JP2940410B2 - Manufacturing method of coil parts - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a coil component used for electronic equipment for electric equipment, industrial use, and consumer use.

[0002]

2. Description of the Related Art A conventional method for manufacturing a coil component will be described with reference to FIGS.

First, as shown in FIG. 10, a winding 2 is wound around a bobbin 1 having a plurality of winding grooves 1b divided by a plurality of intermediate flanges 1a, and flanges 1c at both ends of the bobbin 1.
The lead wire 4 of the winding wire 2 is wound around the wiring terminal 3 implanted in the bobbin, soldered, and connected to the bobbin 1 by EE or EI.
The coil body 6 is assembled by incorporating the magnetic core 5 of the mold, the coil body 6 is housed in an insulating case 7, and the insulating case 7 is filled with an insulating resin 8 in a vacuum as shown in FIG. Manufacturing.

When the insulating resin 8 is filled, the individual coil parts 11 are formed by using a casting pallet receiving jig 10 provided with a holding hole 9 having a shape slightly larger than the outer shape of the insulating case 7 as shown in FIG. Was filled with the insulating resin 8. A receiving rib 7a is provided on the upper part of the outer peripheral portion of the insulating case 7, and is held by a receiving jig 10 so that the insulating resin 8 is filled so as to float above the lower plate 12 of the casting pallet.

In the case of the insulating case 7 having no such receiving ribs 7a, the positioning is performed within the height of the insulating case 7, as shown in FIG.

As shown in FIG. 11, the filled insulating resin 8 is cured by heating to a predetermined temperature.

[0007]

In the above-mentioned conventional method of manufacturing a coil component, the coil component 11 which can be simultaneously filled in the vacuum tank for a predetermined time when the insulating resin 8 is filled.
However, there was a problem that the quantity of lacquer was limited and the productivity was lacking.

In order to improve the productivity, the number of coil parts 11 that can be accommodated in the vacuum tank at one time should be increased. However, it is necessary to increase the size of the casting pallet. In addition, it is necessary to improve the performance of the vacuum pump of the vacuum tank, and the equipment becomes large, which is disadvantageous in terms of economy.

Further, it is necessary to insert and remove one coil component 11 into and from each holding hole 9 of the receiving jig 10 of the casting pallet. It is necessary to improve the operability of insertion and removal, so that the holding position of the insulating case 7 varies, and the insulating resin 8 spills out of the insulating case 7 depending on the discharge position of the nozzle filling the insulating resin 8,
There is a drawback that it adheres to the outside of the insulating case 7 and lowers the commercial value.

Further, since the holding jig 10 is provided in the receiving jig 10, it is necessary to consider the layout of the holding jig 10 and the shape of the receiving jig 10 to secure the strength of the end. It has been extremely difficult to increase the number of coil components 11 that can be held on the mold pallet.

As described above, conventionally, productivity has not been improved, and it has been difficult to provide an inexpensive coil component in terms of cost.

An object of the present invention is to provide a method of manufacturing a coil component which eliminates the above-mentioned conventional drawbacks, is excellent in productivity, and is advantageous in cost.

[0013]

Means for Solving the Problems The present invention to solve the above problems, a coil body constituted by incorporating the core into the bobbin of wound winding, the several linked insulation case group double insulation Each insulating case is filled with insulating resin, and after the filled insulating resin is cured , it is connected at the opening surface of the adjacent insulating case.
Then, cut the connecting part with a thickness smaller than the thickness of the insulating case.
This is a method of separating into individual coil parts .

[0014]

According to the above method, a large number of insulating cases can be arranged in a small space, which is advantageous for filling the insulating resin in a vacuum, thereby improving the productivity and reducing the cost.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a coil component according to an embodiment of the present invention will be described below with reference to the drawings.

First, an embodiment of the present invention will be described with reference to FIGS. In FIG. 1, a plurality of intermediate collars 2
A winding 22 such as a copper wire is wound around a bobbin 21 in which a plurality of winding grooves 21c are formed by 1a and both end flanges 21b, and a winding terminal 22 is mounted on a wiring terminal 23 implanted on both end flanges 21b of the bobbin 21. The lead wire 24 is wound and connected by solder, and a magnetic core 25 made of an EE-type or EI-type ferrite core is incorporated into the bobbin 21 to form a coil main body 26.

The coil body 26 is housed in an insulating case 27 to which a plurality of coils are connected from the opening of the insulating case 27.
The group of insulating cases 27 is made of a resin such as polybutylene terephthalate, and is connected to the adjacent insulating case 27 by a thin connecting portion 28 at the opening surface.

The coil body 26 is housed in each of the insulating cases 27 of the group of insulating cases 27 having such a configuration, and the group of insulating cases 27 is set in a vacuum tank. Insulating resin 29
Fill. The reason why the insulating resin 29 is filled in a vacuum is to ensure that the inside can be filled, and that no voids are generated.

When the filling of the insulating resin 29 is completed, the insulating resin 29 is cured by heating, and the connecting portions 28 of the respective insulating cases 27 are cut by the cutting blades 30 to separate them into individual coil parts.

FIG. 2 shows four insulating cases 27 connected to connecting portions 28.
FIG. 9 is a top view showing a state in which the coil bodies 26 are respectively housed in the components connected with each other to prepare for filling with the insulating resin 29;
FIG. 3 is an explanatory view showing the connecting portion 28 in a cross-section. The thickness of the connecting portion 28 is preferably thin in consideration of cutting later, but when the insulating resin 29 is filled, the position of each insulating case 27 is firmly determined. The strength is necessary, and if the strength is not provided, the position of the insulating case 27 will be incorrect when filling the insulating resin 29 with the discharge nozzle, and it will not be possible to charge accurately.

Further, the connecting portion 28 after the insulating resin 29 is cured.
4 and 5, V-shaped grooves 31 can be provided in advance on both sides at the center of the connecting portion 28 in order to easily and surely cut the slab. This is V on one side
The groove 31 may be provided.

Further, as shown in FIGS. 6 and 7, window holes 32 may be provided at regular intervals in the connecting portion 28 to facilitate cutting of the connecting portion 28.

As shown in FIG. 8 and FIG.
Instead of providing the window holes 32 provided at predetermined intervals, the long window holes 32 and the short window holes 32 may be alternately formed.

In the above embodiment, the case where four insulating cases 27 are connected by the connecting portion 28 is shown.
The number can be increased as many as 8, 8, 10,..., And it is preferable to select this quantity in view of the size of the equipment such as the vacuum tank and the economical efficiency.

Although the cutting of the connecting portion 28 has been described using the cutting blade 30, it is needless to say that the cutting can be performed by using any cutting means such as a laser, a water flow, and a polishing, a cutter, or a hot wire. The cutting means can be selected with reference to the finished condition of the cut surface.

[0026]

As is apparent from the above embodiments, the present invention uses a vacuum tank or the like to fill the insulating resin because a plurality of insulating cases accommodating the coil body are connected by the connecting portion. A large number of insulation cases can be arranged in a small space to streamline productivity, eliminating the need to attach and detach to the casting pallet, the position of each insulation case is also accurate, and errors in filling the insulation resin can occur. This has the effect of significantly increasing the productivity and significantly reducing the cost, and is of great industrial value.

[Brief description of the drawings]

FIG. 1 is a sectional view showing one embodiment of a method for manufacturing a coil component of the present invention.

FIG. 2 is a top view showing a state before the insulating resin is filled.

FIG. 3 is a sectional view of a main part showing a state of the connecting part.

FIG. 4 is a sectional view of a connecting portion showing another example.

FIG. 5 is an enlarged sectional view of the main part.

FIG. 6 is a top view showing still another example.

FIG. 7 is a sectional view of the connecting portion.

FIG. 8 is a top view showing still another example.

FIG. 9 is a sectional view of the connecting portion.

FIG. 10 is a top view of a conventional coil component manufacturing method before filling with an insulating resin.

FIG. 11 is a sectional view of a coil component obtained by the same method.

FIG. 12 is an explanatory view showing a casting pallet holding the insulating case.

FIG. 13 is an explanatory view showing another conventional casting pallet.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 21 Bobbin 21a Intermediate flange 21b Both ends flange 21c Winding groove 22 Winding 23 Wiring terminal 24 Lead wire 25 Magnetic core 26 Coil body 27 Insulating case 28 Connecting part 29 Insulating resin 30 Cutting blade 31 V-shaped groove 32 Window hole

Claims (2)

(57) [Claims] The method according to claim 1 coil body constituted by incorporating the magnetic core of the winding bobbin wound, housed respectively in the insulating case of several linked insulation case group birefringence, an insulating resin to the respective insulating case After filling, and after curing the filled insulating resin, it is connected at the opening surface of the adjacent insulating case.
First, cut the connecting part thinner than the thickness of the insulating case
Manufacturing method of a coil component that is separated into individual coil components . 2. The method for manufacturing a coil component according to claim 1, wherein the connecting portion is provided with window holes at regular or irregular intervals.