JP3228068B2 - Manufacturing method of sheet-shaped punched coil and transformer using the same - 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 thin plate punched coil used for various electronic devices and a transformer using the same.

[0002]

2. Description of the Related Art In recent years, in order to meet the needs for higher frequency and thinner transformers, thin-plate-shaped coils have been widely used.

In order to provide a thin transformer at low cost, it is necessary to make a thin plate coil at low cost.
It is necessary to employ a coil formed by a punching method due to factors such as an increase in cost and an increase in current capacity in terms of an increase in film thickness in a print coil formed by an etching method.

[0004] Also, demands for thinner and lower cost power supply devices have been increasing, and it is no exaggeration to say that a key part of the differentiation is a transformer.

As a transformer using a thin plate-shaped punched coil, those shown in FIGS. 12A, 12B and 13 are generally used.

FIG. 12 shows a conventional transformer.
This will be described with reference to FIGS.

In FIG. 1, reference numeral 1 denotes a completed thin-plate coil, 2
Is a magnetic core, 1a is a thin-plated punched coil formed with one turn, 3 is a lead terminal, 4 is an insulating film, 1b is a multiple-turned thin-plated punched coil formed in a spiral shape, and 3a is from inside the coil. Reference numeral 5 denotes a drawer insulating tape.

Referring to FIG. 12 (a), a thin-plate punched one-turn coil 1a will be described. Insulating film 4 is sandwiched from both sides so as to form a thin-plate coil finished product 1, which is shown in FIG. As described above, the magnetic core 2 is incorporated in the laminated thin-plate coil 1 to complete the thin transformer.

Referring to FIG. 12 (b), a thin plate-shaped punched coil 1b will be described. Since the coil is formed in a spiral shape, one lead terminal 3a is formed inside the coil. Therefore, this drawer terminal 3
a is folded back from the inside to the outside, and
a and the pull-out insulating tape 5 is inserted between the coil 1b and
Further, the insulating film 4 is sandwiched from both sides so as to be sandwiched to form a thin-plate coil finished product 1. Next, FIG.
As shown in FIG. 3, a thin transformer is completed by incorporating the magnetic core 2 into the laminated thin plate coil product 1.

[0010]

However, in the above-mentioned conventional structure shown in FIG.
The only way to determine the positions of the turn coil 1a and the insulating film 4 is to use the lead-out terminal 3. However, since the draw-out terminal 3 is movable, it cannot be said to be an accurate and accurate positioning means. Coil 1a
Move, and the coil 1a
Insulation failure may occur between the magnetic core 2 and the magnetic core 2.

In the conventional configuration shown in FIG. 12B, the only means for determining the positions of the thin plate-shaped punched coil 1b and the insulating film 4 is the lead terminal 3 which is originally outside the coil. , And the insulating tape 5 is inserted in advance.
It is folded back out of the coil, and two terminals, the terminal 3a and the original lead terminal 3, are used as a reference.
Since the positioning accuracy is worse than that of FIG. 2 (a), when the insulating film 4 is attached or the lead-out terminal 3a is folded back, the coil 1b moves and the coil 1a and the magnetic core in the portion of Aa as in the case of FIG. Insulation failure occurs between the two. In addition, there is a possibility of insulation failure due to contact between the coils in the portion B in the drawing.

As a result, abnormalities and troubles in electrical performance due to a change in inductance in the production process are caused.

[0013] As another conventional technique using a thin-plate coil, US Pat.
No. 4, No. 4, No. 4
Japanese Patent Application Laid-Open No. 679911 discloses a technique in which a double-sided printed coil is bent and a terminal inside the coil is further pulled out.
No. 95136, Japanese Patent Application Laid-Open No. 61-184806, etc., formed by bending a thin plate conductor.
Japanese Unexamined Patent Publication No. 4-141707 discloses a method in which the position of a terminal is determined by shifting the position of an annular flat-plate conductor coil,
Japanese Unexamined Patent Application Publication No. 196507/1992 discloses a method in which a punched coil with terminals is formed by bending, a method in which a printed coil is formed by etching and folded to complete a thin plate coil as disclosed in Japanese Unexamined Patent Publication No. 4-206906,
Japanese Patent Application Laid-Open No. 2-82817, in which U-shaped coils with terminals are formed with terminal positions shifted from each other.
Various technologies, such as a configuration in which a terminal is turned from the inside to the outside of a coil formed in a spiral shape and used as a lead terminal as disclosed in Japanese Patent Application Laid-Open No. 07-0707, are disclosed.

When a thin conductive plate is manufactured by a punching method, the most problematic problem is that the coil and the magnetic core or the insulation between the coil and the coil are most problematic as described in the conventional example of FIGS. 12 (a) and 12 (b). In other words, how to ensure quality, and in order to solve this problem, a method of positioning the punched coil and the insulating film must be specified.

In consideration of this point, it is considered that the material, the shape and the configuration of the terminal, and the method of drawing out the terminals are already known. However, even in the conventional literature, the presentation of the above-mentioned problem and the method of solving the problem are not specified. is there.

The present invention solves the above-mentioned problems. By preventing the movement of the coil alone and showing a method of positioning the coil and the insulating film, the insulation between the coil and the magnetic core and between the coil and the coil can be maintained, and a high level can be maintained. It is an object of the present invention to provide a method of manufacturing a sheet-shaped punched coil that can be produced with high quality and a high-quality transformer at low cost.

[0017]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention provides a method for manufacturing a sheet-like punched coil.
A first step of punching out the basic shape of the thin-plate coil in a state where at least a part of the lead terminal portion of the coil is connected to the coil connecting portion; and a thin plate connected to the coil connecting portion.
To sandwich the coil with an insulating film, a second step of is laminated an insulating film and a thin plate coil, co
Make sure to separate the coil terminal from the coil connection
And a third step of punching a final shape. Further, the present invention is characterized in that a magnetic core is incorporated by using at least one thin-plated punched coil manufactured by using this manufacturing method as a transformer.

[0018]

According to the above construction, since the coil is integrated with the connecting portion, the movement of the coil alone can be reliably prevented, and the position of the coil can be determined by using the connecting portion. Since the relative position is determined, the insulating film can be attached to the fixed position, the coil does not move when the insulating film is attached, and the insulation can be maintained. Furthermore, according to the manufacturing method of the present invention, a high-quality thin-plate coil can be produced by a punching method, so that there is no quality loss and a thin transformer can be produced at low cost.

[0019]

【Example】

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

In FIGS. 1 and 2, basically, FIG.
13 (a) and 13 (b), the same components as those in the prior art in FIG. 13 will be denoted by the same reference numerals, and will not be described in detail.
1 and 2, 3b is a lead terminal connecting portion, 4a is a continuously formed insulating film, 6 is a coil connecting portion, 7
Is a feed pitch reference portion, 8 is a magnetic core insertion hole portion, and X ₁
−X ₂ , X ₃ −X ₄ , and Y ₁ −Y ₂ indicate cutting reference lines.

The manufacturing process will be described with reference to FIGS. 1 (a), 1 (b) and 1 (c) and FIG. First, as shown in FIG. 1A, in a first step, a thin plate-shaped conductor was connected to the coil connecting portion 6 and a part of the lead terminal 3 of the coil, that is, the drawing terminal connecting portion 3b in the drawing. In the state, the basic shape of the thin plate coil 1a is punched. Next, the thin-plate coil 1 is sequentially punched using the feed pitch reference portion 7 to produce a continuous coil.

Further, in the second step shown in FIG. 1 (b), the insulating film 4a is bonded so as to be sandwiched from above and below while the thin plate coil 1a is still connected to the coil connecting portion 6. At this time, since the relative position of the thin coil 1a is determined with respect to the coil connecting portion 6, if the position of the insulating film 4a is determined using the coil connecting portion 6, the position of the thin coil 1a and the insulating film 4a can be determined. Since the positional relationship can be easily determined, the insulating film 4a can be attached to a fixed position. Further, since the thin coil 1a is connected to the coil connecting portion 6 so as not to move, the thin coil 1a does not move even when the insulating film 4a is bonded.

As a result, a necessary distance can be secured for the relationship between the thin-plate coil 1a and the insulating film 4a, and the most important insulation can be secured. In this state, the process proceeds to the third step shown in FIG. 1C, in which the hole 8 into which the magnetic core is inserted is punched out, and along the cutting reference lines X ₁ -X ₂ , X ₃ -X ₄ , and Y ₁ -Y _2. Then, the final shape is punched out to complete the individual shape coil having the final shape shown in FIG.

As described above, according to the manufacturing method of this embodiment, the movement of the thin coil 1a alone can be prevented, and the relative positions of the thin coil 1a and the insulating film 4a are determined. Can be stuck, the movement of the thin-plate coil 1a at the time of sticking the insulating film 4a is eliminated, and a thin-plate punched coil that can maintain insulation can be manufactured.

In this embodiment, the expression of FIG. 1 is explained by a manufacturing method of forming a continuous coil called a progressive die as a die, but X ₁ -X ₂ , X ₃ in FIG. 1 (c). −
If the punching along the section line X ₄ in the first single-type performed earlier in the process shown in FIG. 1 (a) producing pieces coils are also contemplated. Even in this case, the same effect can be obtained if the individual coil is punched in a state where at least a part 3b of the lead terminal portion, which is the basic configuration of the present invention, is connected to the coil connecting portion 6. is there.

In this embodiment, the punching of the magnetic core insertion hole 8 is performed in the third step of FIG. 1C, but in the second step of FIG. The effect of the present invention can be obtained even if it is performed in advance, and thus the steps are not limited.

(Embodiment 2) Hereinafter, a second embodiment of the present invention will be described with reference to FIG.

In FIG. 4, reference numeral 4b denotes an individual insulating film. FIG. 3 is basically the same as the first embodiment, except that an individual insulating film 4b is used in the second step.

The manufacturing process will be described with reference to FIG. 3. The individual insulating film 4 b is punched or cut in advance, and then the second step is performed based on the thin plate coil 1 a and the coil connecting portion 6. Since they are bonded, the positional relationship between the insulating film 4b and the thin plate coil 1a can be determined in the same manner as in the first embodiment.

As described above, according to the present embodiment, in addition to the effects obtained in the first embodiment, unique effects such as a simple mold structure and a small amount of the insulating film 4 can be obtained.

(Embodiment 3) Hereinafter, a third embodiment of the present invention will be described with reference to FIGS.

In the third embodiment of the present invention, the basic shape of the thin-plate coil has all the lead terminals outside the coil, and
This is a description of a method of punching and manufacturing a thin plate coil in the case of a two-turn configuration in which two turn coils are continuously formed.

In the figure, basically, the same components as those in FIGS. 1 to 3 are denoted by the same reference numerals and will not be described in detail.

FIGS. 4 (a), 4 (b) and 4 (c) and Example 1
The difference between FIGS. 1A, 1B, and 1C is that
The basic shape of the plate coil is to form two continuous one-turn coils
Only in that the coil 1c has a 2-turn configuration
is there. In FIG. 5, X _Five-X₆, X₇-X₈Is bent
The horizontal lines are shown.

4A, 4B, and 4C are the same as those in the first embodiment, and thus the description thereof is omitted. The fourth manufacturing process will be described with reference to FIG. In this embodiment, since the two-turn coil 1c is used as described above, the punching of the final shape is completed at the end of the third step in FIG. 4C, but the thin shape shown in FIG. When completing the transformer, the magnetic core 2 cannot be incorporated. Therefore, FIG.
As shown in FIG. 5B, the two-turn coil is alternately folded along the folding lines X ₅ -X ₆ and X ₇ -X ₈ shown in FIG. 5A as shown in FIG. 5B. Complete. In this way, by bending a single-piece coil in which two one-turn coils are continuously formed, that is, in this case, the two-turn coil 1c can be incorporated into the magnetic core 2 and a thin transformer can be completed.

That is, by adding the fourth step shown in FIGS. 5A, 5B and 5C,
The unique effect that even a one-turn coil 1a as shown in FIG. 2 can be easily manufactured without external connection even with a two-turn thin plate-shaped punched coil which needs to be formed by connecting terminals externally. It can be obtained in addition to the effects obtained in the first embodiment.

In this embodiment, as shown in FIG. 6, an individual insulating film 4b may be used.

(Embodiment 4) Hereinafter, a fourth embodiment of the present invention will be described with reference to FIGS.

In the figure, reference numerals 1d and 1e denote respective symmetric coils, and reference numeral 3c denotes a comb-shaped multiple terminal.

In this embodiment, as shown in FIG. 7, symmetrical coils 1d and 1e having a plurality of comb-shaped terminals 3c having a constant terminal pitch interval are used, and as shown in FIG. In the first step, unnecessary portions 9 indicated by oblique lines in FIGS. 8B and 8C are deleted and the basic shape of the thin-plate coil is punched out using one of the coils 1d and 1e. is there.

As described above, according to the present embodiment, the coil having a one-turn or multiple-turn configuration shown in the first or third embodiment can be easily manufactured by a common head flow process. Further, since the multiple terminals 3c are in the form of a comb, the extraction position can be arbitrarily selected by leaving only necessary portions of the extraction terminals. Further, by making the coils 1d and 1e symmetrical, the width of the hoop of the thin conductive plate to be used first can be reduced, so that a specific effect that the yield of materials can be improved can be obtained.

(Embodiment 5) Hereinafter, a fifth embodiment of the present invention will be described with reference to FIGS.

The fifth embodiment of the present invention is directed to a method for punching a thin-plate coil in the case where the basic shape of the thin-plate coil is a plural-turn spiral winding having one lead terminal portion in the coil. This corresponds to FIG. 12B showing a conventional example.

9 to 11, basically, the same components as those in FIGS. 1 to 3 are denoted by the same reference numerals and will not be described in detail. 9 to 11 and Example 1,
The only difference between FIG. 2 and FIGS. 1 to 3 is that the basic shape of the thin-plate coil is a multiple-turn spiral winding having one lead-out terminal 3a in the coil.

FIGS. 9 (a), 9 (d) and 9 (e) are the same as those in the first embodiment, and will not be described. FIGS. 9 (b) and 9 (c) and FIGS. The manufacturing method of this embodiment will be described with reference to b). In the present embodiment, since the basic shape of the thin plate coil is a spiral winding shape like a plurality of turns 1b having one lead terminal portion 3a in the coil, the core is previously formed as shown in FIG. 9 (b). The hole of the insertion hole 8 is formed like the insulating film 4a. This insulating film 4a is used in the second step of FIG.
After finishing the final shape punching in the third step (c), FIG.
As shown in FIG. 5, the terminal 3a in the coil is folded back, and the terminal 3a is drawn out of the coil to complete a thin plate-shaped punched coil.

In the present embodiment, the step of folding the lead-out terminal 3a is described as being provided after the third step. However, after the second step of FIG. 9D, the lead-out terminal 3a as shown in FIG. 3A, and the process of FIG.
The final shape of the third step may be punched in the state as shown in FIG.

As described above, according to this embodiment, FIG.
(C) using an insulating film 4a having a hole formed therein, and providing a folding step of the lead terminal 3a in the coil after or before the third step to provide the insulating film 4a.
12B can be accurately adhered to a fixed position, so that the drawer insulating tape 5 which was conventionally required as shown in FIG. It can be obtained in addition to the effects obtained in the first embodiment.

It is needless to say that the same effect can be obtained by using the individual insulating film 4b shown in FIG. 9 (c).

[0049]

As described above, the present invention provides a first step of punching out a basic shape of a thin-plate coil in a state where at least a part of a lead terminal portion of the coil is connected to a connecting portion of the coil; Disconnect the thin coil connected to the connection.
A second step of bonding the insulating film and the thin plate coil so as to sandwich with the edge film, and a coil connection
Since the third step of punching out the final shape so as to separate the lead terminal of the coil from the portion is adopted, (1) the thin plate coil alone can be prevented from moving.

(2) An insulating film can be attached at a fixed position. (3) The movement of the thin plate coil when attaching the insulating film is also eliminated.

(4) A sheet-like punched coil capable of maintaining insulation can be completed. In the case where an individual insulating film is used in the second step, (5) the mold structure can be simplified.

(6) The amount of the insulating film used can be reduced. Further, the basic shape of the thin plate coil is formed by a plurality of turns in which all the lead terminals are provided outside the coil, and a plurality of one-turn coils are continuously formed, and after the final shape punching in the third step, In the case where the step of bending one coil is provided as a fourth step after the third step, (7) a thin plate punched coil having a plurality of turns can be easily manufactured without external connection. .

Further, in the case of using a symmetrical coil having a large number of comb-shaped terminals in which the terminal pitch intervals are constant, (8) a coil having a plurality of turns from one turn can be a common head flow step. .

(9) The drawer position can be arbitrarily selected. (10) The yield of materials can be improved.

Further, in the second step, an insulating film in which the basic shape of the thin-plate coil is formed in a spiral winding shape like a plurality of turns having one lead terminal in the coil and a hole is formed is used in the second step. At the same time, in the case where the lead terminal in the coil is turned back after or before the third step and the terminal is pulled out of the coil, (11) the draw-out insulating tape becomes unnecessary.

(12) The step of attaching the drawer insulating tape can be reduced. As described above, according to the manufacturing method of the present invention, a high-quality sheet-like coil can be produced by a punching method,
By incorporating a magnetic core using at least one sheet-like punched coil manufactured by using the manufacturing method of the present invention, (13) a transformer without quality loss can be produced at low cost. In addition, by using this thin transformer for a power supply device, (14) the cost and thickness can be differentiated. This has a great effect, and is of great industrial value.

[Brief description of the drawings]

FIG. 1 shows a first example of a method for manufacturing a sheet-shaped punched coil of the present invention.
Showing the manufacturing process of the embodiment of FIG.

FIG. 2 is a plan view showing a finished product of the thin plate coil.

FIG. 3 is a view showing a manufacturing process of the sheet-shaped punched coil of the second embodiment.

FIG. 4 is a view showing a manufacturing process of the thin plate-shaped punched coil of the third embodiment.

FIG. 5 shows a fourth example of the sheet-shaped punched coil of the third embodiment.
Diagram showing the manufacturing process of

FIG. 6 is a view for explaining a manufacturing process of the thin plate-shaped punched coil of the third embodiment.

FIG. 7 is a plan view of a target coil showing the fourth embodiment.

FIG. 8 is a plan view for explaining the fourth embodiment.

FIG. 9 is a view showing a manufacturing process of the thin plate-shaped punched coil of the fifth embodiment.

FIG. 10 is a view showing a step of folding a lead terminal in the coil according to the fifth embodiment.

FIG. 11 is another view showing the step of folding the lead-out terminal in the coil according to the fifth embodiment.

FIG. 12 is a plan view of a conventional punched coil.

FIG. 13 is a perspective view of a transformer using a general punching coil.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Thin-plate coil finished product 1a 1-turn coil 1b Multiple-turn coil 1c 2-turn coil 1d Symmetric coil 1e Symmetric coil 2 Magnetic core 3 Lead terminal 3a Lead terminal in coil 3b Lead terminal connection part 3c Comb-shaped many terminals 4 Insulating film 4a Continuous insulating film 4b Individual piece insulating film 5 Pull-out insulating tape 6 Coil coupling part 7 Feed pitch reference part 8 Core insertion hole 9 Coil unnecessary part A part Insulation failure part between coil and magnetic core B part Insulation by contact between coil and coil failure portion _{X 1 -X 2, X 3 -X} 4, Y 1 -Y 2 cutting reference line _{X 5 -X 6, X 7 -X} 8 fold line

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) H01F 17/00-19/08 H01F 41/00-41/12 H01F 27/28

Claims (6)

(57) [Claims] 1. A first step of punching out a basic shape of a thin-plate coil in a state where at least a part of a lead terminal portion of a coil is connected to a coil connection portion;
Sandwich the connected thin coil with insulating film
A second step of bonding the insulating film and the thin plate-shaped coil so as to draw out the coil from the coil connecting portion.
And a third step of punching a final shape so as to cut off the sheet. 2. The method according to claim 1, wherein an individual insulating film is used in the second step. 3. The basic shape of the thin-plate coil is formed by a plurality of turns in which a plurality of one-turn coils are continuously formed with all the lead terminals outside the coil, and the final shape in the third step. The method for producing a thin plate-shaped punched coil according to claim 1 or 2, wherein a step of bending the individual coil after the punching is provided as a fourth step after the third step. 4. The method according to claim 1, wherein a symmetrical coil having a large number of comb-shaped terminals having a constant terminal pitch interval is used. 5. A second step in which a basic shape of a thin-plate coil is formed in a spirally wound shape of a plurality of turns having one lead terminal portion in a coil, and a perforated insulating film is used in a second step. 3. The method according to claim 1, further comprising, after or before the third step, a step of folding a lead terminal in the coil and drawing the terminal out of the coil. 6. A transformer incorporating a magnetic core using at least one sheet-like punched coil manufactured by using the manufacturing method according to claim 1.