JPH01208821A - Coil parts and manufacture thereof - Google Patents

Abstract

PURPOSE:To mechanize winding work and wiring work without scaling up the internal dimensions of a closed magnetic circuit core, and to improve productivity by winding a coil bobbin and soldering a lead winding section and a pin terminal. CONSTITUTION:Coil bobbins 2 and 4, which are molded with a resin and both ends of which have collars, are butted, thus constituting one coil bobbin. Gears 3, 5 are formed simultaneously to one parts of the bobbins 2, 4, and pins 6 and 9, lower end sections of which are formed to a U shape, are implanted to notch sections 15 in one parts of the collars on the outsides of the bobbins 2, 4. When these parts are manufactured, the pins 6, 9 are implanted to the bobbins 2, 4 fitted so as not to be brought into contact with a magnetic core 1, winding-start leads 10 are wound directly, and a driving gear 14 is engaged with the gears 3, 5 for the bobbins 2, 4 and winding is conducted. Winding-end leads are also wound directly on the pins 6, 9, pin terminals 12 are inserted into terminal holes 7, 8, and soldering is performed at the same time as the pins 6, 9 on which leads are wound.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to a coil component used in various electronic devices and a method for manufacturing the same.

BACKGROUND OF THE INVENTION Conventionally, this type of coil component has been constructed as shown in FIGS. 19, 20, and 21. In Fig. 19, 20 is a mouth-shaped closed magnetic circuit core made of ferrite, 21 and 22
It has flanges at both ends and the middle formed by injection molding of polypropylene, and has a molded structure that is divided into two parts,
23 is a terminal plate made of injection molded phenol resin, 24 is a pin terminal implanted in the terminal plate 23, and 26 is a gear simultaneously molded on the outer surface of the flanges at one end of the molded bobbins 21 and 22. Further, in FIG. 20, 26 is a coil, and 27 is a wire fixing adhesive using polyamide. Furthermore, in FIG. 21, 28 and 29 are lead grooves provided in the collars of the forming bobbins 21 and 22, 30 and 31 are winding start leads, 25 is a gear, and 32 is a driving gear. A method of manufacturing a conventional coil component configured as described above involves forming lead grooves 28.
When the bobbin is rotated, the tip of the lead is pulled out to 29 and the magnetic core is 2o.
The driving gear 32 is stored in the gear 26 so as not to come in contact with the gear 26.
are engaged to rotate the forming bobbins 21 and 22 and start winding. After the winding is completed, the wire is fixed with a wire stopper 27 shown in FIG. 20 to prevent the wire from loosening. After that, the winding start lead 30° 31 is raised from the lead groove 28.29, the terminal plate 23 and the molded bobbin 21.22 are fitted and fixed, and both the winding start lead and the winding end lead are wrapped around the pin terminal 24 by soldering. It was manufactured by

Problems to be Solved by the Invention In such a conventional configuration, lead grooves 28 and 29 are necessary to support the winding start leads 30 and 31, but they are completely unnecessary after manufacture. In addition, the gear 25 is also completely unnecessary after manufacturing, which affects the space constraints and shape dimensions of the coil section, and increases the magnetic path length of the closed magnetic circuit magnetic core 2o, reduces the cross-sectional area, and reduces the restriction on the number of turns per turn. These results were unfavorable in terms of performance, such as a decrease in current resistance or an increase in DC resistance. Furthermore, the inside of the closed magnetic circuit magnetic core 20 is molded into a bobbin 21.2.
In order to wind the wire by rotating the bobbin 2, the pin terminal 24 is attached to the bobbin 2.
If 1.22 is directly set, the shape and magnetic path length of the closed magnetic circuit magnetic core 20 will increase due to the length, and it will be difficult to directly plant the pin terminals 24. Therefore, the terminal plate 23 will be molded and prepared separately. It is necessary to install the pin terminals 24 in advance, which increases the number of parts and costs. In this case, as a solution, there is a method of increasing the internal dimensions of the closed magnetic circuit magnetic core 20 to the extent that the pin terminal 24 can rotate, but the protrusion dimension of the pin terminal 24 from the molded bobbin 21, 22 is required to be 3 to smm. Therefore, the coil parts with a height of about 1QIT1m are originally 15~
It is 17mm, which is not practical. Furthermore, the forming bobbin 21.
22 and the terminal plate 23 is that the winding start leads 30, 31 are first supported in the lead grooves 28, 29, and after the winding is finished, they are raised from the lead grooves 28, 29 and the terminal plate 23 is After fitting into the molded bobbin 21.22, pin terminal 2
You need to wrap it around 4. Similarly, the lead at the end of the winding cannot be wrapped directly around the pin terminal 24, so it must be fixed with the wire fixing adhesive 27, and the terminal board 24 must be fixed.
After fitting into the bobbin 21, 22, it is necessary to wind it around the pin terminal 24. In this manufacturing method, the winding work of the winding start lead and the winding end lead and the wiring work of bottle winding are separated, so it is difficult to mechanize and the work is done manually, making it unsuitable for mass production. However, there were many problems such as an increase in incidental work and high costs.

The present invention solves these problems by making it possible to mechanize the winding and wiring work without increasing the internal dimensions of the closed magnetic circuit core, thereby improving productivity at low cost. The purpose of the present invention is to provide a coil component that can be used as a coil component and a method for manufacturing the same.

Means for Solving the Problems In order to solve this problem, the present invention has a magnetic core K constituted by a closed magnetic circuit, two divided coil bobbins having flanges at both ends, which are fitted into the magnetic core, and the flanges of the coil bobbins are fitted into the magnetic core. A lead winding part is provided inside, a coil winding start lead is directly wound around the lead winding part provided inside the collar, and a gear rotated by a drive source is engaged with a gear part provided in advance on a part of the coil bobbin. The coil bobbin is rotated to wind the wire, and the final winding series lead of this winding is wound directly onto the lead winding section.Then, the pin terminal is inserted into the hole provided in the lead winding section, and the lead wire is wound. The lead winding part and the pin terminal are soldered together.

Function As mentioned above, two ・-z
The coil bobbin e1 is put together, a lead winding part is provided inside the coil bobbin, and the winding start and end winding leads are directly wound on this lead winding part, and then the pin terminal is inserted into the bobbin. And it can facilitate mechanization of wiring work.

Example Embodiments of the present invention will be described below with reference to the accompanying drawings.

1 and 2 are according to the first embodiment of the present invention,
FIG. 1 is an exploded perspective view of the coil component, and FIG. 2 is an enlarged perspective view of the portion where the pin 6 and pin terminal hole 7.8 are located. FIG. 3 is a perspective view of the completed coil component, in which 1 is a magnetic core formed from ferrite into a mouth shape, 2 and 4 are two-part coil bobbins molded from resin with flanges at both ends; By butting the two together, one coil bobbin is constructed. 3 and 5 are coil bobbins 2.4
It is a gear that is simultaneously molded into a part of the . 6 and 9 are pins whose lower ends are shaped like an opening, and are implanted in a notch 16 in a part of the outer collar of the coil bobbin 2.4. 11.11'
12 is a pin terminal 13, 13' is a coil, and 14 is a drive gear for rotating a gear 3.5 formed integrally with the coil bobbin 2.4. .

In the method for manufacturing the coil component according to the present invention configured as described above, the pin 6.9 is implanted in the coil bobbin 2.4 fitted so as not to contact the magnetic core 1, and the winding start lead 10 is directly wound. As shown in FIG. 6, the drive gear 14 is engaged with the gears 3.6 of the bobbins 2 and 4, and the bobbins 2.4 are rotated to perform winding. After the winding is completed, the winding end lead is also wound directly around the remaining pin 6.9, and the pin terminal 12 is inserted into the terminal hole 7.8 provided in front of the pin 6.9 as shown in Figs. 3 and 4. Insert the pin 6.9 so that the pin terminal 12 is located at the mouth-shaped portion of the pin 6.9, and solder the pin 6.9 at the same time as the pin 6.9 around which the lead wire is wound. Here, in the embodiment shown in FIG. 1, the case where the gear 3.5 is provided in the center buckle has been explained, but the case where the gear is provided in both or one side of the flanges at both ends is also similar. Wrapping can be performed. In the above embodiment, the shape of the magnetic core 1 in the shape of an opening is fixed vertically, but it goes without saying that it is also possible to fix the magnetic core 1 in the shape of an opening horizontally as shown in FIG. . Furthermore, as shown in FIG. 7, a bobbin 2.4 can be combined with the central magnetic path portion of the head-shaped magnetic core 1 to wind one winding.

Next, a second embodiment shown in FIGS. 8 to 11 will be described. The difference from the first embodiment is that instead of the pin 6.9 with a mouth-shaped portion at the bottom, a truncated conical ring 6M made of metal has a terminal hole 7.8 formed in the center! L, 9& is planted in the notch 15 of the collar of the bobbin 2.4, and this ring 6a
, 9 & are wound with the winding start lead IQ and winding end lead of the winding wire. After winding, press fit the pin terminal 12 into the terminal hole 8 and solder it to the lead 7 pin terminal 12 at both ends of the coil 130. It electrically connects the

Next, a third embodiment will be described using FIGS. 12 to 16. In the embodiment shown here, a stepped notch 15ia is provided in the collar of the bobbin 2.4, and the terminals 6b and 9b bent into an NCL shape are insert-molded so that both ends protrude from different parts. , the winding start lead 1 of the coil 13
0 to terminal 6b.

Wind it around one protrusion of bobbin 2, 4' kta.
After rotating and winding using 3.5, terminal 6b
, a terminal hole 7 provided in a position close to the other protrusion of 9b.
．． 8, press-fit the pin terminal 12 into the lead wrapping part, and terminal 6.
A completed product is obtained by connecting the contact portions between b, 9b and the pin terminal 12 with solder.

Further, a fourth embodiment will be described using FIGS. 16 to 18. The embodiment shown here is based on the notch 1 of the bobbin 2°4.
After installing the bobbin 2.4 into the magnetic core 1, a protrusion 60.90 is provided in which the terminal hole 7.8 is provided at the center of the magnetic core 5 and an opening 16 communicating with the terminal hole 8 is formed in the middle part in the height direction. The winding start lead 1o is wound around the opening 16 of the protruding parts 6C and 90, and the bobbin 2.4 is rotated using the gear 3.5 to perform winding to form the coil 13. Wrap the final lead around the protruding portions 60, 9c, and insert the pin terminal 12 from above into the terminal hole 7.8 provided in the collar of the bobbin 2.4 in Fig. 18 axc.
Press fit as shown in FIG. 2, and solder the contact portion between the lead and the pin terminal 12 through the opening 16 to complete the finished product.

Although the first to fourth embodiments have been described above, the bobbin 2.
Pin 6.9 for winding the lead around the notch 16 formed in a part of the collar of No.4. Ring la, 94, terminal sb, g
b or a protrusion 60.90 is provided, and after winding the coil 13 in a position close to the winding part of this lead, the pin terminal 12
In this method, the leads and pin terminals 12 are soldered directly or indirectly by press-fitting them.

In either of these embodiments, the part around which the lead is wound can be made large enough so that it does not interfere with rotating the bobbin 2°4 around the magnetic core 1 when winding the coil 13, and the part where the lead is wound can be made large enough so that it does not interfere with rotating the bobbin 2°4 around the magnetic core 1 when winding the coil 13. By press-fitting the terminals 12, productivity is improved.

Effects of the Invention As described above, according to the present invention, the space for the lead groove can be eliminated, and by providing the gear in the center or at the flange, the magnetic path length can be shortened with the cross-sectional area of the conventional magnetic core. The number of parts can be removed without deteriorating the performance of inductance, DC resistance, etc., and the winding work and wiring work are not separated.
Mechanization becomes possible and contributes to improving quality of life.
Excellent effects such as significant cost reduction can be achieved.

[Brief explanation of the drawing]

FIG. 1 is an exploded perspective view of a coil component according to an embodiment of the present invention, FIG. 2 is an enlarged perspective view of the lead winding section, and FIG. 3 is a perspective view of a completed coil component according to an embodiment of the present invention. , Figure 4 is an enlarged perspective view of the part where the lead is wound after the pin terminal is inserted.
FIG. 5 is a side view of a coil component in the middle of the winding process according to an embodiment of the present invention, FIGS. 6 and 7 are perspective views of a coil before winding according to Ike's embodiment, and FIG. An exploded perspective view of the embodiment, FIG. 9 is a perspective view of the lead winding part, and FIG. 10 is the same coil. Fig. 11 is a perspective view of the finished part, Fig. 12 is an exploded perspective view of the third embodiment, Fig. 13 is a perspective view before winding, Fig. 14a , b is a front view showing the process of winding and connecting the leads, FIG. 15 is a perspective view of the finished product,
Fig. 16 is an exploded perspective view of the fourth embodiment, Fig. 17 is a perspective view before winding, Fig. 18 a-c is an explanatory diagram showing the winding and wiring process, and Fig. 19 is a conventional coil component. Exploded perspective view of 2nd
FIG. 0 is a perspective view of a conventional coil component completed by assembling FIG. 19, and FIG. 21 is a side view of the conventional coil component in the middle of the winding process. 1... magnetic core, 2.4......, 3.
5... Gear, 6,611,6kk, 6Q, 9,
9tL, 9b, 90...pin, ring, terminal,
Projection, end, 8...Terminal hole, 10...
The lead wire is wound at the part, 11.11'... winding part,
12...pin terminal, 13...coil,
14... Drive gear, 15... Notch,
16...Opening. Name of agent: Patent attorney Toshio Nakao and 1 other person No. 1
Figure 2 Figure 3 Figure 4 Figure 5 Figure 3.5 Figure 6 Figure 8 Figure 10 Figure 19'a Figure 12 Figure 14 Figure ρ Figure 16 Figure 17 Figure In18 Figure 19 Figure 20 Figure 21 Q

Claims (6)

[Claims] (1) A gear part is provided on a coil bobbin which is divided into two with a flange on both ends of a magnetic core composed of a closed magnetic circuit, and a coil is wound around the coil bobbin using the gear part, and one part of the flange of the coil bobbin is provided. A notch is provided in the part, a winding part is provided in the notch for winding the leads at the beginning and end of the coil, a pin terminal is attached near this winding part, and the pin terminal and the winding part are soldered. Coil parts connected by. (2) A coil bobbin with flanges at both ends is divided into two parts in a magnetic core composed of a closed magnetic circuit, and the divided parts are used to fit into the magnetic core and formed as part of the collar of this coil bobbin. A winding part for winding the coil lead is provided in the notch, and a hole for inserting a pin terminal is provided near the winding part, and the coil winding start lead is wound around the lead winding part, and then the winding part is inserted into the gear part previously provided on a part of the coil bobbin. A coil is constructed by meshing gears rotated by a drive source, rotating a coil bobbin, and winding the wire.The final lead is wound around the other lead winding part, and the pin terminal is inserted into the pin terminal insertion hole. A method for manufacturing coil parts in which the winding part around which the rear lead is wound and the pin terminal are soldered. (3) The method for manufacturing a coil component according to claim 2, wherein the winding portion around which the lead is wound is a pin having a U-shaped portion at the bottom. (4) The method for manufacturing a coil component according to claim 2, wherein the winding portion around which the lead is wound is a truncated conical ring with a terminal hole formed in the center. (5) The winding part for winding the lead is an L with both ends protruding at different positions in the stepped notch provided in the collar of the coil bobbin.
3. The method of manufacturing a coil component according to claim 2, wherein the terminal is shaped like a letter, a lead is wound around one end of the terminal, and a pin terminal is soldered to the other end of the terminal. (6) The method of manufacturing a coil component according to claim 2, wherein the winding portion around which the lead is wound is a protruding portion formed integrally with the bobbin, having an opening in the middle portion, and a terminal hole in the center.