JP3422000B2 - Wire loop, method for manufacturing wire loop, and method for manufacturing transformer - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil or transformer such as a transformer for a small power source used as an electronic component or an inductance coil for a small motor, and more particularly to a coil or transformer for a high frequency with a small number of turns. Is.

[0002]

2. Description of the Related Art Conventionally, this kind of coil or transformer is generally formed by winding a conducting wire around a bobbin using a winding machine and mounting it on an EI core, a CI core, or a pot-shaped core. .

[0003]

In the conventional manufacturing and assembling processes, it is necessary to attach / detach the bobbin to / from the winding machine, winding the wire, and mounting the core. Therefore, the productivity is low. ,
And there was a problem that the cost was high.

The present invention is a line and a method for manufacturing the line which are suitable for mass production by mechanization in an extremely simple process.
It is an object of the present invention to provide a method for manufacturing a transformer .

[0005]

To achieve the above object, according to the Invention The linear ring of the present invention includes a guide member having a folded pattern whose surface is contiguous on one plane are insulated, the legs of both sides the a plurality of comb teeth corresponding to the folded pattern, a pair of members which are combined to tooth engagement between the mating teeth and the teeth to each other, conductors of the folded pattern
The engaging each other comb teeth of the pair of members by sandwiching, when its <br/>, shaped into a coil shape by bending by pushing the straight portions adjacent to each other of the conductors in the comb teeth tip opposite directions characterized in that consists of a pair of shaping members, a core fitted through the coil of the shaped said guide member.

[0006] The method of manufacturing line wheels according to the present invention, the surface by processing the insulated been conductors, forming a continuous folded pattern in one plane, the legs of both sides is the a plurality of comb teeth corresponding to <br/> flashing pattern folding,挾the conductors of the folded pattern between a pair of shaping members are combined to tooth engagement between the mating teeth and the teeth to each other So
Wherein the comb teeth of the pair of members are engaged with each other, then the press straight portions adjacent to each other of the conductors in the comb teeth tip each other
Consists of a step of shaping the coiled bend in the opposite direction to have a step of fitted through the core in the coil of the shaped said guide member
It is characterized by

The transformer manufacturing method of the present invention is the first
A second conductor partially over and above the conductor of
Processed conductors that are stacked together and the number of turns
And a step of forming a continuous folded pattern of two layers, and a plurality of legs on both sides corresponding to the folded pattern.
Has comb teeth, and the teeth are engaged between each other's teeth
Between the pair of shaping members that are combined so that
The conductor of the pattern is sandwiched between the comb teeth of the pair of members.
The conductors to each other at the comb teeth tip.
A step of shaping the coiled bend each other by pressing the adjacent straight portions in the opposite direction, characterized in that comprising the step of fitted through the core in the coil of the shaped said guide member.

[0008]

According to the above construction, if the folded patterns, which are laminated in one layer or two layers and are continuous on one plane, are sandwiched between the pair of shaping members and pushed in so that the teeth are engaged with each other, the straight line portions adjacent to each other are formed. Are separated on the opposite side and are easily shaped into a coil. Therefore, by inserting an EI core or a CI core in the coil, a coil or a transformer can be easily formed.

In this case, the pair of shaping members become a bobbin if they are made of an insulating material such as plastic, and become a part of the core if they are made of a magnetic material such as ferrite.
If it is removed after assembly, it will function as a mere jig.

Also, if every other straight line portion of the folded pattern is attached to the surface of the substrate and the other straight line portion is lifted by the shaping member inserted through the through hole from the back surface of the substrate, it is easily coiled. It can be shaped and the loop or transformer can be built and mounted directly on the substrate.

[0011]

Embodiments will be described in detail below with reference to the drawings. 1 to 4 show a first embodiment of the present invention, which is a case of a transformer. Reference numerals 1 and 2 shown in FIG. 1 are conductor foils whose surfaces are insulated, and are partially laminated and adhered to each other. This laminated conductor foil is pressed, for example, to form a conductor foil 10 having a continuous folding pattern with different folding numbers on one plane as shown in FIG. 3a and 3b in FIG. 3 have a substantially U-shaped cross section, and the legs on both sides have a plurality of comb teeth corresponding to the conductor foil 10 of the folded pattern, and the teeth are engaged with each other. It is a pair of shaping members combined so that they may fit. In the case of this embodiment, the shaping members 3a and 3b are made of plastic and serve as a bobbin for the coil. 4 shown in FIG.
a and 4b are EI cores made of ferrite, for example.

Now, as shown in FIG. 5, the teeth and the repeating pattern are aligned between the pair of shaping members 3a and 3b, and the conductor foil 10 having the folded pattern is sandwiched between the shaping members 3a and 3b. When the teeth are pressed so as to engage with each other, the adjacent straight portions of the conductor foil 10 in the folded pattern are pressed by the teeth and are separated from each other on opposite sides, and shaped into a coil. That is, looking at the shaped shape of the conductor foil 10 in the folded pattern, it has a coil shape as shown in FIG.

Therefore, the transformer is constructed by inserting the EI core shown in FIG. 4 into the coil of FIG. 6 formed on the bobbin and fixing the EI core with a fastening metal fitting (not shown). If the lead-out lead portions 2a, 2b of the conductor foil 2 having a small number of turns are used as the primary side input terminals and the lead-out lead portions 1a, 1b of the conductor foil 1 having a large number of turns are used as the secondary side output terminals, a booster transformer is obtained.

In the embodiment, the transformer was constructed by using two layers of insulated conductor foils having different numbers of folded patterns, but three layers of the conductor foil were used to construct a three-phase transformer. You can also do it. Needless to say, an inductance coil can be obtained by forming the folded pattern with only one layer of the conductor foil.

In the above embodiment, the pair of shaping members are made of plastic and used as the bobbin, but they may be made of magnetic material such as ferrite. 8 and 9 show a second embodiment of the present invention, in which 6 is a shaping member made of ferrite. If the conductor foil 7 of the folded pattern is sandwiched between the pair of shaping members 6 and pushed in so that the teeth are engaged with each other, the conductor foil 7 of the folded pattern is shaped into a coil as shown in FIG. Another I-shaped core 8 is inserted through the coil. In this embodiment, the ferrite of the shaping member 6 forms a magnetic path together with the I-shaped core 8.

10 and 11 show a third embodiment of the present invention, in which 11 is a shaping member as a jig. If the conductor foil 12 of the folded pattern is sandwiched between the pair of shaping members 11 and pushed in so that the teeth are engaged with each other, the conductor foil 12 of the folded pattern is shaped into a coil as shown in FIG. The coils are provided with EI cores 4a and 4b. After penetrating the core, the shaping member 11 may be pulled out.

As is clear from the above embodiments, the folded pattern can be easily formed from a single-layer or multi-layer insulated conductor foil, and the folded pattern can be shaped into a coil. It suffices if it is sandwiched and pressed into the member, which is also extremely easy. Therefore, by inserting a core into the coil, it is possible to construct a wire wheel or a transformer, and without the need for a winding machine as in the past, and without requiring manpower, it is excellent in mass productivity. It becomes a manufacturing method.

For example, a predetermined hole is opened in the printed circuit board,
By adopting a method in which the folding pattern is sandwiched and the shaping members are engaged from both sides, the structure of the coil and transformer, and even the assembly of the small motor can be performed simultaneously with the mounting on the printed circuit board, and The connection processing of the lead terminals is also easy.

12 to 16 show a fourth embodiment of the present invention, which is an example in which a wire ring is directly built and mounted on a printed circuit board. FIG. 12 shows a conductor foil whose surface is insulated, for example, a conductor foil is stretched on a flexible insulating substrate, which is formed by punching or the like and has a continuous folded pattern conductor foil on one plane. Is. The folded pattern conductor foil 15 is also insulated with an insulating film or the like. Figure 13
1 shows a printed circuit board 17 in which a plurality of substantially Z-shaped through holes 16 corresponding to every other straight line portion of the folded pattern and the bent portions at both ends thereof are arranged, and a copper foil pattern 18 is formed at a necessary position. Has been done.

Therefore, as shown in FIG. 14, a conductor foil having a folded pattern is formed in the through holes 16 arranged in the printed circuit board 17.
When 15 pieces are placed together, every other straight line portion 15a of the folded pattern is placed on the through hole 16 and every other straight line portion 15a.
15b overlaps the substrate surface between the through holes 16 adjacent to each other. The substrate surface of this overlapping portion and the conductor foil 15 of the folded pattern are attached with an adhesive. The lead-out terminal portions 15c at both ends of the folded pattern overlap the copper foil pattern 18 and are joined later.

Next, as shown in FIG. 15, a shaping member 20 having a plurality of comb teeth whose cross sections are substantially U-shaped and whose legs on both sides correspond to the folding pattern is used. Insert through the through-hole 16 from the back surface of 17 and push every other linear portion 15a adjacent to the linear portion 15b attached to the substrate of the folded pattern to lift it, separate it from the attached linear portion, and shape it into a coil. To do. The coil of the conductor foil in this shaped state is penetrated with the CI core 21 shown by the alternate long and short dash line in FIG. Finally, the shaping member 20 is removed.

In the present embodiment configured as described above, it becomes possible to directly build and mount the coil on the printed circuit board 17, and the lead terminal processing is also easy.

In the fourth embodiment, the substantially Z-shaped through hole is formed in the printed board, but it is easily understood that the through hole may be provided only in the portion of the shaping member through which the comb tooth is inserted. 17 and 18 show a fifth embodiment of the present invention, in which a pair of two through holes corresponding to both ends of every other straight line portion 23a of the conductor foil 23 of the folded pattern are provided. twenty four
A printed circuit board 22 in which a plurality of pairs of through holes are formed is used. In this embodiment, as the conductor foil 23 of the folded pattern, a continuous folded pattern of two layers with different numbers of folded is used, and a transformer having one side as the primary side and the other side as the secondary side is configured. This folded pattern 1
Similar to the fourth embodiment, the alternate linear portions 23b are bonded to the substrate, and the alternate linear portions 23a are lifted by the shaping member to be shaped into a coil.

Also in this embodiment, the transformer can be directly built and mounted on the printed circuit board 22, and the lead terminal processing can be extremely facilitated.

[0025]

As described above, according to the present invention,
It is small and lightweight, facilitates the manufacturing of wire rings and transformers with excellent frequency characteristics, is excellent in mass productivity, and significantly reduces costs. Further, by combining with a printed circuit board or the like, a great effect such as easy mounting and terminal processing can be achieved.

[Brief description of drawings]

FIG. 1 shows an insulated conductor foil according to a first embodiment of the present invention partially laminated and adhered to each other.

FIG. 2 is a diagram showing a folded pattern formed by processing the conductor foil of the same example.

FIG. 3 is a perspective view of a shaping member as a bobbin of the same embodiment.

FIG. 4 is a perspective view of an EI core used in the embodiment.

FIG. 5 is a diagram showing a state in which a folding pattern is sandwiched by a shaping member.

FIG. 6 is a perspective view showing a state in which a shaping member is engaged to shape the folded pattern into a coil shape.

FIG. 7 is a perspective view of a folded pattern shaped into a coil.

FIG. 8 is a perspective view showing a shaping member made of ferrite according to a second embodiment of the present invention.

FIG. 9 is an assembled sectional view of the embodiment.

FIG. 10 is a perspective view of a shaping member as a jig according to a third embodiment of the present invention.

FIG. 11 is an assembly explanatory diagram of the embodiment.

FIG. 12 is a perspective view showing a folded pattern according to a fourth embodiment of the present invention.

FIG. 13 is a plan view of the printed circuit board according to the embodiment.

FIG. 14 is a view showing a state in which a conductor foil having a folded pattern is attached to the printed board of the embodiment.

FIG. 15 is a cross-sectional view showing a state in which the conductor foil of the folded pattern of the embodiment is shaped into a coil.

FIG. 16 is a view showing a state in which the core is inserted through the shaped coil of the example.

FIG. 17 is a plan view of a printed circuit board according to a fifth embodiment of the present invention.

FIG. 18 is a view showing a state in which a conductor foil having a folded pattern is attached to the printed circuit board of the example.

[Explanation of symbols]

1,2… Insulated conductor foil, 3a, 3b, 6,11,20… Shaping member, 4a, 4b… EI core, 7,10,12,15,23… Folded pattern conductor foil, 17,22… Print substrate.

Claims (4)

(57) [Claims] 1. A conductor having an insulative surface and having a continuous folded pattern on one plane, and legs on both sides having a plurality of comb teeth corresponding to the folded pattern, and between the mating teeth of each other. Consists of a pair of members that are combined so that the teeth are engaged with each other, and the comb teeth of the pair of members are engaged with each other by sandwiching the conductor of the folded pattern.
A pair of shaping members for pushing linear portions of the conductor adjacent to each other by comb teeth to bend in opposite directions to shape the coil, and a core penetrating the shaped coil of the conductor. The line wheel to do. Wherein said shaping member is a jig, Senwa of claim 1, wherein after assembling and removing. 3. A step of processing a conductor whose surface is insulated to form a continuous folded pattern on one plane,
The leg portions on both sides have a plurality of comb teeth corresponding to the folding pattern, and the conductor of the folding pattern is sandwiched between a pair of shaping members that are assembled so that the teeth are engaged with each other. Then, the comb teeth of the pair of members are engaged with each other, and at that time, the linear portions of the conductors which are adjacent to each other are pressed by the tips of the comb teeth to bend the conductors in opposite directions to form a coil, and the shaped conductor is shaped. A method for manufacturing a wire ring, comprising the step of penetrating a coil with a core. 4. A conductor in which a second conductor is partially and insulated from each other and laminated on a first conductor is processed to form a continuous folding pattern of two layers having different folding numbers on one plane. And the folding pattern between a pair of shaping members that have a plurality of comb teeth corresponding to the folding pattern on both sides and are engaged with each other so that the teeth engage with each other. And the comb teeth of the pair of members are engaged with each other, and at that time, the linear portions of the conductor that are adjacent to each other are pressed in opposite directions by the tips of the comb teeth to bend each other to form a coil shape, and And a step of piercing the core of the conductor coil, the method of manufacturing a transformer.