JPH0696979A - Manufacture of rectangular air core coil for surface mounting - Google Patents

Abstract

PURPOSE:To manufacture a rectangular air core coil easily and highly accurately by rotating a wire member clamp mechanism section at a predetermined position while holding a wire member to form one side of a tubular air core coil and then unclamping the mechanism section and moving the mechanism section to a position for holding a wire member. CONSTITUTION:A wire member 11 drawn out straight from a wire guide 21 is held at a predetermined position by means of a receiving claw 23 and a retaining claw 24. Under that state, a wire member clamp mechanism section 25 is rotated by about 90 deg. to bend a rectangular air core coil 12 thus forming one side of a coil. Subsequently, the retaining claw 24 is opened to release the wire member 11 and the wire member clamp mechanism section 25 is moved to a position where the mechanism section 25 does not come into contact with the wire member 11 on a plane. The mechanism section 25 is then rotated reversely by 90 deg. and brought closer, by the length corresponding to one inner side of the rectangular air core coil 12, to the wire guide 21. The mechanism section 25 is then advanced to a position where the wire member 11 can be held and the wire member 11 is held by means of the receiving claw 23 and the retaining claw 24.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a square air core coil for surface mounting.

[0002]

2. Description of the Related Art As a conventional method for manufacturing a square air core coil for surface mounting, there is a core wire winding method in which a wire is wound around a core bar having a quadrangular cross section and then pulled out from the core bar. As another method, there is a method of crushing the air-core coil wound into a cylindrical shape to flatten it.

However, in the case of the core wire winding method, the wire rod is caught at the corners of the rectangular core metal, and it is often difficult to pull out the air core coil from the core metal. Further, FIG. 9 is a plan view of the air core coil with the cored bar pulled out.
Even if it is pulled out of 1, the air core coil 92 is twisted due to the spring back and is not straightened in the length direction. As a method to make it easier to pull out the air core coil from the core metal, there is also a method of rounding the four corners of the core metal with a quadrangular cross section, but again, the air core coil is twisted due to springback, Does not straighten in the length direction. In order to make the air-core coil straight in the length direction, there is a method of using a heat-sealing wire and fixing the wire rods when wound around the core metal. However, the trouble of heating and the difficulty of removing from the core metal are inevitable.

Further, in the case of the method of crushing the air-core coil wound in a cylindrical shape to flatten it, there are variations in shape as shown in FIG. 10, and the connecting electrode portions 101 at both ends are not flush with each other. There's a problem.

[0005]

The method for manufacturing a square air-core coil for surface mounting of the present invention solves such a conventional problem by continuously bending the four corners of the square air-core coil one by one. . As a result, the rectangular air-core coil can be manufactured accurately and easily.

[0006]

According to the method of manufacturing a square air core coil for surface mounting according to the present invention, a wire rod is clamped by a wire rod clamp mechanism portion and pulled out to a predetermined position, and the mechanism portion is moved at a predetermined position. Repeating the first step of forming one side of the rectangular air-core coil by rotating 90 degrees, the second step of releasing the clamped state by the wire rod clamp mechanism portion and moving the clamp mechanism portion to the position for holding the wire rod. Is characterized in that each side of the coil is sequentially formed.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a method for manufacturing a square air core coil for surface mounting according to the present invention will be described below with reference to FIGS. FIG. 1 is a perspective view of a surface-mounting rectangular air-core coil made by the manufacturing method of the present invention. 2 to FIG.
The above is a series of explanatory views of the method for manufacturing the square air-core coil for surface mounting of the present invention. Note that FIG. 2, FIG. 3, FIG. 6, FIG.
FIG. 8 is an explanatory diagram when viewed from the lateral side of the drawn wire rod, and FIGS. 4 and 5 are explanatory diagrams when viewed from the upper side of the drawn wire rod in the vertical direction. Also, all the figures are exaggerated for ease of understanding.

In FIG. 1, reference numeral 11 is a wire rod, and 12 is a square air core coil for surface mounting. One turn of the rectangular air-core coil 12 is wound in a square, and the four corners are bent substantially at right angles.

In FIG. 2 to FIG. 8, 21 is a wire rod 1.
1 is a wire guide, 23 and 24 are receiving claws and pressing claws of the wire rod clamp mechanism 25, and 26 is a cutter.
First, as shown in FIG. 2, the wire 11 drawn straight out from the wire guide 21 is sandwiched by the receiving claw 23 and the pressing claw 24 at a predetermined position. Then, as shown in FIG. 3, in a state where the wire rod 11 is sandwiched between the receiving claw 23 and the pressing claw 24, the wire rod clamp mechanism portion 25 is rotated by about 90 degrees, and the first side of the rectangular air-core coil 12 is bent and formed. . In this case, the rotation angle of the wire rod clamp mechanism portion 25 is set to allow for the springback amount of the wire rod, and the wire rod is finally stabilized at a bending angle of about 90 degrees.

Next, as shown in FIG. 4, after the pressing claw 24 is opened and the wire rod 11 is opened, the wire rod clamp mechanism portion 25 is moved to a position where it does not contact the wire rod 11 in plan view. And
As shown in FIG. 5, after rotating the wire rod clamp mechanism portion 25 by about 90 degrees contrary to the case of FIG. 3, the line guide is moved by the length of one side inside the rectangular air-core coil 12 from the position of FIG. Move closer to side 21. Then, as shown in FIG. 6, the wire 11 is advanced to a position where it can be clamped, and is clamped by the receiving claw 23 and the pressing claw 24.

Next, as shown in FIG. 7, the wire rod 11 receives the claw 23.
The wire rod clamp mechanism portion 25 is moved by the length L of one side inside the rectangular air-core coil 12 in the direction away from the wire guide 21 while being sandwiched by the pressing claws 24. By this operation, the wire rod 11 is pulled out, and the wire rod clamp mechanism portion 25
Return to the predetermined position in FIG. The dotted line indicates the position where the wire rod clamp mechanism portion 25 was located in FIG. 6. And
As shown in FIG. 8, as in the case of FIG.
The second side of the square air-core coil 12 is bent and formed by rotating 5. In this way, one operation of the rectangular air core coil 12 is completed by repeating the operation shown in FIGS. 4 to 8 twice more. A desired number of turns is completed by repeating the operation of completing one turn. The rectangular air-core coil 12 is obtained by cutting a bent portion of the wire rod 11 with a cutter 26. In addition, as shown in FIG.
The length direction of is not inclined at right angles to the wire 11 and is slightly inclined. By sandwiching and bending the wire rod 11 in this state, the portion corresponding to one side of the bent rectangular air-core coil 12 is slightly displaced in the horizontal direction from the portion which is not yet bent. Therefore, even if the bending is repeated, the bent portions do not collide with each other and the molding can be performed for any number of turns.

The method of manufacturing the square air-core coil for surface mounting of the present invention has been described above. In FIG. 7, the amount of movement from the position where the wire rod clamp mechanism portion holds the wire rod to the predetermined position where the wire rod is bent, namely, By changing the length L of one side of the square air-core coil 12 each time, a rectangular air-core coil for surface mounting wound in a rectangular shape can be produced.

[0013]

According to the method for manufacturing a square air-core coil for surface mounting of the present invention, when forming the corner of the square air-core coil for surface mounting, the rotation of the wire rod clamp mechanism portion in consideration of the springback amount of the wire rod. Easy to set in the corner. Therefore,
This allows the four corners to be bent at right angles.

Further, since it is not the core wire winding, it is not difficult to take out the air core coil from the core metal, and twisting does not occur. Further, there is no problem when using the heat fusion wire. Further, by changing the movement amount of the wire rod clamp mechanism portion, it is possible to easily form a square air core coil for surface mounting having different outer dimensions.

[Brief description of drawings]

FIG. 1 is a perspective view of a surface-mounting rectangular air-core coil manufactured by a manufacturing method of the present invention.

FIG. 2 is an explanatory view of a method for manufacturing a square air core coil for surface mounting of the present invention.

FIG. 3 is an explanatory diagram of a method for manufacturing a square air-core coil for surface mounting of the present invention.

FIG. 4 is an explanatory view of a method for manufacturing a square air core coil for surface mounting of the present invention.

FIG. 5 is an explanatory view of a method for manufacturing a square air core coil for surface mounting of the present invention.

FIG. 6 is an explanatory view of a method for manufacturing a square air core coil for surface mounting of the present invention.

FIG. 7 is an explanatory view of a method for manufacturing a square air core coil for surface mounting of the present invention.

FIG. 8 is an explanatory view of a method for manufacturing a square air core coil for surface mounting of the present invention.

FIG. 9 is a plan view of a surface-mounting rectangular air-core coil made by a conventional cored bar winding method.

FIG. 10 is a front view of a square air-core coil for surface mounting, which is obtained by crushing and flattening a conventional air-core coil wound in a circle.

[Explanation of symbols]

 21 wire guide 22 wire 25 wire clamp mechanism

Claims (1)

[Claims] 1. A wire rod clamp mechanism portion holds a wire rod and pulls it out to a predetermined position, and the mechanism portion is moved to about 90 degrees at the predetermined position.
By repeating the first step of forming one side of the rectangular air-core coil by rotating the wire, releasing the holding state by the wire rod clamp mechanism portion, and moving the clamp mechanism portion to the position for holding the wire rod. A method for manufacturing a square air-core coil for surface mounting, comprising forming each side of the square air-core coil in sequence.