery of the winding connection portion 3CC.

  Then, in the lead wire insertion step S6, the lead wire 100A is moved backward until the winding connection portion 3BB in which the core wire 102 is inserted into the inner periphery comes out (arranged) from the concave front surface portion 13A toward the concave portion 13 side. Further, the lead wire 100B is also moved rearward until the winding connection portion 3CC in which the core wire 102 is inserted in the inner periphery comes out (arranged) from the concave portion front surface portion 13A toward the concave portion 13 side.

(Soldering process S7)
Soldering is performed on the winding connection portion 3BB and the winding connection portion 3CC disposed behind the front surface portion 13A of the recess. Accordingly, the lead wire 100A and the winding connection portion 3BB are electrically connected, and the lead wire 100B and the winding connection portion 3CC are also electrically connected (soldering step S7).

  Then, the lead wire 100A connected to the conducting wire 3A is pulled forward (moved), and the winding connection portion 3BB is stored in the lead wire insertion hole 10A (winding connection portion storing step S8). Further, the lead wire 100B connected to the conducting wire 3A is also pulled (moved) forward, and the winding connection portion 3CC is stored in the lead wire insertion hole 10A (winding connection portion storing step S8). The winding connection portion 3BB is accommodated in the lead wire insertion hole 10A, and the winding connection portion 3CC is also accommodated in the lead wire insertion hole 10B, whereby the winding connection portion 3BB and the winding connection portion 3CC are short-circuited. Can be prevented.

(Insertion member insertion step S9)
Next, the insertion member 12 is inserted into the communication hole 11 (insertion member insertion step S9). As described above with reference to FIG. 5 and the like, when the insertion member 12 is inserted into the communication hole 11 in a state where the lead wire 100A is inserted into the lead wire insertion hole 10A, the lead wire 100A is inserted into the lead wire insertion hole 10A. It is in a state of being sandwiched between the inner peripheral surface and the insertion member 12. That is, the lead wire 100 </ b> A is attached so as not to move easily with respect to the lead wire attachment portion 9. In addition, the lead wire 100B is inserted into the communication hole 11 in a state where the lead wire 100B is inserted into the lead wire insertion hole 10B, so that the lead wire 100B is connected to the inner peripheral surface of the lead wire insertion hole 10B and the insertion member. 12 is sandwiched between the two. That is, the lead wire 100B is also attached so as not to move easily with respect to the lead wire attachment portion 9.

  Therefore, even if a pulling force acts forward on the lead wires 100A and 100B, the lead wires 100A and 100B are difficult to move, and the connection portion between the core wire 102 and the winding connection portions 3BB and 3CC is disconnected. Can be prevented.

(Bobbin storage step S10)
As described above, the winding portion 3 is formed, and the bobbin 2 in which the lead wires 100A and 100B are attached to the lead wire attachment portion 9 so as to be connected to the conductor 3A is inserted into the frame 4 from above the frame 4. The coil body 1 is housed and the manufacture of the coil body 1 is completed (bobbin housing step S10).

  According to the above-described manufacturing process, it is possible to manufacture a coil body having a configuration in which a connecting portion with a conducting wire is hardly divided even if a tensile force acts on the lead wire. According to the manufacturing process described above, the winding connection portion 3BB can be easily accommodated in the lead wire insertion hole 10A, and the winding connection portion 3CC can also be easily accommodated in the lead wire insertion hole 10B.

  In the insertion member insertion step S <b> 8, the insertion member 12 is preferably heated to a temperature equal to or higher than the softening temperature of the covering portion 101 when the insertion member 12 is inserted into the communication hole 11. By doing in this way, since the coating | coated part 101 can be softened when inserting the insertion member 12 in the communicating hole 11, it becomes easy to insert the inserting member 12 in the communicating hole 11. FIG. In addition, since the covering member 101 is deformed by the insertion member 12 in a softened state, the covering member 101 can be easily bited into the insertion member 12. Therefore, the forward movement of the lead wires 100A and 100B can be more reliably restricted.

  When the insertion member 12 is heated to a temperature higher than the softening temperature of the covering portion 101, the insertion member 12 is made of a material having a softening temperature higher than that of the covering portion 101. Here, the softening temperature refers to a temperature at which the rigidity and viscosity of the material decrease and the fluidity increases. In general, for polymer materials, it refers to the glass temperature. For example, when the insertion member 12 is formed of LCP resin (liquid crystal polymer) and the covering portion 101 is formed of polyvinyl chloride, the covering portion 101 is softened by heating the insertion member 12 to around 70 degrees. In this state, the insertion member 12 can be inserted into the communication hole 11.

(Modification 1)
As shown in FIG. 8, the communication hole 11 and the insertion member 12 have shapes in a cross section perpendicular to the insertion direction of the insertion member 12 into the communication hole 11 so that the lead wires 100A and 100B are connected to the lead wire insertion holes 10A and 10B. It is good also as a long-axis ellipse in the direction (left-right direction) orthogonal to an insertion direction (front-back direction).

  By configuring the communication hole 11 and the insertion member 12 as shown in FIG. 8 as described above, the insertion member 12 can be prevented from rotating in the communication hole 11. That is, for example, when either one of the lead wire 100A or the lead wire 100B is pulled, a force for rotating the insertion member 12 acts. When the lead wire is pulled and the insertion member 12 rotates, the insertion member 12 bites into the covering portion 101 and the lead wire easily moves forward. By making the communication hole 11 and the insertion member 12 elliptical, the insertion member 12 can be made difficult to rotate in the communication hole 11. In addition, by making the insertion member 12 into an elliptical shape with a long axis in the left-right direction, the insertion member 12 can bite into the covering portion 101 and the lead wires 100A and 100B can be moved more forward. Can be limited.

(Modification 2)
As shown in FIG. 9, the insertion member 12 may be formed with a protruding portion 12 </ b> A at a portion in contact with the lead wires 100 </ b> A and 100 </ b> B in a state of being inserted into the communication hole 11. By forming the protrusion 12 </ b> A on the insertion member 12, the protrusion 12 </ b> A can be firmly bitten into the covering portion 101 when the insertion member 12 is inserted into the communication hole 11. Thereby, the movement to the front of lead wire 100A, 100B can be restrict | limited more. The protruding portion 12A has a pointed tip (a pointed shape) in a shape in a cross section orthogonal to the insertion direction of the insertion member 12 into the communication hole 11. The protrusion 12A does not have to be pointed at the tip, but by making it pointed, the protrusion 12A can be easily bited into the covering portion 101, and the lead wires 100A and 100B can be more reliably moved forward. Can be limited.

(Modification 3)
As shown in FIG. 10, the cross-sectional shape of the communication hole 11 and the insertion member 12 is an ellipse having a long axis in the left-right direction, and when the insertion member 12 is inserted into the communication hole 11, A protrusion 12A that bites into the lead wires 100A and 100B may be formed. With this configuration, the insertion member 12 can be made difficult to rotate in the communication hole 11, and the protrusion 12A can be firmly bitten into the covering portion 101, and forward of the lead wires 100A and 100B. Can be more reliably restricted.

  In the above-described embodiment and its modifications, the communication hole 11 is shown as a configuration example that penetrates the upper surface 9A and the lower surface 9B of the lead wire attachment portion 9. However, the communication hole 11 may not penetrate the lead wire attachment portion 9. That is, the communication hole 11 communicates with the lead wire insertion holes 10A and 10B, and the insertion member 12 inserted into the communication hole 11 connects the lead wires 100A and 100B to the inner peripheral surfaces of the lead wire insertion holes 10A and 10B. It is only necessary to be disposed in the lead wire insertion holes 10A and 10B so as to be sandwiched between the lead wires.

(Modification 4)
As shown in FIG. 11, widened portions 12 </ b> B and 12 </ b> C may be formed at both ends of the insertion member 12 such that the width of both ends is wider than the diameter of the inner periphery of the communication hole 11. FIG. 11A shows a cross-sectional view of the insertion member 12. FIG. 11B shows a cross-sectional view of the lead wire attachment portion 9 before the insertion member 12 is inserted. FIG. 11C shows a cross-sectional view of the lead wire attachment portion 9 in a state where the insertion member 12 is inserted into the communication hole 11. By forming the widened portions 12 </ b> B and 12 </ b> C in the insertion member 12, it is possible to prevent the insertion member 12 inserted into the communication hole 11 from coming out of the communication hole 11. The widened portion 12 </ b> C formed on the distal end side when the insertion member 12 is inserted into the communication hole 11 is press-fitted into the communication hole 11 and formed to have a thickness that can pass through the communication hole 11. The outer peripheral surface of the widened portion 12C is formed on a slope so as to become narrower toward the tip side. Therefore, it is easy to insert the insertion member 12 into the communication hole 11.

(Modification 5)
As shown in FIG. 12, a widened portion 12 </ b> D that is widened only in the front-rear direction may be provided at the distal end portion in the insertion direction of the insertion member 12 into the communication hole 11. That is, the widened portion 12 </ b> D is disposed at a position that does not pass through the lead wire insertion holes 10 </ b> A and 10 </ b> B when the insertion member 12 is inserted into the communication hole 11. FIG. 12A is a front view of the insertion member 12. FIG. 12B is a bottom view of the insertion member 12. FIG. 12C shows a cross-sectional view of the lead wire attachment portion 9 before the insertion member 12 is inserted. FIG. 12D is a cross-sectional view of the lead wire attachment portion 9 in a state where the insertion member 12 is inserted into the communication hole 11. By forming the widened portion 12D in the insertion member 12 at the above-described position, the widened portion 12D does not hit the lead wires 100A and 100B when the insertion member 12 is inserted into the communication hole 11. Therefore, it is easy to insert the insertion member 12 into the communication hole 11.

  The configurations of the modified examples 4 and 5 can be applied to the embodiments including the above-described modified examples 1 to 3.

  In the above-described embodiment and its modifications, the insertion member 12 is inserted into the communication hole 11, but the communication hole 11 may be filled with an adhesive instead of the insertion member 12. The adhesive filled in the communication hole 11 is cured and adhered to the lead wires 100A and 100B, so that the lead wires 100A and 100B are moved forward even when a force pulling forward acts on the lead wires 100A and 100B. It becomes difficult to move.

DESCRIPTION OF SYMBOLS 1 ... Coil body 2 ... Bobbin 3A ... Conductor 9 ... Lead wire attaching part 10A, 10B ... Lead wire insertion hole 11 ... Communication hole 12 ... Insertion member 12A ... Projection part 12B, 12C ... Widening part 16A, 16B ... Opposite part (opposite) Part to do)
100A, 100B ... Lead wire 101 ... Cover member

Claims (8)

In the coil body in which the conducting wire is wound around the bobbin,
A lead wire attaching portion to which a lead wire attached to the bobbin and connected to the conducting wire is attached;
In the lead wire mounting portion,
A lead wire insertion hole into which the lead wire is inserted;
A communication hole that intersects a part of the lead wire insertion hole and communicates with the lead wire insertion hole;
Formed,
An insertion member is inserted into the communication hole,
In a state where the insertion member is inserted into the communication hole, the interval between the insertion member and the portion of the inner peripheral surface of the lead wire insertion hole facing the insertion member is narrower than the thickness of the lead wire.
A coil body characterized by that. 2. The coil body according to claim 1, wherein the communication hole and the insertion member have a shape in a cross-section orthogonal to the insertion direction of the insertion member to the communication hole, and the insertion direction of the lead wire into the lead wire insertion hole. An ellipse in which the major axis is arranged in a direction orthogonal to
A coil body characterized by that. The coil body according to claim 1 or 2,
In the insertion member, a protrusion is formed in a portion that comes into contact with the lead wire in a state of being inserted into the communication hole.
A coil body characterized by that. The coil body according to claim 3, wherein the protrusion of the insertion member has a pointed tip in a shape in a cross section perpendicular to the insertion direction of the insertion member into the communication hole.
A coil body characterized by that. The coil body according to any one of claims 1 to 4,
The communication hole passes through the lead wire mounting member,
At both ends of the insertion member inserted into the communication hole, widened portions having a width wider than the diameter of the inner periphery of the communication hole are formed.
A coil body characterized by that. The coil body according to claim 5,
The widened portion of the widened portion, which is the distal end side in the insertion direction of the insertion member into the communication hole, is disposed at a position that does not pass through the lead wire insertion hole when the insertion member is inserted into the communication hole. ing,
A coil body characterized by that. A bobbin around which a conducting wire is wound;
A lead wire attaching portion to which a lead wire attached to the bobbin and connected to the conducting wire is attached;
In the lead wire mounting portion,
A lead wire insertion hole into which the lead wire is inserted;
A communication hole that intersects a part of the lead wire insertion hole and communicates with the lead wire insertion hole;
Formed,
An insertion member is inserted into the communication hole,
In the state where the insertion member is inserted into the communication hole, a coil having a gap between the insertion member and the portion of the inner peripheral surface of the lead wire insertion hole facing the insertion member is narrower than the thickness of the lead wire In the manufacturing method of the body,
A winding connection part forming step of forming a winding connection part spirally wound around an end of the conducting wire;
A winding step of winding the conductive wire around the bobbin;
A lead wire inserting step of inserting the lead wire into the lead wire insertion hole and inserting an end portion of the lead wire into the winding connection portion;
A soldering step of soldering the end of the lead wire inserted into the winding connection portion and the winding connection portion;
An insertion member insertion step of inserting the insertion member into the communication hole;
The manufacturing method of the coil body characterized by having. In the manufacturing method of the coil object according to claim 7,
The insertion member is heated to a temperature equal to or higher than a softening temperature of a covering portion that covers the lead wire before being inserted into the communication hole.
The manufacturing method of the coil body characterized by the above-mentioned.

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