JP4420425B2 - Bobbin for coil and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a small coil bobbin used in an electronic apparatus such as a mobile phone and a radio timepiece, and a method for manufacturing the same.
[0002]
[Prior art]
In recent years, electronic devices have been pursued to be smaller and lighter with higher performance and more functions. Examples are mobile phones and radio clocks. The coil parts used in these electronic devices are also required to be miniaturized. As a general coil bobbin, a magnetic bobbin is manufactured by using a magnetic material as a core material and assembling an insert mold or a flange. In order to meet the market demand, manufacturing a small bobbin for a coil requires precise equipment, requires many man-hours for assembly, has a poor yield, and increases costs. Therefore, there is a need for a manufacturing method in which a large number of coil bobbins are produced and produced, thereby significantly reducing costs and improving productivity (for example, Patent Document 1).
[0003]
[Patent Document 1]
JP-A-7-288216 (pages 2 and 3, FIGS. 1 and 2)
[0004]
In the above-described prior art manufacturing method, a coil bobbin coupling body is formed by continuously forming a plurality of coil bobbins having a winding core portion around which a coil is wound and a flange comprising flanges provided at both ends thereof. By placing a core material made of resin or glass at the center of the cavity portion where the cavity portion is formed, and filling the cavity portion with a composite material mixed with heat-melted ferrite and resin through the injection portion, A coil bobbin coupling body in which a core material is insert-molded is molded, and a coil is wound around the winding core portion in the state of the coupling body, and then the flange portion is cut to manufacture a desired coil bobbin.
[0005]
[Problems to be solved by the invention]
However, the above-described method for manufacturing a coil bobbin has the following problems. That is, the length of the coil bobbin coupling body in which the core material is insert-molded is limited by the length of the core material to be supplied. Further, after the coil is wound around the coil bobbin, the coil terminal is tangled to the coil terminal connection terminal and soldered and connected. However, this connection work is difficult for a very small coil bobbin.
[0006]
The present invention has been made in view of the above-described conventional problems, and an object of the present invention is to provide a coil bobbin capable of mass-producing a small coil bobbin with high accuracy at low cost and a method for manufacturing the same.
[0009]
The coil bobbin manufacturing method according to the present invention is a coil bobbin manufacturing method having a coil winding core portion and flange-shaped flange portions provided at both ends thereof. and column plurality on for molding at the same time, sets a step of setting said coiled core to the mandrel having a cavity forming a hollow portion by the lower jig, the on jig the lower jig and, upper, pouring resin than one which is formed in resin injection port of the lower jig, the steps constituting the bobbin assembly for coil formed integrally with the flange portion on the coiled core portion, wherein after the injection resin is cured, a predetermined of said flange portion of the process and, the row and column in the array of the coil bobbin assembly to form a coil terminal connecting patterns on said flange portion of the coil bobbin assembly Forming the row direction cutting lines to divide in position, the bobbin for a given said coil by dicing in the column direction cutting line which divides I through between the coil winding core part in parallel perpendicular to the row direction cutting line And the step of performing .
[0010]
The coil bobbin manufacturing method according to the present invention is characterized in that the step of setting the coil core portion is a core supply step of setting a plurality of rows of cores made of rod-shaped magnetic bodies.
[0011]
The coil bobbin manufacturing method according to the present invention is characterized in that the step of setting the coil winding core is a lead frame supply step of setting a lead frame obtained by pressing a plate-like magnetic body. is there.
[0012]
In the method for manufacturing a coil bobbin according to the present invention , the step of forming the coil terminal connection pattern is a printing step, and the conductive bobbin assembly is attached to the flange portion after the coil bobbin assembly is mounted on a printing jig. The coil terminal connection pattern is formed by printing and curing .
[0013]
The coil bobbin manufacturing method according to the present invention forms the symmetrical flange portion by dicing the row direction cutting line so that a predetermined position of the flange portion is bilaterally symmetric in the dicing step. It is characterized by this.
[0014]
In the method for manufacturing a coil bobbin according to the present invention, in the dicing process, the row-direction cutting line is diced so that a predetermined position of the flange portion is left-right asymmetric, thereby forming the left-right asymmetric flange portion. It is characterized by this.
[0015]
In the coil bobbin manufacturing method according to the present invention, in the dicing step, a plurality of the coil bobbins connected and formed may be formed by changing a dicing position of the flange portion of the coil bobbin assembly. It is a feature.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a coil bobbin and a manufacturing method thereof according to the present invention will be described with reference to the drawings. 1 to 5 show a single coil bobbin according to the first embodiment of the present invention, and FIG. 1 is a perspective view of a coil bobbin having a symmetrical left and right flange portion. FIG. 2 is a plan view of the coil bobbin of FIG. FIG. 3 is a front view of the coil bobbin of FIG. FIG. 4 is a left-right asymmetric flange portion, and FIG. 5 is a plan view of two coil bobbins.
[0018]
1 to 3, reference numeral 1 denotes a coil bobbin. The coil bobbin 1 is configured by forming a coil core portion 2 with a core made of a magnetic wire such as ferrite or amorphous, and provided at both ends thereof. The bowl-shaped flange portion 3 is integrally molded with a thermoplastic or thermosetting resin such as an epoxy resin. Further, a conductive paste such as silver-based, for example, Ag-Pb is printed on the flange portion 3 by means such as screen printing to form the coil terminal connection pattern 4. The four coil terminal connection patterns 4 are formed at predetermined positions of the flange portions of the coil bobbin assemblies arranged in rows and columns when manufacturing the coil bobbins, which will be described later. This occurs when dicing, two of which are dummy patterns 4a. The two dummy patterns 4a are used for reinforcement when the coil bobbin 1 is mounted on the substrate on the back side.
[0019]
The aforementioned coil terminal connection pattern 4 may be formed by plating or the like instead of printing.
[0020]
A desired coil can be obtained by winding the coil around the coil core 2 of the coil bobbin 1 with a predetermined number of turns and then soldering the terminal with the coil terminal connection pattern 4.
[0021]
FIG. 4 shows the flange portion 3 cut so as to be asymmetrical when the flange portion of the coil bobbin assembly is diced at a predetermined position. The flange portion 3 is formed in a left-right asymmetric type because the direction is selected when the coil bobbin 1 is automatically supplied. Further, a double winding coil (not shown) is also required for direction selection. In the double-winding coil, one coil terminal is connected to the left dummy pattern 4a, and the other coil terminal is connected to the right coil terminal connection pattern 4. As described above, a coil that can be automatically supplied can be obtained by making the flange portion 3 asymmetrical.
[0022]
FIG. 5 shows that when the flange portion of the coil bobbin assembly is diced at a predetermined position, a desired number, for example, two series of coil bobbins 1a can be easily obtained by changing the dicing position. it can.
[0023]
Next, a method for manufacturing the above-described coil bobbin will be described. 9 and 10, first, in the core supplying step, a cavity is formed by the upper jig 6 and the lower jig 7 for simultaneously forming a plurality of rows and columns of the coil bobbins 1 at a predetermined interval. Using the forming jig 5 having the cavity portion, the coil winding core portion 2 is formed in the guide groove 7a formed at both ends of the lower jig 7 as shown in FIGS. 9 and 10A. A core (wire) 2a made of a rod-like magnetic material such as ferrite or amorphous is dropped and set at equal intervals.
[0024]
In the resin injection step, as shown in FIGS. 10B to 10D, the upper jig 6 is positioned and set on the lower jig 7, and one of the upper jig 6 and the lower jig 7 is set. For example, a thermoplastic or thermosetting resin such as an epoxy resin is poured from the resin injection port 6 a provided in the upper jig 6 as an injection resin 3 a, and the flange portion 3 is integrally formed on the coil core portion 2. To do. In the case of epoxy resin injection, it is necessary to wash the release agent in advance.
[0025]
In the printing process, after the injection resin is cured, the coil bobbin assembly 1A removed from the forming jig 5 is attached to the printing jig, and a silver-based, for example, Ag-- A conductive paste such as Pb is printed by means such as screen printing and cured to form the coil terminal connection pattern 4. Since printing is performed in an aggregate, a plurality of coil terminal connection patterns 4 can be simultaneously performed in one step. The coil terminal connection pattern 4 may be formed by plating or the like instead of printing.
[0026]
The dicing process includes a row (X) direction cutting line that is divided at a predetermined position of the flange portion 3 of the coil bobbin assembly 1A arranged in the row and column, and a direction orthogonal to the row (X) direction cutting line. A predetermined coil bobbin 1 (FIG. 1) can be formed by dicing along a row (Y) direction cutting line that is divided between the parallel cores.
[0027]
In the coil bobbin manufacturing method described above, as shown in FIG. 9, the coil bobbin assembly 1A is an assembly of 80 pieces (10 × 8). Mass production is possible.
[0028]
6 to 8 show a single coil bobbin according to the second embodiment of the present invention, and FIG. 6 is a perspective view of a coil bobbin having a symmetrical flange. FIG. 7 is a plan view of the coil bobbin of FIG. FIG. 8 is a front view of the coil bobbin of FIG.
[0029]
6 to 8, reference numeral 11 denotes a coil bobbin. The coil bobbin 11 has a coil core 12 formed of a core made of a magnetic plate material such as ferrite or amorphous, and the coil core 11 The insulating coating 14 and the flange-shaped flange portions 13 provided at both ends of the insulating coating 14 are integrally molded with a thermoplastic or thermo-thermosetting resin such as an epoxy resin. Further, similarly to the first embodiment, a silver-based conductive paste such as Ag-Pb is printed on the flange portion 13 by means of screen printing or the like, and the coil terminal connection pattern 4 is printed. Form. The four coil terminal connection patterns 4 are formed at predetermined positions of the flange portions of the coil bobbin assemblies arranged in rows and columns when manufacturing the coil bobbins, which will be described later. This occurs when dicing, and two of them are dummy patterns. The two dummy patterns 4a are for reinforcement when the coil bobbin 11 is mounted on the substrate on the back side. The above-described coil terminal connection pattern 4 may be formed by plating or the like instead of printing.
[0030]
A desired coil can be obtained by winding the coil around the coil core 12 of the coil bobbin 11 and then soldering the terminal with the coil terminal connection pattern 4.
[0031]
Although not shown in the drawings, as described in the first embodiment, when the flange portion of the coil bobbin assembly is diced at a predetermined position, the flange portion is cut so as to be asymmetrical, or The position of dicing may be changed so that a desired number of bobbins for coils, for example, can be easily obtained. Since the action and effect by this was demonstrated in 1st Embodiment, description is abbreviate | omitted.
[0032]
Next, a method for manufacturing the above-described coil bobbin will be described. 11 and 12, first, in the lead frame supplying step, a plate-like magnetic body such as ferrite or amorphous forming the coil winding core portion 12 is punched to form positioning holes 12 and slits 12a at predetermined intervals. A lead frame 12 </ b> A with the coil winding core 12 formed thereon is prepared. Using the forming jig 15 having a cavity portion formed by the upper jig 16 and the lower jig 17 for simultaneously forming a plurality of rows and columns of the coil bobbins at a predetermined interval, the lower jig is used. The positioning hole 12 of the lead frame 12A is set together with the positioning pin 18 implanted in the tool 17. As described above, a large number can be processed with high accuracy by pressing the plate-like magnetic body to form the lead frame 12A.
[0033]
In the resin injection step, the upper jig 16 is positioned and set on the lower jig 17, and one of the upper jig 16 and the lower jig 17, for example, a resin injection port provided in the lower jig 17. A thermoplastic or thermosetting resin such as an epoxy resin is poured from 17a, and the insulating coating 14 is integrally formed on the flange portion 13 and the coil core portion 12. In the case of epoxy resin injection, it is necessary to wash the release agent in advance. By integrally forming the insulating coating 14 on the coil winding core portion 12 with the same resin as the flange portion 13, it is possible to prevent coil disconnection / short circuit due to the edge of the core during coil winding.
[0034]
In the printing process, as in the first embodiment, after the injected resin is cured, the coil bobbin assembly removed from the forming jig 15 is attached to the printing jig, and a predetermined position of the flange portion 13 is set. Then, a conductive paste such as silver-based, for example, Ag-Pb, is printed by means such as screen printing and cured to form the coil terminal connection pattern 4. Since the coil bobbin is an assembly, the coil terminal connection pattern 4 can be printed in one step. The coil terminal connection pattern 4 may be formed by plating or the like instead of printing.
[0035]
In the dicing process, the row (X) direction cutting line that is divided at a predetermined position of the flange portion of the coil bobbin assembly arranged in the row and the column is parallel to the row (X) direction cutting line. A predetermined coil bobbin 11 can be formed by dicing along a row (Y) direction cutting line that divides between cores.
[0036]
In the above-described method for manufacturing a coil bobbin, as shown in FIGS. 11 and 12, the coil bobbin assembly is an assembly of 56 pieces (7 × 8), so that it is small, highly reliable, highly accurate and inexpensive. It is possible to mass-produce a simple coil bobbin.
[0037]
【The invention's effect】
As described above, according to the present invention, a coil bobbin having a pattern for connecting a coil end, a small-sized coil bobbin in an aggregate, accurately and mass-produced, and an inexpensive coil bobbin and a method for manufacturing the same are provided. It is possible to provide.
[Brief description of the drawings]
FIG. 1 is a perspective view of a single coil bobbin according to a first embodiment of the present invention, in which a flange is symmetrical to the coil bobbin.
2 is a plan view of the coil bobbin of FIG. 1. FIG.
FIG. 3 is a front view of the coil bobbin of FIG. 1;
4 is a plan view of a coil bobbin whose flange portion is asymmetrical in FIG. 1; FIG.
FIG. 5 is a plan view of two coil bobbins in FIG. 1;
FIG. 6 is a perspective view of a single coil bobbin according to a second embodiment of the present invention, the coil bobbin having a symmetrical left and right flange portion.
7 is a plan view of the coil bobbin of FIG. 6. FIG.
8 is a front view of the coil bobbin of FIG. 6. FIG.
FIG. 9 is a plan view of the coil bobbin assembly for explaining the method for manufacturing the coil bobbin according to the first embodiment of the present invention.
10 (a) is a cross-sectional view taken along line A in FIG. FIG. 10B is a sectional view taken along line B in FIG. FIG. 10C is a sectional view taken along line C in FIG. (D) is the DD sectional view taken on the line of FIG.
FIG. 11 is a plan view of a state in which a lead frame is set on a lower jig for explaining a manufacturing method according to a second embodiment of the present invention;
12 is a cross-sectional view taken along line EE after the upper jig is set in the lower jig of FIG. 12 and the resin is injected. FIG.
[Explanation of symbols]
1, 11 Coil bobbin 1a Double coil bobbin 1A Coil bobbin assembly 2, 12 Coil winding core 2a Core (wire)
3, 13 Flange part 4 Coil end connection pattern 4a Dummy pattern 5, 15 Molding jig 6, 16 Upper jig 6a, 17a Resin inlet 7, 17 Lower jig 7a Guide groove 8 Positioning pin 12A Lead frame 12a Slit 12b Positioning hole 14 Insulating film 18 Positioning pin X, Y Cutting line

Claims (7)

  In a method for manufacturing a coil bobbin having a coil winding core part and flange-shaped flange parts provided at both ends thereof, the coil bobbin is formed at a predetermined interval at the same time in a plurality of rows and columns at the same time. A step of setting the coil winding core portion in a forming jig having a cavity portion formed with a tool, and setting the upper jig on the lower jig, and forming the upper jig on one of the upper and lower jigs. A step of forming a coil bobbin assembly by pouring resin through the resin injection port and integrally forming the flange portion on the coil core; and after the injection resin is cured, the coil bobbin assembly Forming a coil terminal connection pattern on the flange portion, a row direction cutting line for dividing at a predetermined position of the flange portion of the coil bobbin assembly arranged in the row / column, and the row direction cutting On the line Forming a predetermined coil bobbin by dicing with a cutting line in the column direction that divides and passes between the coil core parts that are crossed in parallel with each other. . The method for manufacturing a bobbin for a coil according to claim 1 , wherein the step of setting the coil winding core portion is a core supply step of setting a plurality of rows of cores made of rod-shaped magnetic bodies. The method for manufacturing a bobbin for a coil according to claim 1 , wherein the step of setting the coil core portion is a lead frame supply step of setting a lead frame obtained by pressing a plate-like magnetic body. The step of forming the coil terminal connection pattern is a printing step, and after the coil bobbin assembly is mounted on a printing jig, a conductive paste is printed and cured on the flange portion to thereby form a coil terminal connection pattern. The manufacturing method of the bobbin for coils of any one of Claim 1 to 3 characterized by forming. In the dicing step, the row-direction cutting lines by dicing so as to be symmetrical to a predetermined position of the flange portion, claim 1, wherein 4 to form the flange portion of the symmetric The manufacturing method of the bobbin for coils of Claim 1. In the dicing step, the row-direction cutting lines by dicing so as to be asymmetrical to a predetermined position of the flange portion, any one of claims 1-4, characterized by forming the flange portion of the asymmetrical The manufacturing method of the bobbin for coils of Claim 1. In the dicing step, by changing the dicing position of the flange portion of the coil bobbin assemblies, any one of the preceding claims, characterized in that to form the coil bobbin in which a plurality of coupling form 4 The manufacturing method of the bobbin for coils as described in any one of.

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