JP3682951B2 - Coil manufacturing method, coil component and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a coil and a coil component, and more particularly to a method for manufacturing a so-called alpha coil and a method for manufacturing a coil component.
[0002]
[Prior art]
There is a so-called alpha winding (α winding) as a method of winding the coil. This is a winding method devised so that the lead-out to the terminal after winding is led out from the outermost periphery of the winding part at both ends. The volume α is described in, for example, JP-A-61-39835 (hereinafter referred to as JP-A-1) and JP-A-64-32609 (hereinafter referred to as JP-A-2).
[0003]
That is, as can be seen from the drawings from the beginning to the end of winding of the α winding shown in FIGS. The two ends 2a and 2b of the winding are wound in the directions of arrows A and B in opposite directions to form an α shape as shown in FIG. 12, and finally the winding shaft 1 is wound as shown in FIG. This is a winding method for forming the winding portion 3 having two stages in the axial direction.
[0004]
Thus, in the coil with the α winding, since there is no bent portion for pulling out on the fixed winding shaft 1 side as in the prior art, dielectric breakdown and scratches are not induced, and there is no strength and thermal deterioration, and reliability. In addition, since the space for drawing out the lead wire from the winding shaft 1 side becomes unnecessary, the occupation ratio of the winding portion 3 becomes extremely good. Furthermore, there is a merit that productivity is improved because a lead-out operation (terminal joint portion) such as bending or welding is not required.
[0005]
By the way, the winding used for a single coil or coil component is usually an insulation coated conductor having a round cross section, but has a rectangular cross section as shown in the cross section of FIG. 14 as shown in FIG. A strip-shaped rectangular wire 5 (also referred to as a ribbon wire) is also adopted in part. Unlike a normal winding with a round cross section, the rectangular wire 5 can be densely wound so that there is almost no gap between the winding portions, so that the coil cross-sectional area can be increased and the DC resistance Rdc can be kept low. A coil with excellent direct current superposition characteristics can be obtained. As an example of a coil using the flat wire 5, the publication 2 describes an electromagnetic device (choke coil or the like) in which the flat wire 5 is wound around a drum-shaped core.
[0006]
In addition, there is a so-called self-bonding conductive wire among the insulation coated conductive wires used as coils. For example, as shown in the cross-sectional view of the rectangular wire 5 in FIG. 14, the self-bonding lead wire has a cross-sectional structure in which an insulating coating layer 9 and a fusing material layer 8 are sequentially laminated around the lead wire 10. After the winding, the fusing material layer 8 is melted by heating or solvent treatment, and adjacent wires are bonded to each other, and then solidified so that the whole coil is solidified so that the winding does not come apart. . In general, polyurethane, polyester, polyamide imide or the like is used as the insulating coating material of the insulating coating layer 9, and polyamide or epoxy is used as the bonding material of the bonding material layer 8.
[0007]
Next, a method of winding the α winding around the winding shaft in the conventional coil or coil component will be described.
[0008]
The publication 1 specifically describes a method for manufacturing a two-layer coil using a winding machine. In general, “One or more layers of wire rods are drawn out from the supply bobbin around which the wire rod is wound, wound around the pull-out bobbin, and the portion joined to the core of the wire rod gradually moves from one layer to the other. Then, the supply bobbin and the draw-out bobbin are rotated in a planetary direction with respect to the roll core in opposite directions so that the wire rod from the supply bobbin and the wire rod from the draw-out bobbin are adjacent to each other and predetermined. The wire is wound around the winding core a number of times, and both ends of the wire rod are pulled out to the outer periphery of each layer to cut at least the wire rod from the supply bobbin. ”
[0009]
[Problems to be solved by the invention]
In the conventional coil manufacturing method using the α winding method as described in the above publication 1, it is necessary to store the wire (winding) in advance in the drawer bobbin via a pulley or roller. Must be handled with care so as not to cause twisting of the rectangular wire, and the complexity of the apparatus and the troublesome preparation in the coil winding process cannot be ignored. However, although it is required to realize a simple and quick α winding method, the requirement has not yet been satisfied due to the particularity of the α winding.
[0010]
In addition, although the effectiveness of α winding is recognized, a low-cost and stable manufacturing method for high-performance coil parts with a closed magnetic circuit structure using α winding has not yet been established. ing.
[0011]
The present invention has been made in view of the above circumstances, and a novel coil manufacturing method by a simple and efficient winding method to which α winding is applied, and a coil having a novel structure using the coil by the winding method It aims at providing the manufacturing method of components.
[0012]
[Means for Solving the Problems]
The present invention
(1) A rectangular wire having a rectangular cross-section in which an insulating coating layer and a fusion material layer are sequentially laminated around a conducting wire is used as a winding material, and both ends of the flat wire are clamped to a clamp portion of a winding machine, and the rectangular The flat wire is wound in opposite directions while the clamp portion is moved obliquely with respect to the winding axis so that the center of the wire is obliquely inclined with respect to the winding axis, and 2 in the axial direction of the winding axis. A step of forming a stepped winding portion, and a step of energizing and heating both ends of a rectangular wire wound around the winding shaft through the clamp portion to self-fuse the winding portion. The above object is achieved by providing a method for manufacturing a coil.
[0013]
(2) In addition, a step of forming a core core having a T-shaped cross-section having a recess-shaped outer core and a collar portion at one end of the core, a step of forming a terminal electrode on the outer core, and (1 ), The step of bending the both ends of the air core coil to form a terminal joint, and the air core coil as the outer core. The step of bonding the terminal bonding portion to the terminal electrode of the outer core while interiorly, the step of inserting the core portion of the core core into the air core coil, and the core core and the outer core are mutually connected. The object is achieved by providing a method for manufacturing a coil component, comprising the step of bonding and fixing.
[0014]
(3) In addition, a step of forming a core core having a T-shaped cross section having a concave-shaped outer core and a flange at one end of the core, a step of forming a terminal electrode on the outer core, and the above (1) ), A step of forming a coil in the core portion of the core core, a step of bending both ends of the coil to form a terminal joint portion, and a terminal of the coil A method of manufacturing a coil component, comprising: a step of bonding a joint portion to a terminal electrode of the outer core; and a step of bonding and fixing the core core on which the coil is formed and the outer core to each other. By providing the above, the above object is achieved.
[0015]
(4) Further, the object is achieved by providing a coil component manufactured by the method for manufacturing a coil component according to (2) or (3).
[0016]
DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of a coil and coil component manufacturing method according to the present invention will be described with reference to the drawings, taking an air-core coil and a chip-shaped inductor as typical examples.
[0017]
FIG. 1 and FIG. 2 are schematic views showing the state of winding start and winding end with respect to the winding axis of the winding machine used in the present invention. FIG. 3 and FIG. 4 are schematic views showing the winding start and winding end states of the T-shaped core core of the winding machine used in the present invention. FIG. 5 is a perspective view of an air-core coil by α winding of a rectangular wire manufactured by the manufacturing method of the present invention, and FIG. 6 is a perspective view of a completed air-core coil in which a terminal joint portion is formed.
[0018]
First, an example of a method of manufacturing a coil according to the present invention is as follows: (a) a rectangular wire having a rectangular cross section in which an insulating coating layer and a fusion material layer are sequentially laminated around a conducting wire; and (b) the rectangular wire. Are clamped while applying tension (pulling force) to the clamp portions provided on the two flyers of the winding machine, and (c) the center of the rectangular wire is obliquely applied to the winding axis. A step of forming a winding portion having two stages in the axial direction of the winding shaft by winding both ends of the rectangular wire in opposite directions while moving the clamp portion so as to approach the winding shaft (α winding step); And (d) having a step of energizing and heating both ends of a rectangular wire wound around the winding shaft through the clamp portion to self-fuse the winding portion.
[0019]
As for (a), the rectangular wire 5 of the self-bonding conductor described above in the conventional example is used. As for (b), the flat wire 5 serving as the winding is cut in advance to a predetermined length that is slightly longer than the length of the lead wire at the winding portion plus both ends, and both ends thereof are shown in FIG. 1 or FIG. As shown in the figure, it is clamped (fixed) to the clamp portions 13a and 13b at the tips of the clampers 12a and 12b of the two flyers 11a and 11b facing each other by an appropriate pressing mechanism (a mechanism such as clamping, gripping, and biting). The
[0020]
With regard to (c), the two flyers 11a and 11b are provided with a tension mechanism such as a spring (not shown) and have an arm shape or a wheel shape that rotates around the central axis of the winding shaft 1 or the T-shaped core core 28. The clamp portions 13a and 13b at the tips of the clampers 12a and 12b that hold both ends of the flat wire 5 are rotated while applying an appropriate tension to the flat wire 5 with rotation as shown in FIG. It moves so that it may approach the core of the shape core core 28, and alpha winding is carried out. The winding method in which the two flyers 11a and 11b are wound facing each other as described above is referred to as a double flyer method.
[0021]
As for (d) above, current is applied to both ends of the flat wire 5 wound around the winding shaft through the clamp portion during or after winding using the flyer 11a, 11b itself or at least the clamp portions 13a, 13b as a conductive metal material. Is flown and heated, and the fusion material layer 8 of the winding portion 3 is melted and self-fused. In this regard, it is preferable that the insulating coating layer 9 of the flat wire 5 of the clamp portions 13a and 13b is peeled off in advance to expose the conductive wire 10 before energization.
[0022]
After the step (d), if necessary, (e) a step of bending both ends of the coil to form a terminal joint is added. For example, in the air-core coil 20 of the α-wound rectangular wire 5 as shown in FIG. 5 manufactured through the steps (a) to (d), both ends 21a and 21b are bent. Thus, for example, as shown in FIG. 6, terminal joint portions 22a and 22b are formed. The terminal joint portions 22a and 22b may be appropriately subjected to a plating process such as solder plating, or the insulation coating layer 9 remains attached if thermocompression bonding is performed to a terminal as a component of a coil component as will be described later. But you can.
[0023]
In the above manufacturing method, when the air-core coil 20 is manufactured, the winding shaft 1 is a winding shaft of a winding machine, and a coil component is wound directly on a winding core such as a drum core or a T core. In the case of manufacturing, as in the case of the T-shaped core core 28 of the schematic diagram showing the winding start state of the winding machine of FIG. 3 and the schematic diagram showing the winding end state of the winding machine shown in FIG. The core of the T-shaped core core 28 becomes a winding shaft and is appropriately mounted and fixed to the winding machine.
[0024]
In the coil manufacturing method described in detail above, both ends of the rectangular wire 5 cut in advance to a predetermined length are clamped and simultaneously wound by the double flyer method, so that a guide such as a conventional pull-out bobbin or pulley is used. Is not required, and the preparatory work for the winding machine becomes very simple, and there is no fear of kinking of the flat wire 5, so that efficient coil production becomes possible. In addition, since both ends of the rectangular wire 5 are clamped and wound, it is possible to self-fuse relatively easily than hot air or solvent treatment by immediately energizing and heating during winding or immediately after winding. There is.
[0025]
Next, FIG. 7 shows a method for manufacturing a coil component including a coil wound directly on a core of a magnetic core such as the air core coil 20 or the T-shaped core 28 manufactured by the above-described coil manufacturing method. This will be described with reference to the exploded perspective view of FIG. 9 and the cross-sectional views of FIGS.
[0026]
First, a coil component 30 having an air-core coil 20 as a constituent element as shown in FIG. 7 has a collar portion at one end of an outer core 25 and a core portion 26 provided with a cylindrical coil storage portion 24 having a concave cross section. A step of forming a T-shaped core core 28 having a cross section including 27, a step of forming terminal electrodes 29a and 29b on the outer core 25, a step of manufacturing the air-core coil 20 by the above-described coil manufacturing method, The step of forming terminal joint portions 22a and 22b at both ends of the air core coil 20, and the terminal joint portions 22a and 22b are disposed in the outer core while the air core coil 20 is housed in the coil housing portion 24 of the outer core 25. Joining the 25 terminal electrodes 29a and 29b by thermocompression bonding, arc welding, soldering, etc., inserting the core portion 26 of the T-shaped core core 28 into the center hole of the air-core coil 20, and T-shaped core core A step of bonding and fixing 8 and the said outer core 25 by an adhesive such as epoxy adhesive, is manufactured by sequentially through the manufacturing process with. The cross section becomes a structure as shown in the cross section of FIG. 8, and a closed magnetic circuit structure is provided while providing a gap G for stabilizing characteristics (improves magnetic saturation and improves DC superimposition characteristics). Combined with the wound coil 20, an extremely high performance coil component 30 is completed. In this method of manufacturing the coil component 30, since the air-core coil 20 is manufactured separately from the core, there is an advantage that the assembling process, particularly the terminal joining process by thermocompression bonding, is simplified and high reliability is obtained.
[0027]
Next, the coil component 40 having the T-shaped core core 28 as a constituent element as shown in FIG. 9 does not use the air-core coil 20 unlike the coil component 30, but the T-shaped core core 28. A coil 35 including a winding portion 3 in which a flat wire 5 is directly wound with α is used as a constituent element. Hereinafter, the manufacturing method includes a step of forming a T-shaped core core 28 having a T-shaped cross-section having a recess-shaped outer core 25 and a flange portion at one end of the core portion, a terminal electrode 29a on the outer core 25, 29b, a step of forming a coil 35 in which the winding portion 3 is wound around the core portion 26 of the T-shaped core core 28 by the above-described coil manufacturing method, and both ends of the coil 35 Forming the terminal joint portions 22a and 22b, joining the terminal joint portions 22a and 22b of the coil 35 to the terminal electrodes 29a and 29b of the outer core 25, and forming the coil 35. The T-shaped core core 28 and the outer core 25 are bonded and fixed to each other. The cross section has a structure as shown in the cross sectional view of FIG. 10. The only difference from the coil component 30 is that the constituent coil 35 is a cored coil from the beginning. Is closely attached to the core portion 26 of the T-shaped core core 28, so that the number of turns can be increased as compared with the case of the air-core coil 20 in which a gap S must be provided in a certain dimension, and the magnetic characteristics are further improved. It becomes good. In other words, the coil component can be further downsized to obtain predetermined characteristics.
[0028]
The coil components 30 and 40 are inductors such as choke coils, and the magnetic core to be used is not particularly limited. However, the shape of the winding core is not limited to the T shape but may be an I shape, and the material is also particularly limited. However, nickel zinc ferrite and manganese-zinc ferrite are preferred. Further, if a rectangular wire 5 having a thickness of 0.05 to 0.1 mm and a width of about 1 mm is used, further miniaturization can be realized.
[0029]
【The invention's effect】
Since the coil manufacturing method and the coil component and the manufacturing method thereof according to the present invention are configured as described above,
(1) According to the coil manufacturing method of the first aspect, there is no fear of twisting of the rectangular wire, and an air-core coil or a cored coil by α winding can be manufactured very efficiently.
[0030]
(2) In the coil component manufacturing method according to the second aspect and the coil component manufactured thereby, in particular, the air-core coil is efficiently manufactured and the assembly process is simplified.
[0031]
(3) In the method of manufacturing a coil component according to claim 3 and the coil component manufactured thereby, the coil component in which the cored coil is manufactured efficiently and has excellent magnetic characteristics (DC superimposition characteristics). It becomes.
[Brief description of the drawings]
FIG. 1 is a schematic diagram showing a winding start state with respect to a winding axis of a winding machine used in the present invention.
FIG. 2 is a schematic view showing a winding end state with respect to a winding axis of a winding machine used in the present invention.
FIG. 3 is a schematic view showing a winding start state with respect to the T-shaped core core of the winding machine used in the present invention.
FIG. 4 is a schematic diagram showing a winding end state for a T-shaped core core of a winding machine used in the present invention.
FIG. 5 is a perspective view of an air-core coil by α winding of a rectangular wire manufactured by the manufacturing method of the present invention.
FIG. 6 is a perspective view of a completed air-core coil formed with a terminal joint according to the present invention.
FIG. 7 is an exploded perspective view of a coil component using an air-core coil according to the present invention.
FIG. 8 is a cross-sectional view of a coil component using an air-core coil according to the present invention.
FIG. 9 is an exploded perspective view of a coil component using a cored coil according to the present invention.
FIG. 10 is a cross-sectional view of a coil component using a cored coil according to the present invention.
FIG. 11 is a view showing the start of winding of α winding of a coil.
FIG. 12 is a diagram showing an intermediate state of α winding of the coil.
FIG. 13 is a diagram showing the end of winding of the α winding of the coil.
FIG. 14 is a cross-sectional view of a flat wire that is a self-bonding lead wire.
FIG. 15 is a diagram showing the shape of a flat wire that is a self-bonding lead wire.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Winding axis 2 Winding 3 Winding part 5 Flat wire 8 Fusion material layer 9 Insulation coating layer 10 Conductor 11a, 11b Flyer 12a, 12b Clamper 13a, 13b Clamp part 20 Air-core coil 22a, 22b Terminal junction part 25 Outer core 26 winding core part 27 collar part 28 T-shaped cores 29a and 29b terminal electrodes 30 and 40 coil parts 35 coils

Claims (4)

A rectangular wire having a rectangular cross section in which an insulating coating layer and a fusion material layer are sequentially laminated around the conducting wire is used as a winding material, and both ends of the flat wire are clamped to a clamp portion of a winding machine, and the center of the rectangular wire is Two ends of the rectangular wire are wound in opposite directions while the vicinity is obliquely applied to the winding shaft and the clamp portion is moved so as to approach the winding shaft, thereby forming two steps in the axial direction of the winding shaft. A coil manufacturing method comprising: a step of forming a winding portion; and a step of energizing and heating both ends of a rectangular wire wound around the winding shaft through the clamp portion to self-fuse the winding portion. Method. A step of forming a core core having a T-shaped cross-section having a concave-shaped outer core and a flange at one end of the core, a step of forming a terminal electrode on the outer core, and the coil according to claim 1. A step of manufacturing an air-core coil by a manufacturing method, a step of bending both ends of the air-core coil to form a terminal joint, and a terminal joint while the air-core coil is built in the exterior core Bonding to the terminal electrode of the outer core, inserting the core portion of the core core into the air core coil, and bonding and fixing the core core and the outer core to each other; The manufacturing method of the coil components characterized by having. A step of forming a core core having a T-shaped cross-section having a concave-shaped outer core and a flange at one end of the core, a step of forming a terminal electrode on the outer core, and the coil according to claim 1. A step of forming a coil in the core portion of the core core by a manufacturing method; a step of bending both ends of the coil to form a terminal joint portion; and a terminal joint portion of the coil as the outer core. A method of manufacturing a coil component, comprising: a step of bonding to the terminal electrode; and a step of bonding and fixing the core core on which the coil is formed and the exterior core to each other. A coil component manufactured by the method for manufacturing a coil component according to claim 2.

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