JPH06224054A - Bobbin for transformer and manufacture thereof - Google Patents

Abstract

PURPOSE:To standardize a bobbin for transformer to make it possible to correspond to the specifications of various products as well as to realize a miniaturization of the bobbin and a cost reduction in the bobbin. CONSTITUTION:A bobbin is provided with a bobbin main body 10, terminal holding parts 15 are provided integrally with the train body 10 on both sides of the main body 10, the holding parts 15 are respectively provided with lead parts 11 for terminal use, a core insertion hole 16 is provided in one surface of the main body 10 and a coil insertion part 13, in which a plurality of sheet coils 17 consisting of a flat coil are inserted and can be stacked, and conductor wire distributing parts 14 for distributing lead wires 23 of the coils 17 inserted in the insertion part 13 among the lead parts 11 are provided integrally with the main body 10. At the time of manufacture of the bobbin, lead frames 9 are manufactured, the main body 10 and the holding parts 15 are molded integrally with the lead frames 9 and after that, the lead parts 11 are cut off from the frames 9 and the bobbin is formed in such a way as to bend the point parts of the lead parts 11.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a transformer bobbin which uses a sheet coil in which a copper wire is spirally and flatly formed, and a method of manufacturing the same.

[0002]

2. Description of the Related Art FIG. 7 is an explanatory view of the prior art.
Inside, 1 is a bobbin, 2 is a bobbin collar, 3 is a terminal block, 4 is a partition wall, 5 is a terminal, 6 is a coil, and 7 is a core (E-shaped core).
Indicates.

FIG. 6 shows an example of a conventional transformer. This transformer includes a bobbin 1 and a coil 6 wound around the bobbin 1.
And the core 7 mounted on the bobbin 1. In this transformer, a bobbin 1 is provided with a collar 2, a terminal block 3, and a plurality of partition walls 4, and the terminal block 3 is provided with a plurality of terminals 5.

The coil 6 is divided by the partition wall 4 and wound, and the lead wire of the coil 6 is connected to the terminal 5.

[0005]

SUMMARY OF THE INVENTION The above-mentioned conventional devices have the following problems. : The coil is divided by a partition wall and wound. Therefore, if the number of turns of the coil and the wire diameter are different, the number and structure of the partition walls are different, and the bobbin length is also different.

Therefore, the bobbin must be designed according to the product specifications, the product type structure becomes complicated, and standardization is difficult. In addition, it causes a cost increase. : The bobbin is provided with a collar, a terminal block, a partition wall, etc., and its shape is complicated. Therefore, the manufacturing cost becomes high.

[0007]: The bobbin is provided with a collar, a terminal block, a partition wall and the like, and a coil is wound between the partition walls, so it is difficult to miniaturize the transformer. It is an object of the present invention to solve such conventional problems and standardize a bobbin for a transformer, thereby making it possible to meet various product specifications, and at the same time, to realize miniaturization and cost reduction of the bobbin.

[0008]

FIG. 1 is a diagram for explaining the principle of the present invention. In FIG. 1, the same parts as those in FIG. 7 are designated by the same reference numerals. Further, 9 is a lead frame, 10 is a bobbin main body, 11 is a terminal lead portion, 12 is a cut-and-raised piece, 13
Is a coil insertion part, 14 is a wire distribution part, 15 is a terminal holding part, 16 is a core insertion hole, 17 is a sheet coil, and 23 is a lead wire.

In order to solve the above problems, the present invention has the following configuration. A transformer bobbin includes a bobbin main body 10, and terminal holding portions 15 are integrally provided on both sides of the bobbin main body 10, and each terminal holding portion 15 has a plurality of terminal lead portions 11 constituting terminals. And the bobbin body 10
Of the sheet coil 17 having the core insertion hole 16 on one side thereof and capable of inserting and stacking a plurality of sheet coils 17 each including a flat coil, and the sheet coil 17 inserted into the coil insertion portion 13. The wire distribution part 14 for distributing the lead wire 23 to the terminal lead part 11 is integrally provided.

In the transformer bobbin having the configuration,
Each terminal lead portion 11 was provided with a cut-and-raised piece 12 for connecting the lead wire 23 of the sheet coil 17 inserted in the coil insertion portion 13.

In the method of manufacturing a bobbin for a transformer having the above structure, a lead frame 9 having a plurality of lead portions 11 for terminals integrally formed is manufactured.
Then, the bobbin main body 10 having the coil inserting portion 13 and the wire allocating portion 14 and the terminal holding portion 15 are integrally molded, and then the lead portions 9 for each terminal are separated from the lead frame 9, The tip portion was bent to form a plurality of independent lead portions 11 for terminals.

[0012]

The operation of the present invention based on the above configuration will be described with reference to FIG. When manufacturing a transformer, first, the lead frame 9 having the shape shown in FIG.

A large number of lead portions 11 for terminals are formed on the lead frame 9 at regular intervals. In addition, a cut-and-raised piece 12 for hooking and connecting the lead wire of the coil is formed in each terminal lead portion 11.

Next, the bobbin main body 10 and the terminal holding portion 15 are integrally molded on the lead frame 9 with a thermosetting material or a thermoplastic material. In this case, the bobbin body 1
The coil insertion part 13 and the wire allocating part 14 are integrally molded on one surface of the wire 0.

In this manner, the bobbin main body 10 and the terminal holding portion 15 are integrally molded (resin molded) on the lead frame 9. : For the bobbin manufactured as described above,
As shown in (B), the sheet coil 17 is inserted according to the product specifications.

In this case, the through hole of the sheet coil 17 is
Insert from above the coil insertion portion 13 and stack a number of sheet coils that match the product specifications. And the sheet coil 17
The lead wire 23 of No. 1 is hooked on the cut-and-raised piece 12 while being distributed by the wire distribution unit 14 of the bobbin. afterwards,
The lead wire 23 is fixed by spot welding the hooked portion of the lead wire 23.

Next, the work of the lead frame 9 is separated, and the lead portions 11 for each terminal are separated. Then, by bending the tip of each terminal lead portion 11,
It can be used as a terminal.

A core is inserted into the core insertion hole 16 of the bobbin assembled as described above to form a transformer. By selecting the sheet coil as described above, it is possible to support transformers of various specifications. Therefore, standardization of the transformer bobbin can be achieved.

Further, the bobbin is integrally molded (resin mold).
By using the sheet coil, the bobbin and the transformer can be downsized and the cost can be reduced.

[0020]

Embodiments of the present invention will be described below with reference to the drawings. 2 to 6 are explanatory views (1 to 5) of the embodiment, FIG. 2 (A) is a plan view of the bobbin, and FIG. 2 (B) is FIG.
FIG. 3 (A) is a plan view of the sheet coil, FIG. 3 (B) is a state in which the sheet coil is incorporated, and FIG. 3 (C) is FIG. 5B is a view seen from the ST line direction, FIG. 4A is a view showing a state after the work is separated, FIG. 4B is a view seen from the M direction in FIG. 4A, and FIG. 6 is a view seen from the N direction in FIG. 4 (A) when the core is inserted, FIG.
(A), FIG. 6 (B), and FIG. 6 (C) are modified examples of the sheet coil.

2 to 6, the same elements as those in FIGS. 1 and 7 are designated by the same reference numerals. Further, 18 is an insulator sheet, 19 is a sheet coil body, 20 is an inner peripheral seal portion,
Reference numeral 21 denotes an outer peripheral seal portion, and 22 denotes a through hole.

In this embodiment, a method of manufacturing a transformer including the structure of the bobbin and the method of manufacturing the bobbin will be described. §1: Basic description of bobbin In order to standardize the bobbin for the transformer, a sheet coil (described later) is used for this transformer. That is,
A bobbin for a sheet coil is used for this transformer.

In the bobbin manufacturing process, the lead frame is used and the structure of the bobbin main body is devised so that the bobbin can be easily integrally molded. §2: Description of manufacturing method of transformer In order to manufacture a transformer, it is manufactured by the following steps.

First, the lead frame 9 formed (stamped) into the shape shown in FIGS. 2A and 2B is manufactured. That is, the lead frame 9 has a terminal lead portion 11 for use as a transformer terminal.
Are formed at regular intervals.

Further, the cut-and-raised piece 1 for hooking and connecting the lead wire of the coil to the lead portion 11 for each terminal.
Form 2. : Next, the bobbin main body 10 and the terminal holding portion 15 are integrally molded (resin mold) on the lead frame 9 with a thermosetting material or a thermoplastic material.

In this case, the bobbin body 10 is integrally formed with the coil insertion portion 13 and the wire allocating portion 14. Further, the terminal holding portion 15 is molded in a state in which the tip portion of the terminal lead portion 11 of the lead frame 9 is inserted.

The bobbin molded as described above has the structure shown in FIGS. 2 (A) and 2 (B). As shown, the coil insertion portion 13 is
It is formed in a cylindrical body, and the inside thereof is a core insertion hole 16 for inserting a core.

A plurality of sheet coils (which will be described later) can be inserted into the coil insertion portion 13 to be laminated. A wire allocating section (14) is provided on both sides of the coil inserting section 13. A plurality of protrusions are arranged at predetermined intervals in the wire allocating section (14), and the lead wire of the sheet coil is inserted between the protrusions so as to be distributed.

A sheet coil is inserted into the coil inserting portion 13 of the bobbin manufactured as described above according to the product specifications. The sheet coil used in this case is
It is a coil having the structure shown in FIG.

As shown in FIG. 3 (A), the sheet coil 17 is formed by sandwiching a copper wire in a spiral shape from both sides of a sheet coil main body 19 which is flatly wound and sandwiched between two insulating sheets 18. At the positions of the inner peripheral portion and the outer peripheral portion of the coil body 19, the two insulating sheets 18 are pressure-bonded and heat-melted to form an inner peripheral seal portion 20 and an outer peripheral seal portion 21.
Is formed.

In the sheet coil 17, the lead wire 23 is drawn out of the insulator sheet 18 for connecting the sheet coil body 19. In addition, the portion other than the lead wire 23 that is drawn out is the seal portion 20 on the inner circumference.
And the outer peripheral seal portion 21 completely seal and insulate.

Further, a through hole 22 for inserting into the coil inserting portion 13 of the bobbin is provided inside the seal portion 20 on the inner periphery of the sheet coil 17. The through hole 22 is a hole slightly larger than the outer diameter of the coil inserting portion 13 of the bobbin.

When inserting the sheet coil 17 into the bobbin, as shown in FIGS. 3 (B) and 3 (C), the through hole 22 of the sheet coil 17 is inserted into the coil inserting portion 1 of the bobbin.
Insert in 3 and stack.

In this way, a number of sheet coils 17 that match the product specifications are inserted, but in this case, for example, an assembly robot can be used to assemble them automatically. When this assembly robot is used, the assembly robot grips the lead wire 23 of the sheet coil 17, inserts the sheet coil 17 into the coil insertion portion 13, and connects the lead wire 23 of the sheet coil 17 to the bobbin. The wire is distributed by the wire distribution unit 14, and hooked on the cut-and-raised piece 12.

This work is performed for each sheet coil, and a predetermined number of sheets are stacked. Then, as described above, the portion of the cut-and-raised piece 12 on which the lead wire 23 is hooked is fixed by spot welding or the like.

Next, the work is cut off at the position of the cutting line CL of the lead frame 9 shown in FIG.
The lead portions 11 for each terminal are separated. After that, at the position of the bending line BL, each terminal lead portion 11 is bent 90 ° (bent to the side opposite to the coil insertion portion 13),
Each terminal lead portion 11 is made to be usable as a terminal.

This state is shown in FIGS. 4 (A) and 4 (B). As shown in the figure, each terminal lead portion 11 is bent 90 ° below the bobbin body so that it can be used as a transformer terminal.

The core is inserted into the core insertion hole 16 of the bobbin assembled as described above. For example, as shown in FIG. 5, the E-shaped core 7 is inserted from both sides of the bobbin, and the two E-shaped cores 7 are butted and joined.

In this case, the central leg portion of the E-shaped core 7 is inserted into the core insertion hole 16 and the outer leg portions on both sides are placed outside the bobbin main body 10 to be joined and fixed with an adhesive or the like.
A transformer is completed through the above steps.

§3: Description of Modification of Sheet Coil ...
See FIG. 6. FIG. 6 shows a modification of the sheet coil shown in FIG. : Modification 1 ... See FIG. 6A A sheet coil of Modification 1 is shown in FIG. In this example, in the sheet coil 17 shown in FIG. 3A, the insulator sheet 18 located outside the outer peripheral seal portion 21 is cut off to form a circular sheet coil.

That is, along the outer peripheral seal portion 21,
The outer insulator sheet 18 is cut off, and the outer peripheral portion of the sheet coil 17 is formed in a circular shape. The other structure is the same as that of the sheet coil shown in FIG.

Modified Example 2 ... See FIG. 6B A sheet coil 17 of Modified Example 2 is shown in FIG. 6B. In this example, in the sheet coil 17 shown in FIG.
This is an example in which the outer peripheral seal portion 21 is formed in a rectangular shape along the outer peripheral portion of the insulating sheet 18. The other structure is the same as that of the sheet coil shown in FIG.

Modification 3 ... See FIG. 6C A sheet coil 17 of Modification 3 is shown in FIG. 6C. In this example, in the sheet coil 17 shown in FIG.
This is an example in which the outer peripheral seal portion 21 is provided on the entire surface of the insulator sheet 18 located outside the sheet coil body 19.

In this case, the insulator sheet 18 is rectangular and the sheet coil 17 is also rectangular. The other structure is the same as that of the sheet coil shown in FIG. (Other Embodiments) Although the embodiments have been described above, the present invention can be implemented as follows.

The shape of the coil insertion portion 13 is a cylindrical body,
It can be implemented in any shape such as a quadrangular prism or another polygonal prism. However, it is necessary to make it possible to insert the sheet coil from the upper side.

The wire allocating section can be implemented in any structure as long as the wire can be hooked and distributed. The sheet coil is not limited to that of the above-mentioned embodiment, and other sheet coils (flat shape) can be used.

[0047]

As described above, the present invention has the following effects. : By selecting the sheet coil, it can correspond to the transformer of various product specifications. Therefore, standardization of the transformer bobbin can be achieved. In addition, downsizing and cost reduction of the transformer bobbin can be achieved.

The integral molding (resin molding) of the transformer bobbin using the lead frame can be performed easily and easily, and the cost can be reduced. : Since the transformer is constructed by inserting the sheet coil into the coil inserting portion of the bobbin, the transformer can be easily assembled and the assembly can be automated.

If a lead frame is used to connect the sheet coil and the terminal lead portion by spot welding or the like, a reliable and uniform connection can be achieved. : By assembling the lead wire of the sheet coil by the assembly robot using the wire allocating section, it is possible to meet all product specifications. In this respect, standardization of bobbins can be achieved.

If the structure of the lead frame is changed according to the product, it is possible to easily meet various product specifications.

[Brief description of drawings]

FIG. 1 is a diagram illustrating the principle of the present invention.

FIG. 2 is an explanatory diagram 1 of an embodiment.

FIG. 3 is an explanatory diagram 2 of an example.

FIG. 4 is an explanatory diagram 3 of an embodiment.

FIG. 5 is an explanatory diagram 4 of an example.

FIG. 6 is an explanatory diagram 5 of an example.

FIG. 7 is an explanatory diagram of a conventional technique.

[Explanation of symbols]

 9 lead frame 10 bobbin main body 11 terminal lead portion 12 cut-and-raised piece 13 coil insertion portion 14 connection wire distribution portion 15 terminal holding portion 16 core insertion hole 17 sheet coil 23 lead wire

Claims (3)

[Claims] 1. A flat bobbin body (10) is provided, and terminal holding portions (15) are integrally provided on both sides of the bobbin body (10), and each terminal holding portion (15) has a terminal. And a plurality of sheet coils (17) each having a flat coil and having a core insertion hole (16) on one surface of the bobbin body (10). And a sheet coil (1) inserted in the coil insertion part (13) that can be stacked.
A bobbin for a transformer, characterized in that a lead wire allocating section (14) for allocating the lead wire (23) of (7) to the terminal lead section (11) is integrally provided. 2. A sheet coil (1) inserted into a coil insertion portion (13) of the lead portion (11) for each terminal.
The bobbin for a transformer according to claim 1, further comprising a cut-and-raised piece (12) for connecting the lead wire (23) of 7). 3. A lead frame (9) in which a plurality of lead parts (11) for terminals are integrally formed is manufactured, and the coil insertion part (13) and the wire distribution part are formed in the lead frame (9). (1
The bobbin body (10) having 4) and the terminal holding portions (15) on both sides thereof are integrally molded (molded), and then the lead portions (11) for each terminal are separated from the lead frame (9), The bobbin for a transformer according to claim 1 or 2, wherein the tip portion is bent to form a plurality of independent lead portions (11) for terminals.