JPH0521322B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to coil parts used in motors, relays, transformers, solenoids, and others.

(Prior Art) Coil parts are used in motors, relays, transformers, solenoids, and other devices and parts that apply electromagnetic force.

In coil parts, processing of the ends of wire rods for energizing the coil portion is a problem. Conventional coil components include a direct lead wire method, a terminal method, etc., depending on the method of processing the ends of the wire.

7 and 8 show an example of the direct lead wire method, in which a lead wire 3 is soldered to the end of the wire of a coil portion 2 formed by winding a wire around a bobbin 1. It is designed to be electrically connected to a predetermined location via 3. An insulating tube 4 is placed over the soldering portion, and an insulating tape is wrapped around the outer periphery of the coil portion 2 to prevent the soldering portion from moving unintentionally.

9 and 10 show an example of the terminal method, in which a terminal 6 is projected and fixed on the outer periphery of the bobbin 5, and a coil portion 7 is formed by winding the wire around the bobbin 5. The end portion is soldered to the terminal 6, and an external lead wire is connected to this terminal 6.

(Problems to be Solved by the Invention) According to the above direct lead wire method, it is necessary to manually process the end of the coil after winding. This causes quality problems such as shortages, and also increases costs.

Furthermore, if you try to connect the lead wire to the outside via a terminal part, the terminal part must be retrofitted to the tip of the lead wire, which increases the manufacturing process, and retrofitting the terminal part itself is extremely troublesome. .
Further, according to the above-mentioned terminal method, quality problems are reduced, but since it is necessary to drive the terminal into the bobbin, there are problems in that the cost is high and it cannot be made compact.

The present invention has been made to solve these conventional problems, and in addition to solving quality problems such as incorrect wiring, poor insulation, and insufficient strength, the present invention has a simple configuration, low cost, and It is an object of the present invention to provide a coil component which can be made compact and which can provide a terminal part in a coil extension part through a simple manufacturing process.

(Means for Solving the Problems) The present invention includes a coil portion formed by winding a wire, a coil extension portion formed by folding the wire forming the coil portion to an arbitrary length and combining them into one. and a terminal part connected to the extension part, and one side of the extension part is fixed to the coil part side.

(Function) The coil extension can be used as a lead wire to the outside, and the coil can be energized through the terminal connected to the coil extension.

(Example A) Hereinafter, an example of a coil component according to the present invention will be described with reference to the drawings.

In FIGS. 1 and 2, a coil portion 12 is formed by winding a wire around a bobbin indicated by the reference numeral 11. The bobbin 11 has flanges at both ends, and a pair of protrusions 13 are integrally molded on the outer side of one flange, and three temporary fixing parts 14 are provided on the outer circumference of the one flange. 15 and 16 are integrally molded in a protruding manner at regular intervals. The base portions of each of the temporary fixing portions 14, 15, and 16 are narrow portions. In addition, a stepped portion 17 is formed at the portion where the temporary fixing portions 14, 15, and 16 of the one flange are formed, so that the thickness thereof is reduced.

As shown in FIG. 3, the ends of the wire rod 10 constituting the coil section 12 are folded back to an arbitrary length and an arbitrary number of times, and are then twisted together to form a single wire to extend the coil. Part 18, 20
is formed. The coil portion 12 has an intermediate tap, and the wire material constituting the coil portion 12 is folded back and forth an arbitrary number of times at an arbitrary length.
The coil extension portion 19 is formed by twisting each other into one coil.

The proximal ends of these coil extensions 18, 19, 20 are respectively wound around the narrow parts of the temporary fixing parts 14, 15, 16 of the temporary fixing 11 of the bobbin 11. , 20 are connected to the three terminals 21, 22, 23 of the connector 25.
and are respectively wound around and soldered to three connecting portions 26, 27, and 28 that are electrically integrally formed. Each of these terminals 21, 22,
23 and each connection part 26, 27, 28 and connector 25
The terminal portion is constituted by these. The coil extensions 18, 19, 20 are arranged substantially parallel to each other, and the sheet materials 31, 3 are arranged from above and below.
It is sandwiched between 2. For example, a thick heat-sensitive adhesive tape can be used as the sheet materials 31 and 32, and by doing so, the sheet materials 31 and 32
are glued together to form each coil extension part 18, 19, 2.
0 and each coil extension part 18, 19,
It is designed to prevent 20 delusional movements. The sheet materials 31 and 32 have a length sufficient to span the bobbin 11 and the connector 25, and a small hole at one end of the sheet material 31 is fitted into the protrusion 13 of the bobbin 11, thereby reinforcing the sheet material 31 and further reinforcing the sheet material 31. Each coil extension 18, 19, 20 is reinforced. The ends of each of the sheet materials 31 and 32 on the bobbin 11 side are adhered to the bobbin 11 with adhesives 33 and 34 such as hot melt, and the ends of each of the sheet materials 31 and 32 on the connector 25 side are also adhered with adhesive 3 such as hot melt.
5 and 36, it is bonded to the connector 25.

Next, an example of the method for manufacturing the coil component according to the above embodiment will be explained.

First, as shown in FIG. 4, a first wire rod 10A and a second wire rod 10B are prepared, and each wire rod 1
The end portions of 0A and 10B are folded back and forth an arbitrary number of times to an arbitrary length, and the folded portions are twisted together an appropriate number of times using a winding machine to form an extension to the coil portion. Next, each wire 10A, 10
Wrap the extension portions of B around the connecting portions 26 and 27 of the connector 25, respectively. Next, the length setting rod 38 is lowered as shown in FIG.
Push down the extension part of B with the length setting rod 38 to bypass the extension part, and connect the connector 25 and bobbin 11.
Set the length of the extension between the two to a predetermined length.
The length of the extension between the connector 25 and the bobbin 11 is determined by the equipment in which the coil component is used, and is set to a predetermined length by the descending distance of the length setting rod 38.

Next, by moving the nozzle of the winding machine, the other end of each of the extension parts is fixed to the temporary fixing part 14 of the bobbin 11,
15, and then rotate the bobbin 11 to wrap the wire rods 10A and 10A around the bobbin 11.
10B is wound by the desired number of turns to form a coil portion. Next, the wire rods 10A and 10B connected to the other end of the coil portion are folded back and forth an arbitrary number of times to an arbitrary length, and the folded portions are twisted together to form a coil extension. Next, by moving the noise of the winding machine, each of the wire rods 10
The coil extension parts of A and 10B are attached to the bobbin 11 respectively.
Wrap it around the narrow part of the temporary fixing parts 15 and 16. Next, the length setting rod 38 is lowered again to set the length of each coil extension to a predetermined length, and then the other end of the coil extension of each wire 10A, 10B is connected to the connector 25. Wrap it around portions 27 and 28, respectively.

The bobbin 11 and the connector 25 are sequentially transferred in the direction shown by the arrow in FIG.
A and 10B have coil extensions formed in the same manner as described above, and the connectors 2 that are sent next.
wrapped around the connection parts 26 and 27 of 5, respectively,
Thereafter, winding is continuously performed on the next bobbin 11 through the same steps as those described above.

Wire rods 10A, 10 spanning between each connector 25
B is cut between each connector 25, and then the ends of each wire 10A, 10B wound around each connection part 26, 27, 28 of connector 25 are soldered to each connection part 26, 27, 28. be done.

Each wire rod 10A, 10B is coated with urethane or the like. Therefore, if the coating of the coil extension part formed by folding back each of the wire rods 10A and 10B is peeled off in advance and then folded back and twisted to form the coil extension part, a part of the folded part in the coil extension part will not be disconnected. It is possible to ensure conduction even when the battery is connected, improving safety.

After the winding is completed, the bobbin 11 and the tanector 25 that pairs with the bobbin 11 are arranged on a wide sheet material 32, as shown in FIG. A sheet material is placed thereon and integrated with the sheet material 32 by adhesion or the like. Each bobbin 11 and each connector 25 and the sheet material are integrated using an adhesive such as hot melt as described above. Further, the bobbin 11 and the sheet material are mechanically connected by fitting the protrusions and holes as described above. In this way, the sheet material reinforcing the gap between the bobbin 11 and the connector 25 is cut between the bobbin 11 and the connector 25 that form a pair.

Note that the sheet material does not necessarily have to be wide; an elongated tape-like sheet material having sufficient width and length to straddle the coil extension between the pair of bobbins 11 and the connector 25 may be used. Also, if the required strength is maintained, the use of sheet material may be omitted by reinforcing the coil extensions by gluing them together. In this case, the coating of the wire at the coil extension portion is left unpeeled.

In the embodiment described above, a recess is formed in place of the protrusion 13 formed on the bobbin 11, and the sheet material is mechanically coupled to the bobbin 11 by fitting the protrusion formed on the sheet material side into the recess. You may also do so.

Next, another embodiment of the coil component according to the present invention shown in FIG. 6 will be described. In FIG. 6, the coil portion 41 is a ring material 4 that replaces the bobbin.
The coil part 41 is formed by winding a wire around the outer periphery of the
Adhesive portions 43 made of hot melt or the like are formed at several appropriate locations on the outer periphery. Coil extensions 46, 47, and 48 extend from the coil portion 41 and form both ends and intermediate taps of the coil. Each of the coil extension parts 46, 47, and 48 is formed by reciprocating the wire material constituting the coil part 41 a predetermined length a predetermined number of times, folding it back, and twisting the wire rods together into one wire. . The base of each coil extension part 46, 47, 48 is attached to the outer periphery of the coil part 41 with adhesive parts 51, 52 using hot melt or the like.
Further, each coil extension part 46, 47, 48 is reinforced by adhering reinforcing tape 50 across the base of each coil extension part 46, 47, 48 and the coil part 41. ing.

Each coil extension 46, 47, 48 is connected to a respective connection part of the terminal section in the same manner as in the previous embodiment.

According to the above embodiment, the coil extensions 46, 4
7 and 48 are folded back and forth a predetermined number of times and twisted together.
In addition, the coil portion 41 and the coil extension portions 46, 4
Since important points 7 and 48 are fixed with adhesive, sufficient strength can be obtained without using a bobbin, and the structure can be simplified.

Coil parts according to the present invention include motors, relays,
It can be applied as coil parts for transformers, solenoids, etc.

The strength of the coil extension is increased by folding back the wire and putting it together into a single piece, so if a predetermined strength can be obtained by itself, it is not necessarily necessary to further reinforce the coil extension with a sheet material. Furthermore, if necessary, only important points such as the connection between the coil part and the coil extension part may be adhered with a sheet material, or the entire body including the coil part, coil extension part, and even the connector may be glued with a sheet material. You may also do so. The sheet material may be adhesive tape, cloth, insulating film, or any other material that maintains its strength.

In each of the illustrated embodiments, the intermediate tap protrudes from the coil portion, but the intermediate tap may be omitted.

(Effects of the Invention) According to the present invention, the wires constituting the coil portion are folded back at an arbitrary length and combined into one, thereby forming a coil extension, so that the coil extension itself can be used as a lead wire. This eliminates the need for lead wire assembly work such as peeling the lead wire, crimping the crimp terminal, and press-fitting the terminal into the housing, which shortens the work process.
It has the advantage of lower production costs and no need for lead wires. Further, since a lead wire is not required, there is no need to connect the wire material constituting the coil portion with the lead wire, and incorrect wiring, poor insulation, and poor conduction can be prevented. There is no need for taping or inserting an insulating tube.

Furthermore, since one side of the coil extension is fixed to the coil portion side, the strength of the coil extension can be increased.

Furthermore, since the coil part, coil extension part, and terminal part are integrally formed, there is no need to retrofit the terminal part to the tip of the coil extension part, and the number of manufacturing steps can be reduced. itself can be simplified.

[Brief explanation of drawings]

FIG. 1 is a plan view showing one embodiment of the coil component according to the present invention, FIG. 2 is a partially sectional front view of the same, and FIG.
The figure is a plan view showing the folded state of the wire at the coil extension part of the above embodiment, FIG. 4 is a perspective view showing an example of a method for manufacturing a coil component according to the above embodiment, and FIG. 5 is a coil according to the above embodiment. FIG. 6 is a plan view showing an example of a method for processing a coil extension of a component; FIG. 6 is a plan view showing another embodiment of a coil component according to the present invention; FIG. 7 is a partially sectional plane showing an example of a conventional coil component. 8 is a side view of the same, FIG. 9 is a plan view showing another example of the conventional coil component, and FIG. 10 is a side view of the same. 10, 10A, 10B... Wire rod, 12... Coil part, 18, 19, 20... Coil extension part, 41
...Coil part, 46, 47, 48...Coil extension part.

Claims (1)

[Claims] 1. It has a coil part made by winding a wire, a coil extension part made by folding the wire making up this coil part to an arbitrary length and collecting it into one, and a terminal part connected to this extension part. , a coil component in which one side of the extension part is fixed to the coil part side.