JPH05243055A - Coil device and fabrication thereof - Google Patents

Abstract

PURPOSE:To reduce the number of components and simplify assembling work by arranging a starting end part and a termination end part of each of a primary winding and a secondary winding in a plurality of recessed portions formed in one of flanges of a bobbin, and constructing a terminal of the bobbin with conductor parts of the starting end part and of the termination end part. CONSTITUTION:A plurality of grooves 11 are provided in one flange 3a of a bobbin 3. In these grooves 11 there are inserted terminals 1a, 1'a, 2a of primary windings 1, 1' and a secondary winding. The terminals 1a, 1'a exfoliate an insulating coating 5 to form terminals 1b of the bobbin 3. Hereby, a terminal conductor used conventionally as a lead terminal is omitted to reduce the number of components, and hence the number of assembling processes are also reduced. Further, since a plurality of windings of the primary winding and/or the secondary winding are formed with only one coating conductor wire, winding work is simplified.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil device such as a transformer and a reactor and a method for manufacturing the same.

[0002]

2. Description of the Related Art A bobbin for a coil device having a cavity for inserting a core and a pair of flanges, and a primary winding and a secondary winding having an insulating coating wound between a pair of flanges of the bobbin. Coil devices are well known. For example, Japanese Utility Model Laid-Open No. 3-25219 discloses a transformer in which a primary winding and a secondary winding are wound in layers. This transformer has a structure in which a linear conductor is covered with an insulating coating material to form a primary winding or a secondary winding, and the primary winding or secondary winding is wound around a core. As shown in FIG. 17, each of the primary windings 1, 1 ′ and the secondary winding 2 used in this transformer is formed by applying a triple insulating layer 5 around the outside of a linear conductor 4 and is triple insulated. The layer 5 has a first layer 5a adhered to the linear conductor 4, a second layer 5b coated on the first layer 5a, and a third layer 5c coated on the second layer 5b. .. The primary windings 1, 1'and the secondary windings 2 formed in this way are distributed over the entire space between the pair of flanges 3a, 3b of the bobbin 3 as shown in FIG.
The secondary winding 1, the secondary winding 2, and the primary winding 1'are wound in this order and attached to the core 6. As shown in FIGS. 18 and 19, the primary windings 1 and 1'and the secondary winding 2 of this transformer are
Each of the terminals 1a, 1'a, 2a is wound around a plurality of terminals 7 provided on the flange 3a of the bobbin 3 and fixed by soldering or the like.

[0003]

By the way, in the conventional coil device, since the primary windings 1, 1'and the secondary windings 2 are made of different coated conductors, they are individually wound on the bobbin 3. It had to be turned, and the winding work was complicated. Also, the terminals 1 of the primary windings 1 and 1'and the secondary winding 2
Since a, 1'a, and 2a are respectively wound around the terminals 7 of the bobbin 3 and fixed by soldering or the like, the number of parts is increased, the number of assembling steps is increased, and the soldering points are easily broken. There was a drawback. These drawbacks are not preferable from the viewpoint of cost reduction.

Therefore, an object of the present invention is to provide a coil device which can reduce the number of parts and simplify the assembling work, and a manufacturing method thereof.

[0005]

A bobbin having a cavity into which a core is inserted and a pair of flanges, and a primary winding and 2 having an insulating coating wound between the pair of flanges of the bobbin.
A coil device according to the invention with a secondary winding has a starting end and an ending end of each of the primary winding and the secondary winding arranged in a plurality of recesses formed in one of the flanges of the bobbin and the starting end. The electrically conductive portions of the end portion and the end portion form terminals of the bobbin.

Further, in the method for manufacturing a coil device according to the present invention, the step of inserting the cavity of the bobbin into the protrusion of the rotatable holding device and the one end of the coated conductor wire held by the first holding means of the holding device. Then, the step of locking the bobbin with one holding portion of the bobbin and rotating the bobbin together with the holding device a predetermined number of times, and the step of locking the coated wire in the second concave portion of the bobbin and holding it by the second holding means of the holding device. And cutting the coated conductor between the bobbin and the holding device and peeling off the coating on the end of the coated conductor. The illustrated embodiment includes the step of locking the coated wire held by the second holding means of the holding device in the third concave portion of the bobbin and rotating the bobbin together with the holding device a predetermined number of times. The method further includes the step of engaging with the fourth concave portion and holding the third concave portion of the holding device.

[0007]

The terminals of the coil device can be formed by arranging the starting ends and the endings of the primary winding and the secondary winding in a plurality of recesses of the bobbin and peeling off the insulating coatings of the starting ends and the endings. Therefore, the number of parts can be reduced and the assembling work can be simplified.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention applied to a transformer will be described below with reference to FIGS. In these figures, FIG.
6 to 19 are denoted by the same reference numerals and description thereof will be omitted. As shown in FIG. 1, the transformer according to this embodiment includes a bobbin 3 having a core 6, a cavity 3c into which the core 6 is inserted, and a pair of flanges 3a and 3b.
And a primary winding 1, 1'and a secondary winding 2 wound between a pair of flanges 3a, 3b of the bobbin 3. The bobbin 3 is integrally formed of a flexible thermoplastic synthetic resin such as epoxy. In each of the primary winding 1, 1'and the secondary winding 2, a coated conductor wire in which a triple insulating coating 5 is applied to a linear conductor 4 disclosed in Japanese Utility Model Laid-Open No. 3-25219 (FIG. 17). ) Is used. Further, since the coated conductor wire uses an end portion as a lead terminal, a wire diameter of 0.5 mm or more is selected. The primary winding 1, 1 ′ and the secondary winding 2 are layered over the entire space between the pair of flanges 3 a, 3 b of the bobbin 3, respectively, and the primary winding 1, the primary winding 1 ′ and the secondary winding 2 are arranged in layers. It is wound in the order of. FIG. 5 shows a circuit diagram of this transformer. The primary windings 1 and 1'and the secondary winding 2 each have a terminal 1
a, 1'a, 2a. As the core 6, a combination of an E-shaped core and an I-shaped core or a combination of E-shaped cores is used. As shown in FIG. 2, a plurality of grooves 11 are provided on one flange 3a of the bobbin 3. As shown in FIGS. 2 and 3, each of the terminals 11a, 1'a, 2a of the primary winding 1, 1'and the secondary winding 2 is provided in the plurality of grooves 11.
Are inserted respectively. The terminals 1a, 1'a and 2a have the insulation coating 5 peeled off, and the terminals 1b and 1'of the bobbin are respectively formed.
b and 2b are formed. Further, as shown in FIG. 4, the plurality of grooves 11 are provided with inclined portions 11a, narrow portions 11b and holes 11c, and the primary windings 1, 1'and the secondary windings 2 are respectively provided in the holes 11c. By locking the terminals 1a, 1'a, 2a of the above, the terminals 1a, 1'a, 2a are prevented from being separated from the plurality of grooves 11. Further, escape grooves 12 are provided on both sides of the plurality of grooves 11, and the inclined portions 11 a of the plurality of grooves 11 are provided.
By pressing the terminals 1a, 1'a, 2a locked to the terminals, the plurality of grooves 11 are elastically expanded and the terminals 1a, 1'a, 2
The a can be easily pushed into the hole 11c.

Next, a method of manufacturing the transformer of this embodiment will be described with reference to FIGS. First, as shown in FIG. 6, the hollow portion 3c of the bobbin 3 is inserted into the rectangular projection 21 of the spindle 20 as a rotatable holding device.
A plurality of pins 22 as holding means are provided on an upper side 20a and a lower side 20b of the spindle 20 as viewed in the drawing. Illustration of the plurality of pins on the lower side 20b is omitted. Then, as shown in FIG.
One end of the coated conductor wire 10 is wound around and held by the first pin 22a as a holding means for the first pin 22a of the bobbin 3 in the first groove 22a.
It is locked in the groove 11d. At this time, since the covered conductor wire 10 is locked to the inclined portion 11a of the groove 11, the spindle 2
The coated conductor wire 10 does not come off from the groove 11 by the rotation of 0. After that, the bobbin 3 is rotated together with the spindle 20 in the arrow direction by a predetermined number of turns, and the coated conductor wire 10 is wound over the entire area between the pair of flanges 3a and 3b of the bobbin 3. Subsequently, as shown in FIG. 8, the rotation of the spindle 20 and the bobbin 3 is stopped, the coated conductor wire 10 is locked in the second groove 11e of the bobbin 3, and the second holding means of the spindle 20 serves as the second holding means. Hold on pin 22b. By the above,
The primary winding 1 shown in FIG. 1 is formed.

After forming the primary winding 1, as shown in FIG. 9, the coated conductive wire 10 is held by the third pin 22c as the second holding means of the spindle 20, and the third groove of the bobbin 3 is held. Lock to 11f. Then, the bobbin 3 is rotated together with the spindle 20 in the arrow direction by a predetermined number of turns, and the bobbin 3 is rotated.
Covering wire 1 over the entire space between the pair of flanges 3a, 3b
Wind 0. Then, as shown in FIG. 10, the rotation of the spindle 20 and the bobbin 3 is stopped, the coated conductor wire 10 is locked in the fourth groove 11g of the bobbin 3, and the fourth pin as the third holding means of the spindle 20 is held. It is wound around 22d and held. By the above, the primary winding 1'shown in FIG. 1 is formed.

Here, the spindle 20 and the bobbin 3 shown in FIG. 10 are rotated by half a clockwise direction toward the drawing to cover the side opposite to the side where the plurality of pins 22 are shown, that is, the lower side 20b of the spindle 20. Route the conducting wire 10. afterwards,
The steps shown in FIGS. 7 and 8 are repeated to form the secondary winding 2 shown in FIG. Since these steps are the same as those in FIGS. 7 and 8, the illustration is omitted.

Next, as shown in FIG. 11, a plurality of grooves 11 are formed.
By the pushing means 30 having a plurality of protrusions 30a at positions corresponding to, the coated conductor wire 10 locked to the slanted portions 11a of the plurality of grooves 11 is pressed to elastically expand the plurality of grooves 11 and Each of 10 is pushed at once to be locked in the hole 11c, and the mounted state shown in FIG. 12 is obtained. Next, as shown in FIG. 13, the bobbin 3 and the spindle 20
The coated conductive wire 10 stretched between the two is cut with a cutting tool such as a nipper, and the bobbin 3 is pulled out from the protrusion 21 of the spindle 20 in the arrow direction. Then, as shown in FIG. 14, a pair of upper and lower metal plates 40, 40 having a plurality of holes 40a that match the cross-sectional shape of the conductor portion of the covered conductor 10 in a pair of upper and lower terminals 1a, 1'a of the covered conductor 10. 2a (not shown). Subsequently, the pair of metal plates 40, 40 are heated by the heaters 41, 41 respectively provided on the pair of metal plates 40, 40 and connected to the power source 42 to heat the terminals 1a, 1'a,
The insulating coating 5 of 2a (not shown) is blown. After that, the pair of metal plates 40, 40 are moved in the direction of the arrow, and the insulating coating 5 of the terminals 1a, 1'a, 2a (not shown) of the coated conductive wire 10 is formed.
Is removed to expose the conductor 4, and the terminals 1b, 1'b, 2b of the bobbin shown in FIGS. 2 and 3 are formed.

Finally, the core 6 is placed in the cavity 3c of the bobbin 3 around which the primary winding 1, 1'and the secondary winding 2 are wound as described above.
Is attached to complete the transformer shown in FIG.

According to this embodiment, the following effects can be obtained. (1) Each terminal 1a of the primary winding 1, 1'and the secondary winding 2,
Remove the insulation coating from 1'a and 2a to remove the bobbin terminal 1b,
Since 1'b and 2b are formed, the plurality of terminals 7 of the bobbin used in the conventional example are unnecessary, and the number of parts can be reduced. (2) The step of winding each terminal 1a, 1'a, 2a of the primary winding 1, 1'and the secondary winding 2 of the conventional example around a plurality of terminals 7 of the bobbin and fixing them with solder or the like can be omitted. Therefore, the assembling work can be simplified and the man-hours for assembling the transformer can be reduced. (3) Since a plurality of windings of the primary winding and / or the secondary winding can be formed with one covered conductor wire 10, the winding work can be easily performed.

The embodiment of the present invention is not limited to the above embodiment, and can be modified. For example, in the above embodiment, the coated conductor wire 10 having a wire diameter of 0.5 mm or more is used, but a coated conductor wire having a wire diameter of less than 0.5 mm may be used. In this case, since the hardness of the lead terminal is insufficient, a hollow bobbin 50 having a bobbin mounting portion 51 and a plurality of pipe-shaped electrodes 52 is used as shown in FIG.
The lead terminals on the bobbin 3 side may be inserted into the plurality of pipe-shaped electrodes 52, and the plurality of pipe-shaped electrodes 52 may be electrically connected to the lead terminals by soldering or the like. In the above embodiment, the second and third pins, that is, two pins are used as the second holding means of the spindle 20. However, if the terminal spacing is narrow, even one pin may be used. Good. Further, in the above embodiment, the primary winding 1, 1'and the secondary winding 2
Although the example in which the coated conductors 10 are pushed into the holes 11c of the plurality of grooves 11 at a time after the winding is finished, the coated conductors 10 may be pushed each time the coated conductors 10 are locked in the plurality of grooves 11. Further, the pushing means 30 may be made of synthetic resin or the like and may be left attached to the flange 3 a of the bobbin 3. Further, in the above-described embodiment, as shown in FIG. 14, a method of heating the peeling portion of the insulating coating 5 of the coated conductive wire 10 and peeling after the fusing is shown. However, a peeling tool such as a conventional nipper or wire stripper is used. Insulation coating 5 for the coated conductor 10
May be peeled off.

Further, it will be easily understood that the present invention is not limited to the transformer but can be applied to other coil devices such as a reactor.

[0017]

As described above, in the coil device of the present invention, the lead terminal is formed by the conductive portions at the respective ends of the primary winding and the secondary winding, and the lead terminal is conventionally used as the lead terminal. Since the conductor can be omitted, the number of parts can be reduced and the number of assembling steps can be reduced. Moreover, since a plurality of windings of the primary winding and / or the secondary winding can be formed by one covered conductor, the winding work can be simplified. Further, since it is not necessary to electrically connect the terminals of the primary winding and the secondary winding to the terminals of the bobbin by soldering or the like, it is possible to avoid the disconnection accident of the terminal portion due to the secular change of the soldered portion. The reliability can be significantly improved.

[Brief description of drawings]

FIG. 1 is a sectional view of a transformer showing an embodiment of the present invention.

FIG. 2 is a front view showing a drawn state of windings of the transformer of FIG.

FIG. 3 is a side view of FIG.

FIG. 4 is a sectional view showing a part of the shapes of a plurality of grooves.

5 is a circuit diagram of the transformer of FIG.

FIG. 6 is a perspective view showing a state in which a hollow portion of a bobbin is inserted into a protrusion of a rectangular cross section of a spindle.

FIG. 7 is a perspective view showing a state in which the coated conductive wire is held by the first pin of the spindle and the coated conductive wire is wound around the bobbin.

FIG. 8 is a perspective view showing a state in which the coated conductor wire of FIG. 7 is held by a second pin of a spindle.

9 is a perspective view showing a state in which the coated wire of FIG. 8 is held by a third pin of a spindle and the coated wire is wound around a bobbin. FIG.

FIG. 10 is a perspective view showing a state in which the coated conductor wire of FIG. 9 is held by a fourth pin of a spindle.

FIG. 11 is a cross-sectional view showing a state in which the covered conductor wire locked to the inclined portions of the plurality of grooves is pushed into the hole portion by the pushing means.

FIG. 12 is a perspective view showing a state in which the coated wire of FIG. 10 and the secondary winding side are pushed into the holes of the plurality of grooves of the bobbin.

FIG. 13 is a perspective view showing a state in which the coated conductive wire stretched between the bobbin and the spindle is cut and the bobbin is pulled out from the protrusion of the spindle.

FIG. 14 is a perspective view showing a state in which the insulating coating on the end portion of the coated conductor is peeled off.

FIG. 15 is a perspective view showing another embodiment.

FIG. 16 is a sectional view showing a conventional transformer.

FIG. 17 is a perspective view of a coated conductor wire used in the transformer of FIGS. 1 and 16.

FIG. 18 is a front view showing a drawn state of windings of the transformer of FIG.

FIG. 19 is a side view of FIG.

[Explanation of symbols]

1, 1 '. ． Primary winding, 2. ． Secondary winding, 1a, 1'a,
2a. ． Terminals 1b, 1'b, 2b. ． Bobbin terminal,
3. ． Bobbins 3a, 3b. ． A pair of flanges, 3c. ．
Cavity part, 4. ． Conductor, 5. ． Triple insulating layer, 6. ． core,
10. ． Coated wire, 11. ． Multiple grooves (multiple recesses),
20. ． Spindle (holding device), 21. ． Protrusions, 2
2. ． Pin (holding means)

Claims (4)

[Claims] 1. A coil including a bobbin having a cavity for inserting a core and a pair of flanges, and a primary winding and a secondary winding having an insulating coating wound between the pair of flanges of the bobbin. In the device, the starting and terminating ends of each of the primary winding and the secondary winding are arranged in a plurality of recesses formed in one of the flanges of the bobbin, and the conductive portions of the starting and terminating ends are disposed. A coil device, comprising a terminal of the bobbin. 2. A step of inserting a hollow portion of a bobbin into a protrusion of a rotatable holding device, and holding one end of a covered conductive wire in a first holding means of the holding device, the recess being provided in one recess of the bobbin. Locking and rotating the bobbin together with the holding device a predetermined number of times; locking the coated conductor in a second recess of the bobbin and holding it by a second holding means of the holding device; A step of cutting a coated wire between the bobbin and the holding device and peeling off a coating on an end portion of the coated wire, and a method for manufacturing a coil device. 3. The method according to claim 1, further comprising the step of locking the coated conductive wire held by the second holding means of the holding device in the third recess of the bobbin and rotating the bobbin together with the holding device a predetermined number of times. The manufacturing method of the coil device of 2 ". 4. The method for manufacturing a coil device according to claim 2, further comprising a step of locking the coated conductive wire in a fourth recess of the bobbin and holding the coated conductive wire by a third holding means of the holding device.