JP3996986B2 - Circuit board forming method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates and switching power supplies used for rice cookers, air conditioners, etc., an inverter circuit, the circuit board forming how with electrical circuitry including a coil which is used for audio circuits or the like.
[0002]
[Prior art]
Conventionally, when manufacturing a circuit board equipped with an electric circuit including a coil, a separately manufactured coil is mounted on the surface of the board on which the wiring pattern is formed with a conductor on the back surface, and both ends of the coil conductor are connected. The circuit board is configured by fixing the coil and electrical conduction by inserting it into a pair of mounting through holes provided on the board and joining the wiring pattern and the mounting terminal on the back of the board with solder. Moreover, the coil was formed by winding a thin conducting wire spirally around the annular iron core along its circumference.
[0003]
11 and 12 show a circuit board provided with a smoothing circuit as an example of a circuit board provided with an electric circuit including a conventional coil. 11 and 12, reference numeral 21 denotes a circuit board on which one coil 22 and two capacitors 23 are mounted. The coil 22 is formed by winding a conductive wire 25 around an annular iron core 24 in a spiral shape, and both ends of the conductive wire 25 penetrate the substrate 21 and are joined to a conductor pattern 26 on the back surface by solder 27.
[0004]
Similarly, the lead 28 of the capacitor 23 penetrates the substrate 21 and is joined to the conductor pattern 26 on the back surface by the solder 27.
[0005]
[Problems to be solved by the invention]
However, in the manufacturing process of the coil 22, the process of winding the conductive wire 25 around the annular core 24 serving as a core in a spiral manner is performed using a winding machine, and depending on the case, it depends on manual work. Time is required, and as the number of windings of the conducting wire 25 wound around the annular core 24 increases, the processing time is required, and the productivity is low.
[0006]
The low productivity affects the cost, and the coil processing cost is higher than other electronic components. Therefore, in the case of a circuit board using a coil, there is a problem that the component cost is higher than that of a circuit board not using a coil, and it is difficult to reduce the cost of the circuit board itself.
[0007]
In addition, when manual work is involved in the manufacturing process, there is a risk that a required characteristic value may not be realized or a quality problem such as a distortion of the shape may occur.
[0008]
The present invention is the light of the conventional problems, and its object is to provide a circuit board formed how a circuit board having an electrical circuit can be manufactured with stable quality at a low cost including a coil.
[0009]
[Means for Solving the Problems]
The present invention relates to a circuit board forming method for forming an electric circuit including a coil on a board composed of a conductor and a resin covering the conductor, and forming a comb-shaped part having a plurality of branches extending from a trunk part on the conductor. The iron core is placed on the branch almost parallel to the trunk, the branch is molded so as to wind the iron core, the tip is joined to the root of the adjacent branch, and then the trunk is cut off to place the coil on the substrate. The winding process of the conductor in the manufacture of the coil can be replaced by a process of punching, forming and joining the conductor, which can greatly reduce the time and reduce the cost. It can be automated to stabilize the quality.
[0010]
In addition, by using an integral iron core, it is possible to stabilize the electrical characteristics and quality of the coil.
[0011]
Further, when joining the tips and roots of the branch portions at the same time as other mounted components, one step of coil manufacturing can be reduced, and further cost reduction can be achieved.
[0012]
In addition, a pair of rectangular portions are formed in parallel on the conductor, and the rectangular portions are alternately cut from both sides, and the pieces formed by the cutting are alternately moved up and down to create a space between the upper and lower pieces. If the coil is formed on the substrate by inserting and inserting the iron core into the space from the direction perpendicular to the notch, it is necessary to join using a plurality of iron cores. The reliability can be improved.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the circuit board forming method of the present invention is applied to the manufacture of a circuit board formed by forming a smooth circuit composed of one coil and two capacitors on a board formed so that both surfaces of a conductor are covered with a resin. A form is demonstrated with reference to FIGS.
[0015]
First, in the manufacturing process of the substrate 1, as shown in FIGS. 1 and 4, the substrate 1 is formed by covering both surfaces of the conductor 2 with the resin 3. The range is formed in a state where the resin 3 is not formed. Next, as shown in FIG. 1, the conductor 2 exposed on the surface side at the coil mounting location is made of a plurality of branch portions 5 that become a conductor portion into which the iron core 10 is wound from the trunk portion 6 with a punch or a mold. Punching is performed on the extended pair of comb-shaped portions 4 and 4. These comb-shaped portions 4 are formed so as to be slightly inclined so that the branch portions 5 of the other comb-shaped portion 4 enter between the branch portions 5 and 5 of one comb-shaped portion 4. Further, the tip 5a of the branch part 5 is processed to be thin, and an insertion hole 7 is formed in the root part 5b of the branch part 5 so that the tip 5a can be inserted in a later step.
[0016]
Next, as shown in FIG. 2, the iron core 10 is placed in parallel between the trunk portions 6 and 6 of the two comb-shaped portions 4 and 4, and the branch portion 5 is processed so as to wrap the iron core 10 in a spiral shape. To do.
[0017]
At that time, each branch part 5 is formed so as to wind the iron core 10, and the tip 5 a is inserted into the insertion hole 7 of the root part 5 b of another adjacent branch part 5.
[0018]
Thereafter, as shown in FIGS. 3 and 4, unnecessary portions of the trunk portion 6 in the comb-shaped portions 4 and 4 are punched out with a punch or a die, and the coil winding 9 formed by the branch portion 5 spirals the iron core 10. The coil 11 is finished in a state of being wound in a shape.
[0019]
Next, as shown in FIGS. 5 and 6, the two capacitors 12 are mounted by inserting the leads 13 into the capacitor insertion holes 8 formed at predetermined positions on the substrate 1. However, the mounting procedure of other components such as the coil 11 and the capacitor 12 is not particularly limited. Finally, the tip 5a and the root 5b of the branch part 5 are joined together and the lead 13 of the capacitor 12 and the conductor 2 are joined by the solder 14 at the same time. Thus, a circuit board formed by forming a smoothing circuit including one coil 11 and two capacitors 12 is manufactured.
[0020]
Next, another embodiment of the circuit board forming method of the present invention will be described with reference to FIGS. In addition, about the component same as the said embodiment, the same reference number is attached | subjected and description is abbreviate | omitted and only a different point is demonstrated.
[0021]
In this embodiment, as shown in FIG. 7, a pair of rectangular portions 15 are formed in parallel on the conductor 2 at the coil mounting location, and cuts 16 are alternately formed in these rectangular portions 15 from both sides thereof. Next, as shown in FIGS. 8 and 10, the conductors 2 have spaces 18 corresponding to the cross-sectional shape of the iron core 10 by bending the pieces 17 formed by the cuts 16 and alternately moving them up and down. Mold in a spiral. Although this step is separated from the previous step for the sake of explanation, the process of cutting the conductor 16 and the step of bending and forming it into a spiral shape can be performed simultaneously with a mold or the like. Finally, as shown in FIG. 9 and FIG. 10, the core 10a divided into a pair or more in the space 18 is inserted into the space 18 from the direction perpendicular to the notch 16, and the core 10 is joined by soldering or welding. Constitute. The coil 11 is formed on the substrate 1 by the above process.
[0022]
【The invention's effect】
According to the circuit board forming method of the present invention, as is apparent from the above description, a comb-shaped portion in which a plurality of branches are extended from the trunk is formed on the conductor, and the iron core is substantially parallel to the trunk on the branch. The coil is formed on the substrate by forming the branch part so as to wind the iron core, joining the tip to the root part of the adjacent branch part, and then cutting off the trunk part. The conductor winding process can be replaced by conductor punching, forming, and joining processes, which can significantly reduce time, reduce costs, and automate to stabilize quality. .
[0023]
In addition, by using an integral iron core, it is possible to stabilize the electrical characteristics and quality of the coil.
[0024]
Further, when joining the tips and roots of the branch portions at the same time as other mounted components, one step of coil manufacturing can be reduced, and further cost reduction can be achieved.
[0025]
Also, a pair of rectangular portions are formed in parallel on the conductor, and the rectangular portions are alternately cut from both sides, and the pieces formed by the cutting are alternately moved up and down to create a space between the upper and lower pieces. When the coil is formed on the substrate by forming and inserting the iron core into the space from the direction perpendicular to the notch, it is possible to reduce the number of conductor joints and improve the reliability.
[Brief description of the drawings]
FIG. 1 is a plan view showing a state in which a comb shape is formed on a conductor of a substrate in an embodiment of a circuit board forming method of the present invention.
FIG. 2 is a plan view showing a state in which an iron core is arranged on a substrate and is processed so as to be wrapped with a conductor in the same embodiment;
FIG. 3 is a plan view showing a state where unnecessary conductors are cut and removed in the embodiment;
4 is a cross-sectional view taken along the line AA in FIG. 3;
FIG. 5 is a plan view showing a state in which a smoothing circuit is formed in the embodiment.
6 is a cross-sectional view taken along line BB in FIG.
FIG. 7 is a plan view showing a state in which a conductor of a board is punched into a predetermined shape in another embodiment of the circuit board forming method of the present invention.
FIG. 8 is a plan view showing a state where a conductor is formed into a predetermined shape in the embodiment;
FIG. 9 is a plan view showing a state where a coil is formed by inserting and joining an iron core in the same embodiment;
10 is a cross-sectional view taken along the line CC in FIG. 9;
FIG. 11 is a plan view of a circuit board having a smoothing circuit in a conventional example.
12 is a cross-sectional view taken along the line DD of FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Board | substrate 2 Conductor 3 Resin 4 Comb shape part 5 Branch part 5a Tip 5b Root part 6 Trunk part 10 Iron core 11 Coil 15 Rectangular part 16 Notch 17 Piece 18 Space

Claims (4)

  In a circuit board forming method for forming an electric circuit including a coil on a board constituted by a conductor and a resin covering the conductor, a comb-shaped part in which a plurality of branches are extended from a trunk part is formed on the conductor, and the iron core is branched. The coil is placed on the board by placing the branch part almost parallel to the trunk part, forming the branch part so as to wind the iron core, joining the tip to the root part of the adjacent branch part, and then cutting off the trunk part. A circuit board forming method.   2. The circuit board forming method according to claim 1, wherein the iron core is integral.   2. The circuit board forming method according to claim 1, wherein when the tip and the root of the branch part are joined, joining is performed simultaneously with other mounted parts.   In a substrate forming method for forming an electric circuit including a coil on a substrate constituted by a conductor and a resin covering the conductor, a pair of rectangular portions are formed in parallel on the conductor, and the rectangular portions are alternately cut from both sides. The coil is formed on the substrate by alternately moving up and down the pieces formed by cutting and forming a space between the upper and lower pieces and inserting an iron core into the space from a direction perpendicular to the cutting. A circuit board forming method.

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