JPH0230168B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing a flat frame-shaped coil suitable for use as an antenna coil, and more specifically, a method for manufacturing a frame-shaped flat air-core antenna coil. It is related to.

[Prior Art] Generally, a ferrite antenna in which a coil is wound around a ferrite bar is used as an antenna for small radios and the like.

This ferrite antenna has a polyurethane-coated conducting wire wrapped around a rod-shaped ferrite core, and receives radio waves tuned to it.This ferrite antenna has an extremely high antenna gain, but it is wrapped around a ferrite bar. Since the diametrical mounting size is determined by the winding diameter of the conductor wire installed, there is a limit to mounting it in a narrow space such as inside the bumper of an automobile.

In order to eliminate such defects, some covered conductors are wound around a winding core and then removed, and this is folded into a frame-shaped air-core coil, which is then coated with a synthetic resin material, etc. It has an outer diameter equal to the diameter of the main conductor wire and the thickness of the synthetic resin coating that coats its outer periphery to maintain its shape, and it has the disadvantage that it is not flexible and will not fit when curved. However, there is currently no known method for efficiently manufacturing a frame-shaped flat air-core coil having a thickness close to the diameter of a single wire that eliminates this drawback.

[Object of the Invention] The present invention eliminates the above-mentioned drawbacks and provides a flat frame-shaped coil whose thickness is equal to the diameter of the conductor and the thickness of the synthetic resin member forming a shape-retaining coat thereon.

[Summary of the Invention] In order to achieve the above-mentioned object, the manufacturing method of the present invention includes a first winding frame member having a protruding surface portion slightly higher than the conductor diameter that determines the inner dimensions of the frame-shaped coil on one surface. A second winding frame member is removably attached to the front protrusion side of the frame member, and the required number of insulated conductor wires coated with a self-bonding resin film are wound in the narrow groove formed between the two frame members. After obtaining a flat frame-shaped coil by doing so, heating the conductive wire or melting and solidifying the self-bonding resin coating with a solvent, and then removing the frame-shaped coil from the first and second frame members. In this way, a flat frame-shaped coil whose shape is maintained flat is obtained.

[Configuration of Embodiments of the Invention] As shown in FIG. 1a, the method for manufacturing a flat frame-shaped coil of the present invention first includes a protruding surface portion slightly higher than the diameter of the coil-forming conductor that determines the inner dimensions of the frame-shaped coil on one surface. 2, and mounting threaded rods 3a, 3c which have the same shape as the first wire winding frame material and are pre-attached to the frame material near both ends and at the center thereof. It is composed of through holes 6a to 6c through which threaded rods 3b integral with the support rod 4 are inserted, and a second winding frame member 5 provided with notches 7a to 7c for drawing out conductor ends on the side where the through holes 6a are opened. A winding frame 10 is prepared.

Next, as shown in FIG. 1b, the first winding frame material 1 is
The threaded rods 3a to 3c are inserted through the through holes 6a to 6c so that one surface of the second winding frame member 5 is in contact with the side surface of the protruding surface portion 2, and a thumbscrew 8a is attached to each of the threaded rods 3a to 3c. 8c is screwed, and a narrow groove 9 regulated by the height of the protruding surface portion 2 is formed between both winding frame members.

Next, one end side of the double-insulated conductor 11, which has been coated with a polyvinyl butyral-based soft self-adhesive resin film 11B in advance, is drawn into the narrow groove 9 through the notch 7a and placed in a predetermined position. For example, the number of turns is 5, and the other end is pulled out from the notch 7b to obtain the primary coil 12 (L ₁ ).
In order to prevent the coil from lifting up from the longitudinal straight part of the coil shape, the outer circumference of the pulley PU is made approximately equal to the straight part of the coil in advance during winding, as shown in Figure 2b. The conducting wire 11 is wound with a reverse warp applied thereto.

In addition, in the same figure, M1 is a winding machine frame, M2 is
2 shows a rotational drive source disposed on the frame M1, M3 a motor with a speed reducer, and M4 a ladder belt.

After that, one end of the same conducting wire 11 is drawn through the notch 7b into the narrow groove 9 around which the primary coil 12 is wound, and is wound a predetermined number of turns, for example, three times, and the other end is pulled out through the notch 7c, and the second end is pulled out through the notch 7c. As shown in Figure a, there is a secondary coil 13 (L ₂ ) outside the primary coil 12 (L ₁ ).
get.

Next, a power source (not shown) is connected to both ends of the primary coil 12, and a predetermined current, for example, about 18 A, is passed for a predetermined time, for example, about 4 minutes. , 13 and the winding frame 10 are heated to about 240° C., the self-bonding resin 11B between the conductive wires melts, and the conductive wires become ready for bonding via the insulating coating 11A.

After that, when the coils 12 and 13 are rapidly cooled, the resin solidifies, so as shown in FIG.
The winding frame material 5 is removed by removing thumbscrews 8a to 8c, and the primary and secondary coils 12 and 13, which have been flattened and solidified, are removed from the first winding frame material 1. From the state shown in Figures b and A, the conductors 11 and 11 of each of these coils 12 and 13 are firmly bonded by the self-adhesive resin coating 11B via the insulation coating 11A as shown in Figures 3B and 3B. Solidify, melt and solidify part 1
1C is formed, and a flat frame-shaped coil according to the present invention can be obtained.

Incidentally, during the heating, if a pressing jig is pressed against the outer surface of the conducting wire 11 from the narrow groove 9, the frame-shaped coil 15 can be obtained without deformation.

In addition, in the above embodiment, the self-adhesive resin coating 11
Although an example has been described in which the melt-solidified portion 11C is formed by heating the coating 11B, in this invention, even if the coating 11B is coated with a solvent such as alcohol during the winding process shown in FIG. A melt-solidified portion 11C is formed.

Next, as shown in FIG.
The terminals 121, 121, and 121 of each coil are treated by wrapping tapes 14a-14c around the terminals of
The insulation coating is removed by a certain length from the tips of 122, 131, and 132.

Flat frame-shaped coil 15 manufactured in this way
is attached to pre-prepared parts.

That is, as shown in FIG. 4, it is a synthetic resin plate that is slightly longer than the length of the coil 15, with both ends in the width direction bent toward one side, and the width between the two bent ends is slightly wider than the width of the coil 15. The coil mounting panel 16, which has folded pieces 17a and 17b formed by bending both ends of the member to one side, has terminal plate mounting holes 1 at both ends of a component mounting hole 18 provided on one folded piece 17a side.
9a, 19b and mounting bracket mounting holes 20a, 20b are opened, respectively.

As shown in FIG.
It is constructed of a so-called printed circuit board with a copper foil circuit 23 formed thereon.

The mounting bracket 24 is made by bending a plate-shaped metal piece into an L-shape, and has a pair of mounting holes 25a, 25b corresponding to the mounting holes 20a, 20b on one side, and a mounting hole 26 for another member on the other side. is dawning.

The lead drawer portion 27 has terminal board mounting holes 1 at both ends of a plate member 28 that is large enough to cover the terminal board 21.
A pair of mounting holes 29a, 2 corresponding to 9a, 19b
9b, a recess 30 is formed in the center of the recess 30 having a through hole large enough to accommodate the primary coil 12 and a capacitor 31 having a value that resonates with a specific frequency. In the figure, reference numeral 32 denotes a feeder cable connected to the secondary coil 13, one end of which is drawn through the through hole of the recess 30.

An antenna assembly using the flat frame-shaped coil of the present invention as an antenna coil is assembled from the above-mentioned parts as shown in FIGS. 6 to 8 a to 8 c.

That is, the coil 15 is attached to the coil mounting panel 16.
The terminal 121 of the coil is attached to the copper foil circuit 23 so as to be sandwiched between the folded pieces 17a and 17b of the coil.
122, 131, 132, the lead wire of the capacitor 31, and the core wire of the feeder wire 32 are soldered to the terminal plate 21 and the lead draw-out portion 27 are caulked together, and the pair of mounting brackets 24 are caulked. As shown in FIG. 7, adhesive tape 33 for holding down the coil is attached to both ends, and a frame-shaped flat air core antenna ANT is constructed as shown in the electrical circuit diagram shown in FIG. 9. In the embodiment, two antennas ANT ₁ and ANT ₂ are connected to the feeder line 3 as shown in FIG.
2 and in parallel through the coupler 34 the connector 35
is installed.

[Effects of the Invention] As described above, the present invention has a first winding frame member, which has a protruding surface portion slightly higher than the conductor diameter that determines the inner dimensions of the frame-shaped coil on one side, and a second winding wire on the protruding surface side of the first winding frame member. A flat frame-shaped coil is created by detachably attaching the frame material and wrapping the required number of insulated conductor wires 11 coated with a self-adhesive resin film 11B in the narrow groove 9 formed between the two frame materials. After obtaining No. 15, the self-adhesive resin coating 11B is melted and solidified by heating the conductive wire or using a solvent, and then the frame-shaped coil is removed from the first and second winding frame materials to make it flat. Since a shape-retained flat frame-shaped coil is obtained, the thickness of the air-core coil is approximately equal to the diameter of the conductor wire, and it is flat and highly flexible, so the restrictions on the place of use are significantly reduced, and it is easy to use. It has the advantage of being able to be mass-produced.

[Brief explanation of drawings]

The drawings all show an embodiment of the present invention; FIG. 1a is an exploded perspective view of the winding frame, FIG. 1b is a perspective view of the winding frame assembled so that it can be wound, and Figure a is a configuration diagram of the coil made with this winding frame, Figure 2 b is an explanatory diagram of the winding state in which reverse warpage is applied, and Figure 3
Figure a is a perspective view of a state in which the coil has been wound around the winding frame, Figure 3b is an enlarged sectional view of an insulated conductor coated with a self-bonding resin film, Figure 4 is a perspective view of the antenna assembly, Fig. 5 is a plan view of the terminal board, Fig. 6 is a perspective view of the antenna, Fig. 7 is a plan view of an embodiment of the antenna, and Fig. 8a is A-A in Fig. 7.
The cross-sectional view at the disconnection, Figure 8b, is taken along the line BB in Figure 7.
A cross-sectional view at the disconnection, Figure 8c is taken along C-C in Figure 7.
FIG. 9, which is a cross-sectional view at the time of disconnection, is an electrical circuit diagram of the antenna. DESCRIPTION OF SYMBOLS 1...First winding frame material, 2...Protrusion part, 5...
Second winding frame material, 9...Narrow groove, 11...Insulated conductor wire coated with self-adhesive film, 11
A... Insulating coating, 11B... Self-adhesive resin coating, 11C... Melting and solidifying portion, 15... Flat frame coil.

Claims (1)

[Claims] 1. A second winding frame material is removably attached to the protruding surface side of the first winding frame material, which has a protruding surface part slightly higher than the conductor diameter that determines the inner dimensions of the frame-shaped coil formed on one surface, and both frames A flat frame-shaped coil is obtained by wrapping the necessary number of turns of an insulated conductor coated with a self-adhesive resin film in the narrow groove formed between the materials, and then the conductor is heated or heated with a solvent. By melting and solidifying the fusible resin coating and then removing the frame coil from the first and second winding frame materials, a flat frame coil that is kept flat is obtained. A method for manufacturing a flat frame coil.