JPH0689813A - Air-core coil and its manufacture - Google Patents

Abstract

PURPOSE:To obtain a small-sized air-core coil of low cost which can be automatically mounted on a printed board. CONSTITUTION:This air-core coil is constituted of an air-core part 2 formed by winding a self-welding magnet wire, and a coil retaining plate 4 having almost the same form as the air-core coil part 2 plane. At least a pair of coil lead terminal tying-up parts 5a, 5b are protruded from the periphery of the plate 4. At least one surface of the plate 4 is coated with an adhesive layer 6. A winding-start terminal 3a and a winding-end terminal 3b of the air-core coil part 2 are wound around the coil lead terminal tying-up parts 5a and 5b, respectively. Wire parts of the air-core part 2 are mutually fixed, and the air- core part 2 is fixed to the coil retaining plate 4 via the adhesive layer 6 of the coil retaining plate 4.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an air-core coil suitable for automatic mounting on a printed circuit board and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, as a coil mounted on a printed circuit board, for example, as shown in FIGS. 5 (a) and 5 (b),
A coil portion 22 is formed by winding a self-bonding magnet wire around a plastic coil bobbin 21 having collars 24a and 24b on both sides and terminal fittings 23a and 23b on either one of the collars. Bobbin winding coil 20 in which the winding start end and the winding end end are respectively connected to the terminal fittings 23a and 23b, or FIG.
As shown in (b), the self-bonding magnet wire is wound around the required number of turns using a winding frame (not shown) having a required shape, and then the winding start lead end 31 and the winding are wound. At the end, the self-bonding magnet wire wound with the lead terminal 32 led out is melted and solidified with hot air or a solvent, and then the air-core coil 30 obtained by removing from the reel is used. It had been.

The coil 20 is attached to the printed circuit board 8 by mounting the coil 20 on the printed circuit board 8 in the former bobbin winding coil 20 as shown in FIG.
The terminal fittings 23a and 23b of the coil 20 and the conductive pattern portions 9 and 9 of the printed circuit board 8 are placed so as to face each other,
Solder connection was made by an automatic machine using cream solder or the like. Also, in the latter air-core coil 30 described above, the winding start lead terminal 31 and the winding end lead terminal 32 of the coil 30 are manually connected to the conductive pattern portions 9 of the printed circuit board 8 by soldering.

[0004]

In the case of the former bobbin winding coil 20 described above, although the connecting work of the coil to the printed circuit board can be automated and the like, which is excellent in connection workability, it is necessary to use the bobbin with the terminal fitting. However, there is a drawback that it is difficult to reduce the size of the coil and the cost is increased. On the other hand, in the case of the latter air-core coil 30 described above, there is an advantage that the cost and size of the coil can be easily reduced, but it is very difficult to use an automatic machine for connecting the coil to the printed circuit board. When it is attempted to automate, an automatic machine having a very complicated and expensive structure is required, and in the end, it is necessary to rely on manual work, so that there is a big drawback that the workability of connecting the coil to the printed circuit board is poor.

The present invention has been made to solve the above-mentioned drawbacks of the prior art, and an object thereof is to provide a coil which is small in size, low in cost, and excellent in workability for connecting to a printed circuit board, and a manufacturing method thereof. To do.

[0006]

In order to achieve the above object, a first aspect of the present invention is to provide an air-core coil portion formed by winding a self-bonding magnet wire, and a shape substantially the same as the plane of the air-core coil portion. At least a pair of coil lead terminal entangled portions are formed at the periphery of the coil support plate and an adhesive layer is applied to at least one surface of the coil support plate to form a winding start terminal and a winding end terminal of the air core coil portion. Each of them is wound around the coil lead end entangled portion of the coil support plate, the wires of the air core coil portion are fixed to each other, and the air core coil portion and the coil support plate are bonded to each other. An object of the present invention is to provide an air-core coil characterized by being fixed via layers.

A second aspect of the present invention is that the coil winding frame has substantially the same shape as the plane of the air-core coil portion wound around the winding frame, and at least a pair of coil lead terminal entangled portions are provided on the periphery of the coil winding frame. A coil support plate on which at least one side is coated with an adhesive layer in advance so that the side of the coil support plate on which the adhesive layer is coated abuts the plane of the air-core coil portion to be wound, The self-bonding magnet wire is wound a predetermined number of times by making contact with the side of the coil support plate on which the adhesive layer is applied to form an air-core coil part, and the winding start end and winding end end of the air-core coil part are formed. Each is wound around the coil lead end entangled portion of the coil support plate, and the wires of the air core coil portion are fused and solidified, and the air core coil portion and the coil support plate are provided with an adhesive layer of the coil support plate. Through fusion and solidification And to provide a manufacturing method of the air-core coil, wherein the door.

[0008]

According to the air-core coil of the present invention, a coil support plate is provided on one side of the air-core coil portion, which has substantially the same shape as the plane of the air-core coil portion, and at least a pair of coil lead terminal entangled portions projecting from the periphery. It has a structure in which the winding start end and the winding end end of the air-core coil part are respectively wound around the coil lead end entanglement part of the coil support plate, and this coil support plate solders the coil. The air-core coil has excellent mechanical strength because it is made of a material that has heat resistance that can withstand the temperature at the time of application and mechanical strength that is appropriate, and the coil lead terminal entangled part of the coil support plate is It has a function and enables automatic mounting when mounted on a printed circuit board.

The method of manufacturing the air-core coil of the present invention is
An adhesive layer is provided in advance on at least one surface of the coil support plate, the coil support plate provided with this adhesive layer is inserted into the coil winding frame, and then the coil winding frame is brought into contact with the adhesive layer application surface side of the coil support plate to self-attach. The fusible magnet wire is wound a predetermined number of times to form the air-core coil portion, and thereafter, the wires of the air-core coil portion are fused and solidified, and the air-core coil portion and the coil support plate are connected to the coil support plate. Since this is a manufacturing method in which fusion bonding and solidification are performed via an adhesive layer, there is no need to newly design the coil winding machine, and there is no need to make major changes or additions to the manufacturing process.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An air core coil and a method of manufacturing the same according to one embodiment of the present invention will be described below with reference to FIGS.

1A and 1B show the air-core coil 1 of the present invention mounted and connected on a printed circuit board 8. FIG. 1A is a top view thereof, and FIG. 1B is a side view thereof. Is.
As shown in FIG. 1, in the air-core coil 1 of the present invention, a self-bonding magnet wire is wound a predetermined number of times and a winding start lead terminal 3a and a winding end lead terminal 3b are respectively led out to fix the winding wires to each other. And an air-core coil portion 2 formed in the same manner as the coil width of the coil portion 2 and formed to have substantially the same shape as the plane of the coil portion 2, and a pair of lead terminal binding portions 5a and 5b from the peripheral edge. And a coil support plate 4 formed by projecting a coil, and a winding start lead terminal 3a and a winding end lead terminal 3b of the coil portion 2 are entwined with the lead terminal entwining portions 5a and 5b of the coil support plate 4, respectively. Coil part 2
And the coil support plate 4 are fixed to each other via an adhesive layer 6.

The coil support plate 4 will be described in detail with reference to FIGS. 2 and 3. The plate material of the coil support plate 4 may be a material having heat resistance that can withstand the temperature at the time of soldering the coil and appropriate mechanical strength, and for example, an epoxy resin material containing glass is suitable. . The shape of the coil support plate 4 is formed to be substantially the same as or slightly wider than the coil width according to the planar shape of the coil portion 2 to be used, and the lead end of the coil portion 2 is formed on the periphery of the plate. A pair of entwined portions 5a and 5b are provided so as to project.
The adhesive layer 6 is formed on at least one side of the coil support plate 4.
Is provided. A butyral paint or a solvent-soluble nylon paint is used as the adhesive paint for forming the adhesive layer 6, and the same adhesive paint as that of the self-bonding magnet wire wound around the coil portion 2 is desirable. . In addition,
FIG. 2 shows an example of the support plate 4 formed in the shape of a hollow disc.

Next, the manufacturing method of the coil supporting plate 4 will be explained with reference to FIG. 3. At least one surface as shown in FIG. 3A is coated with an adhesive paint such as butyral paint or solvent-soluble nylon paint and dried. Then, the adhesive layer 6 is provided to a thickness of 0.
A plate material having an appropriate size of about 3 mm, for example, an epoxy resin plate 7 containing glass with an adhesive layer is prepared, and this plate material is pressed into the shape of the coil support plate 4 shown in FIG. 2 as shown in FIG. It is manufactured by punching out many pieces using a machine.

Next, a method of manufacturing the air-core coil of the present invention in the above embodiment will be described with reference to FIG. FIG. 4 shows a side view of a main part of a winding part of a coil winding machine which is normally used, and 10 is a winding shaft of the coil winding machine.
The first collar 11, the winding jig 13 around which the coil portion 2 is wound, and the second collar for setting a predetermined coil winding width in the winding jig 13 between the first collar 11 and the second collar. 12 is inserted, and the inserted first collar 11, winding jig 13, and second collar 12 are fixed to the winding shaft 10 by a fixture 14 provided at the end of the winding jig 13, The department is composed. The winding shaft 10 is rotated by a drive mechanism such as a motor (not shown).

Now, the manufacturing process of the air-core coil of the present invention using the coil winding machine having the above-described structure will be described. First, the coil support plate 4 is attached to the winding jig 13 and the adhesive layer surface 6 of the plate is coiled. The first collar 11 and the coil support plate 4 on the winding shaft 10 in the order shown in FIG.
Insert the winding jig 13 and the second collar 12 that have been inserted,
The winding jig 13 is fixed to the winding shaft 10 by the fixing tool 14 of the winding jig 13. Then, the self-bonding magnet wire is led out from the wire feeder (not shown), and the winding start end is wound around and fixed to one of the lead end binding portions 5a of the coil support plate 4 several times, and then the winding shaft 10 Rotate the first color 11 and the second color 1
The self-bonding magnet wire is wound a predetermined number of times around the winding jig 13 with a winding width set between two winding ends, and the winding end end of the wire after the winding end is the other lead end binding part 5b of the coil supporting plate 4. Wind several times and fix it to finish the winding. In this case, the winding start end and the winding end end of the self-bonding magnet wire should be wound around the lead end binding portions 5a and 5b of the coil support plate 4 after peeling off the pre-solder or insulating film. It is preferable for solder connection with a printed board.

Next, in the state of winding as described above, hot air treatment or solvent treatment is performed between the wires of the coil winding portion of the self-bonding magnet wire and between the coil support plate 4 and the coil portion. , Fusion-solidify between them. After that, the winding jig 13 is extracted from the winding shaft 10 of the coil winding machine, and the coil supporting plate 4 and the coil portion 2 which are integrally formed from the winding jig 13 are removed to obtain the air-core coil 1.

An example of manufacturing the air-core coil 1 of the present invention will be described below. Using the above-mentioned coil winding machine, the coil portion is a type 2 self-bonding polyurethane copper wire having a conductor diameter of 0.12 mm and provided with a butyral-based fusion bonding layer, the number of turns is 100, the coil outer diameter is 25 mm, and the coil winding width is 2. The wire is wound into a 5 mm air-core circle, and the coil support plate at this time is coated with an ethyl alcohol-soluble adhesive paint containing butyral resin as a main component on one side of a 0.3 mm-thick glass-filled epoxy plate and dried. The plate material was punched into a hollow circular shape having an outer diameter of 25 mm and a width of 2.5 mm, and a pair of lead terminal entangled protrusions having a length of 1 mm and a width of 2 mm provided on the periphery. And
After winding, the coil wire and the coil wire were bonded to each other by alcohol solvent bonding. The winding start and winding end terminals of the self-bonding polyurethane copper wire were pre-soldered and then wound around the lead terminal binding portion of the coil support plate 4.

The air-core coil 1 manufactured as described above sufficiently satisfied the specifications in terms of structural dimensions and adhesive strength of each part. Further, the air core coil 1 is attached to the printed circuit board 8
As shown in FIG. 1, the conductive pattern portion 9 of the printed circuit board 8,
9 and the coil lead terminals 3a and 3b were placed in correspondence with each other, cream solder was applied and passed through a heating furnace at about 200 ° C., and good solder connection could be instantly made.

Although the above embodiment describes a circular air-core coil, the present invention is not limited to a circular air-core coil, but may be a square-shaped, triangular-shaped, ladder-shaped or other-shaped air-core coil. Needless to say, it can be applied, and there is no problem even if a plurality of air core coils are laminated and a plurality of pairs of lead terminals are led out.

[0020]

The air-core coil of the present invention can be easily miniaturized and can be produced at low cost, and since the coil can be mounted on a printed circuit board using an automatic machine, efficient mounting means such as surface mounting can be achieved. Can be applied to. Further, according to the method for manufacturing an air-core coil of the present invention, the air coil of the present invention can be obtained by adding a slight improvement to a conventionally known coil winding machine without requiring a coil winding machine based on a new design. The core coil can be easily manufactured.

[Brief description of drawings]

FIG. 1A is a plan view showing a state in which an air core coil of the present invention is mounted on a printed circuit board. (B) is a side view of a state where the air-core coil of the present invention is mounted on a printed board.

FIG. 2A is a plan view of a coil support plate of the present invention. (B) is a side view of the coil support plate of the present invention.

FIG. 3A is a plan view of a plate material for a coil support plate of the present invention. (B) is explanatory drawing which punches a coil support plate from the plate material for coil support plates of this invention.

FIG. 4 is a side view of an essential part of a winding part of a coil winding machine in the method for manufacturing an air-core coil of the present invention.

FIG. 5A is a plan view of a conventional bobbin winding coil. (B) is a side view of the conventional bobbin winding coil.

FIG. 6A is a plan view of a conventional air-core coil. (B) is a side view of the conventional air core coil.

FIG. 7A is a plan view showing a state in which a conventional bobbin winding coil is mounted on a printed circuit board. (B) is a plan view of a state in which a conventional bobbin winding coil is mounted on a printed circuit board.

[Explanation of symbols]

 1 Air-core coil 2 Coil part 3a Coil part winding start lead terminal 3b Coil part winding end lead terminal 4 Coil support plate 5a Lead terminal entangled part 5b Lead terminal entangled part 6 Coil support plate adhesive layer 7 Coil support plate Plate material 8 Printed circuit board 9 Conductive pattern 10 Winding shaft 11 Color 12 Color 13 Winding jig 14 Fixing tool

Claims (2)

[Claims] 1. An air-core coil portion formed by winding a self-bonding magnet wire, and at least a pair of coil lead terminal entangled portions projecting from the periphery of the air-core coil portion having substantially the same shape as the plane of the air-core coil portion. And at least one side is formed with a coil support plate coated with an adhesive layer, each of the winding start terminal and winding end terminal of the air-core coil portion is wound around the coil lead terminal binding portion of the coil support plate, An air-core coil in which wires of an air-core coil portion are fixed to each other and the air-core coil portion and the coil support plate are fixed to each other via an adhesive layer of the coil support plate. 2. A coil winding frame having substantially the same shape as a plane of an air-core coil portion wound around the winding frame, and at least a pair of coil lead terminal entangled portions projecting from the periphery of the coil winding frame and pre-bonded to at least one surface. The coil support plate coated with the layers is inserted and arranged so that the adhesive layer application surface side of the coil support plate is in contact with the plane of the air core coil portion around which the winding is applied, and then the adhesive layer of the coil support plate is attached to the coil winding frame. The self-bonding magnet wire is wound a predetermined number of times by making contact with the coating surface side to form an air-core coil portion, and the winding start end and winding end end of the air-core coil portion are coiled on the coil support plate, respectively. Winding around the lead end entangled portion, fusion-bonding and solidifying the wires of the air-core coil portion, and fusion-solidifying the air-core coil portion and the coil support plate via the adhesive layer of the coil support plate. Air core Ill manufacturing method.