JP2698498B2 - Thin coil holding substrate - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a structure of a thin coil holding substrate applicable to, for example, a surface facing type motor.

[0002]

2. Description of the Related Art The applicant of the present invention has disclosed a metal processed into a wiring pattern so that coils can be accurately arranged at equal intervals and connection between the coil and a stator substrate can be facilitated. A plate and a coil frame made of resin having a plurality of coil insertion portions in a coil shape are integrally formed, a coil is inserted into each coil insertion portion of the coil frame, and this coil is formed into a pattern of the metal plate. We have applied for a utility model registration for the thin coil connected (Japanese Utility Model Application No. 3-53).
737).

FIG. 9 shows an example of a metal pattern plate applicable to the thin coil according to the above application. In FIG. 9, a square member denoted by reference numeral 1 is a metal pattern plate, and a connection pattern 2 is formed on the metal pattern plate 1 by a method such as pressing or etching. In this case, if the punching is performed so that the complete connection pattern 2 finally required is left, a part of the connection pattern 2 is separated from the metal pattern plate 1, so that the connection pattern 2 is not a final pattern. The pattern holding portion 4 is an incomplete pattern in which the pattern holding portion 4 is left in place between the main portion of the metal pattern plate 1 and the connection pattern 2, and the main body portion of the metal pattern plate 1 and the connection pattern 2 It is in the form of being connected together. A substantially ring-shaped pattern 12 is provided on the inner peripheral side of the connection pattern 2, and the connection pattern 2 and the pattern 12 are integrally formed by a terminal portion 8 extending radially from the pattern 12 and a pattern holding portion 5 following the terminal portion 8. Are linked. Reference numeral 9 denotes a terminal for soldering the end of the coil.

After forming all the connection patterns 2 and 12 on the metal pattern plate 1 as described above, a resin is injected onto all the connection patterns 2 and 12 to form a coil frame integrated with the connection pattern 2. . When molding the coil frame with resin, the substantially ring-shaped pattern 12 of the metal pattern plate 1 is used.
Is also covered with a resin, and a coil insertion portion adapted to the shape of the coil is formed at regular intervals in the circumferential direction in order to facilitate the arrangement of the coil in a later step.

According to the thin coil of the above application, the coil can be arranged simply by inserting the coil into the coil insertion portion of the resin-molded coil frame, so that the coil can be easily arranged and the coil positioning accuracy can be improved. In addition, since the connection pattern and the coil frame are integrally formed and the coil is connected to the connection pattern, the coil is inserted and arranged in the coil insertion portion of the coil frame, and the winding start and winding of each coil are performed. If the end is soldered to the connection pattern, an excellent effect is obtained such that the connection is completed and the connection is easy.

[0006]

SUMMARY OF THE INVENTION The present invention has been further improved while taking advantage of such a thin coil. That is, when forming the metal pattern plate integrally so as to cover the metal pattern plate from both sides with a resin coil frame, there is not much problem. There is a possibility that the metal pattern plate is not sufficiently bitten by the metal pattern plate and the metal pattern plate is easily peeled off from the coil frame. In view of the above, the present invention provides a thin-coil holding substrate in which the adhesion between a resin coil frame and a metal pattern plate can be increased so that the metal pattern plate does not come off from the coil frame. The purpose is to do.

[0007]

Means for Solving the Problems The present invention has a coil frame made of resin and having a coil insertion portion, and a metal pattern plate integrally formed with the coil frame and processed into a connection pattern. in the holding substrate of the thin coil formed by, molded the coil frame and one-body metal pattern plate
A projection or notch is provided in the connection pattern portion , and this projection
Alternatively, the notch is embedded in the coil frame .

[0008]

In a case where the metal pattern plate is integrally formed on one side of the coil frame, the resin forming the coil frame is an integrally formed portion of the metal pattern plate with the coil frame.
A connection pattern that wraps the protrusions provided in the connection pattern portion or is an integral part of the metal pattern plate and the coil frame
Filling the notch provided on the down portion, connection pattern portion of the
The protrusion or notch is buried in the coil frame to enhance the adhesion strength between the coil frame and the metal pattern plate.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a thin coil holding substrate according to the present invention will be described below with reference to FIGS. It should be noted that the illustrated embodiment has many components in common with the example of the prior application shown in FIG. 9, and thus the same reference numerals are given to the common components.

In FIG. 1, a connection pattern 2 is formed on a square metal pattern plate 1 by a method such as pressing or etching. In this case, if the punching is performed so that the complete connection pattern 2 finally required is left, a part of the connection pattern 2 is separated from the metal pattern plate 1, so that the connection pattern 2 is not a final pattern. The pattern holding portion 4 is an incomplete pattern in which the pattern holding portion 4 is left in place between the main portion of the metal pattern plate 1 and the connection pattern 2, and the main body portion of the metal pattern plate 1 and the connection pattern 2 It is in the form of being connected together. A substantially ring-shaped pattern 12 is provided on the inner peripheral side of the connection pattern 2, and a terminal portion 8 radially extending from the pattern 12 and a pattern holding portion 5 following the terminal portion 8 are provided.
Thus, the connection pattern 2 and the pattern 12 are integrally connected.

As shown in FIG. 2, a coil frame 3 integrated with the connection pattern 2 by injecting a resin is provided on the connection pattern 2 of the metal pattern plate 1 on which the connection pattern 2 is formed. Form. The coil frame 3 also covers the substantially ring-shaped pattern 12 of the metal pattern plate 1. At the time of resin molding, in order to facilitate coil arrangement in a later step, a substantially trapezoidal coil insertion portion 10 conforming to the planar shape of the coil is provided at regular intervals in the circumferential direction of the coil frame 3.
Are formed at a plurality of locations according to the number of coils.

The above embodiment differs from the example of the prior application shown in FIG. 9 in that, as shown in FIG. 1, the metal pattern plate 1 is formed integrally with the coil frame 3, especially in the connection pattern 2. This is the point that the protrusion 11 is provided. The protrusions 11 are formed on both sides of the connection pattern 2. FIG. 8 (a)
As shown in (b), the protrusion 11 is bent in a direction to bite into the resin constituting the coil frame 3. Therefore,
When the coil frame 3 integrated with the connection pattern 2 is formed by injecting the resin as described above, the molding resin
When viewed from the side of the protrusion 11, the protrusion 11 is buried in the coil frame 3 in a state of being cut into the resin, and the adhesion strength between the connection pattern 2 of the metal pattern plate 1 and the coil frame 3 is determined. Becomes stronger.

After the coil frame 3 is formed of resin as described above, the pattern holding portions 4, 5 of the metal pattern plate 1 are formed.
Is separated by a press punch, and the coil frame 3 is separated from the metal pattern plate 1. The coil frame 3 is a metal pattern plate 1
In order to insert-mold the portion of the connection pattern 2, the connection pattern 2 is integrally held by the coil frame 3. Thus, the holding substrate for the thin coil is completed.

The holding substrate for the thin coil is formed by bending a terminal portion 8 in the coil insertion portion 10 that comes into contact with the beginning of each coil and a terminal portion 9 in the coil insertion portion 10 that comes into contact with the end of each coil. Forming so that is easy to implement. A coil wound in a predetermined shape is inserted and arranged in each coil insertion portion 10. At this time, the insulating coating at the beginning and end of winding of the coil is removed, and then reflow soldering is performed. Of the coil is soldered to the terminal portion 8 and the winding end of the coil is soldered to the terminal portion 9 to complete the connection of the coil. Incidentally, in the illustrated example, each coil is connected in a three-phase Y-shape. Each coil is substantially integrated with the coil frame 3 by connecting each coil to the connection pattern 2 by reflow soldering, but each coil is more firmly integrated with the coil frame 3. For this purpose, each coil may be bonded to the coil frame 3.

The coil applied to the present invention is inserted and arranged in the coil insertion portion 10 of the coil frame 3.
The manufacturing method is not particularly limited as long as it is wound in a flat space in a flat space, but it can be obtained by winding a copper foil around a core with an insulating layer interposed and then cutting the foil. It is desirable to use coils. FIG. 3 shows an example of a manufacturing process of such a coil. As shown in FIG. 3A, an insulating coating is applied to a copper foil 16 as a material, and then one side edge is fixed to a core 15. And copper foil 1
6 is coated with an adhesive, wound around the core 15 a predetermined number of times to form a tube, and after the copper foil 16 is completely bonded between layers, the core 15 is removed. Then, as shown in FIG. A large number of coils 17 are obtained by cutting the copper foil 16 wound into a shape into a predetermined thickness.

The thin coils 17 are inserted into the respective coil insertion portions 10 of the holding substrate formed by insert-molding the connection pattern 2 on the coil frame 3, and the winding start and end of each coil 17 are determined by the terminal portions 8 and 9. Is connected by reflow soldering to complete a thin coil. As is well known, the thin coil obtained in this manner is disposed to face a flat rotor magnet, and the rotor including the rotor magnet is driven to rotate by switching energization to each coil according to the rotation position of the rotor magnet. Can be.

According to the embodiment described above, the coil frame 3 having the coil insertion portion 10 and made of resin, and the metal pattern plate 1 formed integrally with the coil frame 3 and processed into a connection pattern are formed. In the holding substrate for a thin coil having the following features, the projections 11 are provided on the integrally formed portion of the metal pattern plate 1 with the coil frame 3. Therefore, when the resin is injected to form the coil frame 3, Is cut into the coil frame 3 made of resin, the adhesion strength between the connection pattern 2 of the metal pattern plate 1 and the coil frame 3 is increased, and the connection pattern 2 is prevented from peeling off from the coil frame 3. can do.

Next, various modifications of the holding substrate for the thin coil according to the present invention will be described. In the above embodiment,
The connection pattern 2, which is an integral part of the metal pattern plate 1 with the coil frame 3, is provided with the projection 11.
Instead of 1, a notch 21 may be provided as shown in FIGS. In the example of FIG. 4, the portion of the connection pattern 2 is based on
Thus , notches 21 are formed in all parts of the metal pattern plate 1 integrally formed with the coil frame 3. According to this embodiment, when the coil frame 3 is insert-molded together with the metal pattern plate 1, the molding resin forming the coil frame 3 is notched 21 in the connection pattern 2 as shown in FIG.
And the notch 21 is buried in the coil frame 3, so that the connection pattern 2 is firmly adhered to the coil frame 3, and the connection pattern 2 is peeled off from the coil frame 3. Can be prevented.

Instead of the notches 21 provided in the connection pattern 2, holes 20 may be provided as shown in FIGS. When the hole 20 is provided, the same operation and effect as when the notch 21 is provided can be obtained.

The shape of the notch provided in the connection pattern 2 is not particularly limited, and may be, for example, a rectangular notch 22 as shown in FIG. In the case where a projection is provided on the connection pattern 2, the shape of the projection is not particularly limited. For example, as shown in FIG. 7B, a projection 23 having a rectangular shape and no bent portion may be used. Good.

Further, when a projection is provided on the connection pattern 2, as shown in FIG. 8C, a part of the connection pattern 2 may be formed as a projection 25 which is cut and raised diagonally. According to this example, the molding resin of the coil frame 3 is filled so as to surround the projection 25, and the molding resin is also filled in the hole after the projection 25 is cut and raised. The adhesion strength with the pattern 2 becomes stronger.

The present invention is applicable not only to the case where the coil frame is integrally molded with resin only on one side of the metal pattern plate, but also to the case where the coil frame is integrally molded with resin on both sides of the metal pattern plate. Can be applied.

[0023]

According to the present invention, a coil frame having a coil insertion portion and made of resin, and a metal pattern plate integrally formed with the coil frame and processed into a connection pattern are provided. A connection pattern which is an integrally molded part of a metal pattern plate and a coil frame in a thin coil holding substrate made of
When a coil frame is formed by injecting resin, the protrusion is cut into the resin coil frame or the notch is filled with the resin of the coil frame because the protrusion or notch is provided in the And protrusions or notches in the connection pattern
Is embedded in the coil frame made of resin , the adhesion strength between the connection pattern of the metal pattern plate and the coil frame is increased, and the connection pattern can be prevented from peeling off from the coil frame.

[Brief description of the drawings]

FIG. 1 is a plan view showing an example of a metal pattern plate applicable to the present invention.

FIG. 2 is a plan view showing a state in which the coil frame is integrally formed with the metal pattern plate.

FIG. 3 is a perspective view showing an example of a manufacturing process of a coil applicable to the present invention.

FIG. 4 is a plan view showing another example of a metal pattern plate applicable to the present invention.

FIG. 5 is a plan view and a cross-sectional view showing another example of a connection pattern applicable to the present invention and insert molding thereof.

6A and 6B are a plan view and a cross-sectional view showing a connection pattern of the example shown in FIG. 4 and an example of insert molding thereof.

FIG. 7 is a plan view showing various modifications of a connection pattern applicable to the present invention.

8A and 8B are a plan view and a cross-sectional view showing an example of the connection pattern of the example shown in FIG. 1 and the insert molding thereof, and an example of insert molding of another connection pattern.

FIG. 9 is a plan view showing an example of a metal pattern plate that can be used for the thin coil according to the prior application.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Metal pattern plate 3 Coil frame 10 Coil insertion part 11 Projection 21 Notch 22 Notch 23 Projection 25 Projection

Claims (1)

(57) [Claims] 1. A coil frame having a coil insertion portion and made of resin, and a metal pattern plate formed integrally with the coil frame and processed into a connection pattern,
It is formed the coil frame and one body of the metal pattern plate
A projection or notch is provided in the connection pattern portion , and this projection
Alternatively, a holding substrate for a thin coil, wherein the notch is buried in the coil frame .