JPH04343406A - Coil and its manufacture - Google Patents

Abstract

PURPOSE:To make it possible to use thick winding material to easily attain a large current application to a coil, simplify the production process and reduce the production cost. CONSTITUTION:A core main body 2 is composed by integrally forming a winding part 5 on which winding material 1 is wound and flange parts 6a and 6b which control the winding of the winding material 1 in the shaft direction. The one flange 6a of the core main body 2 is provided with a hole 7 and a winding guide groove 8, and a cap 9 which has restriction 10 whose top plane is recessed and the bottom plane is protruded is installed on the flange 6a of the core main body 2 by burying the restriction 10 in a hole 7. Then, a winding material edge 1a leading through the winding guide groove 8 is bent so as to touch the cap 9 and a terminal lead 3 is buried in the recessed part of the restriction 10 of the cap 9 in order to connect the winding material 1 with the terminal lead 3 electrically.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention relates to CTV displays,
The present invention relates to power supply smoothing choke coils for VTRs, OA equipment, etc., or coils used in general noise filters, and a manufacturing method thereof.

0002

2. Description of the Related Art As shown in FIG. 3, a conventional coil includes a winding part 22 around which a winding material 21 is wound, and a disc-shaped flange part that restricts the winding of the winding material 21 in the axial direction. The winding material 21 is led out through a winding guide groove 25 formed on the outer peripheral surface of the flange portion 23, and the end portion 21a of the winding material 21 is formed integrally with the winding material 23.
The winding material 21 and the terminal lead 26 are electrically connected by being wrapped around the terminal lead 26 planted in the flange portion 23 .

0003

However, in the conventional coil shown in FIG. 3, the electrical connection between the winding material 21 and the terminal lead 26 is established by wrapping the winding material end 21a around the terminal lead 26. Since this is done, there is an inconvenience that the wire diameter of the winding material 21 that can be used is limited. That is, when winding the winding material end 21a around the terminal lead 26, it is necessary to wind the winding material end 21a around the terminal lead 26 a plurality of times in order to ensure a reliable conductive connection. However, this winding operation generates stress on the terminal lead 26, leading to a decrease in mechanical strength, and
This results in deformation of the terminal lead 26.

Furthermore, since the winding material 21 is wound multiple times around the terminal lead 26, the apparent diameter of the terminal lead 26 increases, and the terminal can be inserted into the terminal lead insertion hole drilled in another printed wiring board or the like. When inserting the lead 26, the winding material 2
There is a problem in that the terminal lead 26 cannot be inserted all the way to the base of the terminal lead 26 because the tangled portion of the terminal lead 26 becomes an obstacle. This leads to larger electronic devices and the like. For this reason, the wire diameter of the winding material 21 that can be used is limited to approximately 2/3 of the diameter of the terminal lead 26.

[0005] Incidentally, with the recent increase in the screen size of CTV displays, etc., there is a trend toward higher power power supplies for equipment, and there is an increasing demand for higher current capacity for coils. However, in the case of the above-mentioned conventional coil, since the wire diameter of the winding material 21 cannot be increased, there is a natural limit to the above-mentioned increase in current capacity.

Conventionally, therefore, a recess for inserting the terminal lead 26 is provided in the flange portion 23 of the core body 24, and a metal film layer is further coated between the winding guide groove 25 and the recess by vacuum deposition, baking, or the like. A coil has been proposed in which the end portion 21a of the winding material and the terminal lead 26 are electrically connected through the metal film layer without using the above-mentioned tangles. (Refer to Publication No.-35719).

However, in the case of this coil, processing such as vacuum deposition and baking is required, which complicates the manufacturing process, and the end portion 21a of the winding material tends to make insufficient contact with the metal film layer. There is a problem in that even if a soldering process is performed in a post-process, the above-mentioned poor contact cannot be improved. This becomes noticeable when a winding material having a relatively small wire diameter is used.

The present invention has been made in view of the above-mentioned problems, and its purpose is to provide a coil that enables the use of thick winding material and achieves a large current capacity of the coil. It's about doing.

The present invention also provides a method for manufacturing a coil that can be easily assembled without causing poor contact between the winding material and the terminal lead, simplifying the manufacturing process, and reducing manufacturing costs. It is about providing.

0010

[Means for Solving the Problems] The coil A of the present invention has a winding portion 5 around which the winding material 1 is wound and a flange portion 6 that restricts the winding of the winding material 1 in the axial direction. A hole 7 and a winding guide groove 8 are formed in the flange portion 6 of the core body 2, and a cap 9 is provided with a constriction 10 having a concave portion on the upper surface and a raised portion on the lower surface. By embedding it in the flange part 6 of the core body 2,
Furthermore, the winding material end portion 1a led out through the winding guide groove 8
is bent and brought into contact with the cap 9, and the terminal lead 3 is embedded in the concave portion of the constricted portion 10 of the cap 9, thereby electrically connecting the winding material 1 and the terminal lead 3.

Further, in the method of manufacturing the coil A of the present invention, the winding section 5 around which the winding material 1 is wound and the flange section 6 that restricts the winding of the winding material 1 in the axial direction are integrally formed. Adhesives 15 and 12 are dripped onto the hole 7 formed in the flange portion 6 of the core body 2 and a part of the surface of the flange portion 6, and then the hole 7 is filled with a concave portion on the upper surface and a concave portion on the lower surface. After embedding the aperture portion 10 of the conductive cap 9 having the aperture 10 formed as a raised portion, the adhesive 15 and 12
Heat cure.

Thereafter, after winding the winding material 1 around the winding portion 5, the end portion 1a of the winding material 1 is led out through the winding guide groove 8 formed on the outer peripheral surface of the flange portion 6, and then,
The end portion 1a of the winding material is bent and brought into contact with the adhesive 12 on the surface of the cap 9 and the flange portion to temporarily fix the end portion 1a of the winding material to the cap 9. After that, the aperture part 1 of the cap 9
After embedding the terminal lead 3 in the recess 0, the terminal lead 3 and the winding material end 1a are fixed to the cap 9 by soldering.

[0013]

[Operation] According to the above-described coil A of the present invention, since the electrical connection between the winding material 1 and the terminal lead 3 is made through the cap 9, there is no need to tie the winding material 1 to the terminal lead 3, and the terminal Inconveniences such as stress on the leads 3 and an increase in the apparent diameter of the terminal leads 3 are eliminated. This means that
This leads to an increase in the diameter of the winding material 1 wound around the winding portion 5 of the core body 2, and a large current capacity of the coil A can be achieved.

Furthermore, according to the manufacturing method of the present invention, the end portion 1a of the winding material can be temporarily fixed via the adhesive 12 dropped onto a part of the surface of the flange portion 6.
a can be brought into contact with the cap 9 easily and reliably, a contact failure of the winding material 1 can be prevented in advance, and the reliability of the coil A can be improved.

Furthermore, since the adhesive 12 is thermally cured in advance, dirt, dust, etc. do not adhere to the adhesive 12. Therefore, the end portion 1a of the winding material can be reliably temporarily fixed, and subsequent attachment and soldering of the terminal leads 3 can be easily performed. Also,
Since the cap 9 is simply attached to the hole 7 formed in the flange portion 6, there is no need to perform vacuum deposition, baking, etc. as in the conventional case, and the manufacturing process can be simplified and the manufacturing cost can be reduced.

[0016]

Embodiments Hereinafter, embodiments of the present invention will be described with reference to FIGS. 1 and 2. FIG. 1A shows a coil A according to this embodiment.
FIG. 1B is a side view partially cut away, and FIG. 1B is a bottom view thereof (excluding a resin layer and a solder layer).

This coil A has a winding material 1 as shown in the figure.
It consists of a core body 2 around which the core body 2 is wound, two terminal leads 3, and a case 4 that protects the core body 2.

The core body 2 includes a winding section 5 in which the winding material 1 is wound in multiple layers (the illustrated example shows a single layer winding), and a winding section 5 on both sides of the winding section 5 in the axial direction of the winding material 1. A disk-shaped flange portion 6 (6a and 6b) that restricts the winding is integrally formed of, for example, a ferrite material. One flange part 6a has two holes 7 having a diameter larger than the diameter of the terminal lead 3, which are provided symmetrically corresponding to the installation position of the terminal lead. Winding guide grooves 8 from which the end portions 1a of the windings are led out are provided at point-symmetrical positions.

Further, a conductive cap 9 is attached to the surface of the one flange portion 6a through the hole 7. This cap 9 is formed by drawing a plate-shaped conductive material, for example, to form a diaphragm 10 with a concave portion on the top surface and a raised portion on the bottom surface. It is attached to the flange portion 6a of the core body 2 and is fixed via an adhesive 15. In this case, if a taper 11 is provided at the upper peripheral edge of the hole 7, the constricted portion 10 of the cap 9 can be easily inserted into the hole 7, leading to more efficient assembly work.

The winding material 1 is wound in the axial direction along the winding portion 5 of the core body 2, and its end portion 1a extends outward through a winding guide groove 8 formed in one flange portion 6a. derived. The lead-out winding material end 1a is inserted into the winding guide groove 8.
It is bent at the top and brought into contact with the cap 9. At this time, the end portion 1a of the winding material is attached to the cap 9 by the adhesive 12 dripped on a part of the surface of the one flange portion 6a.
is fixed to the flange portion 6a by pressing.

The terminal lead 3 is inserted into a constricted portion (recess) 10 of the cap 9 attached to the flange portion 6a. In this case, the tip of the terminal lead 3 with respect to the axial direction,
If the acute-angled cut 3a is made, for example, the bent end portion 1a of the winding material will become a constricted portion (recess) of the cap.
Even if the terminal lead 3 partially hangs over the cap 9, the terminal lead 3 can be easily inserted into the constricted portion (recess) 10 of the cap 9, leading to more efficient assembly work. In this way, the terminal lead 3 and the winding material 1 are electrically connected via the cap 9.

After that, the terminal lead 3 is soldered.
A solder layer 13 is formed over the end portion 1a of the winding material, and a resin case 4 is attached so as to enclose the entire core body 2 around which the winding material 1 is wound. That is, the resin layer 14 is embedded so as to cover the bottom surface of the core body 2, thereby constructing the coil A according to the present example.

Next, a method for manufacturing the coil A according to this example will be explained with reference to the process block diagram of FIG. 2.

First, adhesives 15 and 12 are dropped onto the hole 7 formed in the flange portion 6a of the core body 2 and on a portion of the surface of the flange portion 6a.

Next, after inserting the constricted portion 10 of the cap 9 into the hole 7 of the flange portion 6a, the adhesive 15 is thermally cured. At this time, the cap 9 is fixed to the flange portion 6a via the adhesive 15. In addition, since the adhesive 12 dropped on a part of the surface of the flange portion 6a is also thermally cured, the adhesive 12 does not adhere to or flow out in excess during subsequent processing, and the adhesive 12 is free from dust and dirt. There is no possibility of dust etc. adhering to it.

Next, after winding the winding material 1 around the winding portion 5 of the core body 2, the end portion 1a of the winding material 1 is led out through the winding guide groove 8 formed on the outer peripheral surface of the flange portion 6a. Then, the end portion 1a of the winding material 1 is bent to form a flange portion 6a.
Contact adhesive 12 and cap 9 on the surface. Thereafter, heat is locally applied to the tip 1a of the winding material 1 that is in contact with the adhesive 12 to soften the underlying adhesive 12. At this point, the winding material end 1a is temporarily fixed with the adhesive 12.

Next, after the terminal lead 3 is inserted into the concave portion of the constricted portion 10 of the cap 9, the terminal lead 3 and the end portion 1a of the winding material are fixed to the cap 9 by soldering. At this point, the terminal lead 3 and the winding material 1 are electrically connected.

Next, after covering the core body 2 with the case 4, a resin layer 14 is embedded and injected into the soldered portion to obtain the coil A according to this example.

As mentioned above, according to the coil A of this example,
Since the electrical connection between the winding material 1 and the terminal lead 3 can be made via the cap 9, there is no need to tie the winding material 1 to the terminal lead 3, which reduces the stress on the terminal lead 3 that conventionally occurs. The inconvenience of an increase in the apparent diameter of the terminal lead 3 is eliminated. This means that the core body 2
This leads to an increase in the diameter of the winding material 1 wound around the winding portion 5, and a large current capacity of the coil A can be achieved.

Furthermore, according to the manufacturing method of the present invention, the end portion 1a of the winding material can be temporarily fixed via the adhesive 12 dropped on a part of the surface of the flange portion 6a. It can be brought into contact with the cap 9 easily and reliably. From this, it is possible to prevent poor contact of the winding material 1 in advance, and to improve the reliability of the coil A. In addition to the thick winding material 1 described above, it is also possible to use the conventional thin winding material. It can also be used.

Furthermore, since the adhesive 12 is thermally cured in advance, the adhesive 12 does not adhere to unnecessary parts or run out, and dirt, dust, etc. do not adhere to the adhesive 12. Therefore, the winding material end portion 1a can be reliably temporarily fixed, and the subsequent attachment and soldering of the terminal leads 3 can be easily performed. Further, since the cap 9 is simply attached to the hole 7 formed in the flange portion 6a, there is no need to perform vacuum deposition, baking, etc. as in the conventional method, and the manufacturing process can be simplified and the manufacturing cost can be reduced. .

[0032]

According to the coil according to the present invention, it is possible to use a thick winding material, and it is possible to easily achieve a large current capacity of the coil. Further, according to the manufacturing method of the present invention, it is possible to easily assemble the wire without causing poor contact between the winding material and the terminal lead, and it is possible to simplify the manufacturing process and reduce the manufacturing cost.

[Brief explanation of drawings]

FIG. 1A is a partially cutaway side view of a coil according to the present embodiment. B is a bottom view (excluding the solder layer and resin layer).

FIG. 2 is a process block diagram showing a method for manufacturing a coil according to this embodiment.

FIG. 3A is a side view showing a coil according to a conventional example. B is its bottom view.

[Explanation of symbols]

A Coil 1 Winding material 2 Core body 3 Terminal lead 4 Case 5 Winding part 6a, 6b flange part 7 holes 8 Winding guide groove 9 Cap 10 Aperture part 12,15 Adhesive

Claims (2)

[Claims] Claim 1: A hole and a winding are provided in the flange portion of a core body, which is formed integrally with a winding portion around which a winding material is wound and a flange portion that restricts winding of the winding material in the axial direction. A conductive cap having a diaphragm formed with a guide groove, a concave portion on an upper surface, and a raised portion on a lower surface is attached to the flange portion of the core body by embedding the diaphragm portion in the hole, and the conductive cap is attached to the flange portion of the core body. An end portion of the winding material led out through the guide groove is bent and brought into contact with the cap, and a terminal lead is embedded in a concave portion of the constricted portion of the cap, and the winding material and the terminal lead are electrically connected. A coil characterized by: 2. A hole formed in the flange portion of a core body in which a winding portion around which the winding material is wound and a flange portion that restricts winding of the winding material in the axial direction are integrally formed. and a part of the surface of the flange portion, and embedding the aperture portion of the conductive cap having a constriction having a concave portion on the upper surface and a raised portion on the lower surface in the hole, and then embedding the aperture portion in the hole. curing the adhesive, and after winding the winding material around the winding portion, leading out the end of the winding material through a winding guide groove formed on the outer peripheral surface of the flange portion;
After that, the end of the winding material is temporarily fixed by bending the end of the winding material, passing it near the cap or bringing it into contact with the cap, and further contacting the adhesive on the surface of the flange part; A method for manufacturing a coil, comprising the steps of embedding a terminal lead in a concave portion of the constricted portion of the cap, and then fixing the terminal lead and the end of the winding material to the cap by soldering.