JPH07122446A - Tabular coil with lead wire and manufacture thereof - Google Patents

Abstract

PURPOSE:To facilitate the connection of leads to the ferrite core connection terminals of a tabular coil. CONSTITUTION:A photoresist pattern is provided on the surface of an aluminium substrate and a copper film is provided by an electroplating method. A torus- shaped outside coil 21, a torus-shaped intermediate part coil 22 and a torus- shaped inside coil 23 are provided into a concentric form by copper plating and at the same time, a circular outside short ring 24 and a circular inside short ring 25 are respectively provided between the coils 21, 22 and 23. The coils and the short rings are coupled with each other by bridge parts 26a to 26d intersecting orthogonally the coils and the short rings. Both ends of the coils are respectively provided with coupling parts 21a to 23a at the bridge parts and lead wire parts 21b1 to 23b2 are provided along the coil from the coupling parts. Then, a paint film consisting of an epoxy resin is provided on the surface of the substrate by an electrodeposition painting method. The pain film is continuously provided also on the coil parts provided at narrow intervals via a conductor. When the coils are inserted in a core, the lead wire parts can be easily mounted to connection terminals of the coil by bending.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flat-plate coil with a lead wire, and more particularly to a fine-pattern flat-plate coil with a fine pattern for a rotary transformer and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, as a coil with a lead wire, for example, for a rotary transformer which is a rotary cylinder part inside a video tape recorder, 0.1 to 0.2 mmφ is used.
There is one in which a metal wire material such as the enamel wire is wound by a winding machine, fitted in the groove of the ferrite core and fixed by an adhesive. Then, both ends of the copper wire are drawn out to the back surface of the ferrite core through through holes provided in the groove, wound around the connection terminals on the back surface side, and then soldered. However, in the case of a coil using a winding wire, although handling of the lead wire is easy, it is necessary to manufacture the winding wire one by one, resulting in poor work efficiency and high manufacturing cost. Further, it is necessary to separately provide a short ring for shielding between the coils, which results in a large number of man-hours for inserting these into the ferrite core and an increase in assembly cost.

In order to solve the problems of the above-mentioned wound coil, a flat plate type coil having excellent mass productivity and a thin thickness has been considered. For example, there is one in which a copper foil is attached to a resin substrate such as polyimide, and a spiral coil and a short ring are integrally formed by photolithography and etching. This flat coil connecting lead has openings in the polyimide substrate at the lands at both ends of the coil,
It was provided by soldering the lead wire connected to the connection terminal to the exposed copper film.

Further, as another flat plate type coil, for example, as disclosed in JP-A-63-80510,
There is one in which a spiral coil is integrally formed on a metal substrate such as aluminum by the etching method or the electroplating method, and external leads are connected to both ends of the coil by wire bonding. This flat coil is
An external lead was passed through a through hole provided in the groove of the ferrite core, fixed to the groove by an adhesive applied to the groove, and then the metal substrate was removed to assemble.

[0005]

However, in the case of the former flat coil, the spiral coil and the short ring can be formed at one time, which is convenient for handling and assembling to the ferrite core. Regarding the connection of the lead wire, it is necessary to provide an opening in the insulating film and solder the lead wire to the exposed copper conductor, which causes a problem of increasing the number of steps for attaching the lead wire. There is also a problem that a dedicated expensive terminal component is required for attaching the lead wire and a design change of the ferrite core for the winding coil, which is widely used at present, is required.

Further, in the case of the latter flat plate type coil,
Since the substrate can be removed only after the coil is bonded to the ferrite core, there is a problem that the handling is restricted. In addition, when wire bonding is performed, it is necessary to keep the copper surface of the coil clean, which is a problem in terms of process control. DISCLOSURE OF THE INVENTION The present invention is intended to solve the above-mentioned problems, and is a flat plate coil that is manufactured at low cost and that can easily and reliably connect a lead wire of a coil to a connection terminal such as a ferrite core. It is an object to provide a manufacturing method thereof.

[0007]

In order to achieve the above object, the structural feature of the invention according to claim 1 is that the spirally wound membrane conductor coil and the planar shape by covering the membrane conductor coil are provided. An insulating support film that is supported and fixed to a pair of connecting wire portions that are integrally connected to both ends of the film conductor coil and that are provided in substantially the same plane as the film conductor coil, and that are integrally connected to each connecting wire portion. The lead wire portion extending a predetermined length along the membrane conductor coil is provided.

Further, the structural feature of the invention according to claim 2 is that in the flat plate coil with lead wire according to claim 1, the connecting portion of the membrane conductor coil and the lead wire portion to the connecting wire portion is The line width is continuously widened so that both side edges of the connecting portion are curved.

Further, the structural feature of the invention according to claim 3 is that in the flat plate type coil with lead wire according to claim 1 or 2, the lead wire portion is formed in a zigzag shape. .

Further, the structural feature of the invention according to claim 4 is that the spirally wound film conductor coil is connected to the connecting wire part and the connecting wire part connected to both ends of the film conductor coil. A conductor film forming step of providing a linear conductor film forming a lead wire portion extending along the same film conductor coil; an insulating support film forming step of providing an insulating support film on the substrate and covering at least the film conductor coil; The substrate removing step of removing the substrate and the lead wire portion bending step of bending the lead wire portion at the boundary of the connecting line are provided.

[0011]

In the invention according to claim 1 configured as described above, since the spirally wound membrane conductor coil is covered with the insulating support film and integrally formed in a plane, mass production is achieved. It is excellent and provided at a low price. Also,
Since it is formed thin, it can be easily attached to a ferrite core or the like, and the thickness of the ferrite core can be reduced. Further, since the lead wire portions are integrally provided at both ends of the membrane conductor coil via the connecting wire portions, it is not necessary to separately assemble the lead wire portions. Then, when the membrane conductor coil is inserted into the ferrite core or the like, the lead wire portion can be easily attached to the connecting terminal by bending the lead wire portion from the boundary of the connecting wire portion. As a result, the flat plate coil can be easily manufactured and attached to the ferrite core or the like easily and inexpensively, so that a component such as a rotary transformer using the same can be inexpensively and reliably provided.

Further, in the invention according to claim 2 configured as described above, the line width of the connecting portion of the membrane conductor coil and the lead wire portion to the connecting wire portion is continuously widened and both sides of the connecting portion are expanded. By forming the edge into a curved shape, the bent portions of the membrane conductor coil and the lead wire portion can be bent gently instead of at an acute angle when the lead wire portion is bent and connected to a connection terminal such as a ferrite core. As a result, there is no risk of cracks or the like occurring in the bent portion, and the reliability of the flat plate type coil is improved. Also, due to the increased strength of the bent portion, the flat coil may be handled slightly rough, and therefore the winding of the lead wire portion around the connection terminal and the soldering work etc. can be performed more quickly and easily. You can

Further, in the invention according to claim 3 configured as described above, when the lead wire portion of the flat plate type coil with lead wire is formed in a zigzag shape, the lead wire portion is formed in an arc shape. In comparison, since it does not have a bending tendency, the lead wire portion can be easily straightened with bare hands when it is inserted into a through hole such as a ferrite core. Further, by making the zigzag shape straight, the length of the lead wire portion can be made longer than that in the case of the arc shape. As a result, the lead wire portion can be easily inserted into the through hole of the ferrite core or the like, and the winding and soldering work of the lead wire portion around the connection terminal can be performed faster.

Further, in the invention according to claim 4 configured as described above, the spirally wound membrane conductor coil is formed on the substrate, the connecting wire portion is connected to both ends of the coil, and the same film conductor coil is continued to the connecting wire portion. A linear conductor film forming a lead wire portion extending along the substrate is integrally provided, and an insulating support film is provided on the substrate to cover at least the film conductor coil. Then, when the substrate is removed, the insulating support film supports the membrane conductor coil in substantially the same plane. Further, after the substrate is removed, the lead wire portion is bent at the boundary of the connecting wire, whereby the flat plate type leaded coil according to any one of claims 1 to 3 can be obtained.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 schematically shows a part of a rotary transformer component T which is a rotary cylinder component for a video tape recorder using a flat plate coil with leads according to the first embodiment. The rotary transformer component T is provided with a disk-shaped ferrite core 10 and a leaded flat plate coil 20 (hereinafter, referred to as a flat plate coil) inserted in a groove of the ferrite core 10.

As shown in FIG. 2, the ferrite core 10 has a donut disk shape having an outer diameter of 35 mmφ × an inner diameter of 12 mmφ × a thickness of 2 mm, and has a wide outer groove 11a, an intermediate groove 11b and an inner groove 11a for coil insertion on the surface side. A side groove 11c is provided. Between the outer groove 11a and the intermediate groove 11b and the intermediate groove 11b
Between the inner groove 11c and the inner groove 11c, an outer groove 12a and an inner groove 12b for inserting a short ring having a narrow width are provided.
Further, on the front surface side, two sets of grooves 13a each orthogonal to each other and linear between the outer groove 11a and the inner groove 11c and having a narrow width are provided.
1, 13a2 and 13b1, 13b2 are provided. A through hole 14a is provided at the intersection of the outer groove 11a and the groove 13a1 to allow the lead wire portion to pass through on the back side. Similarly, at the intersection of the intermediate groove 11b and the groove 13a2, the through hole 14
b is provided, and a through hole 14c is provided at the intersection of the inner groove 11c and the groove 13b1. Ferrite core 1
On the back surface side of 0, as shown in FIG.
A pair of rod-shaped connection terminals 1 is provided on both sides of 14b and 14c.
5a, 15b and 15c are mounted vertically.

The flat coil 20, as shown in FIG.
An annular outer coil 21, an intermediate coil 22, and an inner coil 23 are concentrically arranged. Each coil 21-2
3 is 6 rings (only 3 are shown in FIG. 3 for convenience)
Is formed by arranging in a spiral pattern at a fixed pitch,
Both ends of the ferrite core 10 have through holes 14a,
A pair of connecting portions 21a, 22a, 23a extending slightly in the radial direction are provided at positions corresponding to 14b and 14c. At the tips of the connecting portions 21a to 23a, a pair of lead wire portions 21b1 and 21b2 extending further in the circumferential direction,
22b1, 22b2 and 23b1, 23b2 are provided. An outer short ring 24 and an inner short ring 25 are disposed between the outer coil 21 and the intermediate coil 22 and between the intermediate coil 22 and the inner coil 23 to magnetically shield the coils. Each coil 21-2
3 and the short rings 24, 25 are bridge portions 26a, 26b and 26 provided at positions orthogonal to each other along the connecting portions 21a to 23a which are the lead wire lead-out positions.
c, 26d.

The bridge portions 26a to 26d are, as shown in FIG. 4, (hereinafter, the portion 26b will be described) a bar 24b extending vertically inward and outward from the short ring 24 and a bar 21c extending inward from the outer coil 21. A gap is provided between the connecting portions 22a extending outward from the intermediate coil 22, and reinforcing bars 21c1 and 22a1 are provided on both sides of the bar 21c and the connecting portion 22a. Then, the coils 21 to 23 and the lead wire portions 21b1 to 23b
2, short ring 24, 25 and bridge portion 26a
26d are integrally supported by a paint film 31 or a photoresist film 32 formed by an electrodeposition coating method, as shown in FIG. However, when providing a photoresist film,
Do not install on the lead wire section.

Next, the manufacturing process of the flat coil with lead wire will be described with reference to the partial sectional view shown in FIG.
First, a photoresist film 51 is applied to both surfaces of an aluminum substrate 50 having a thickness of 0.1 mm, and a predetermined coil pattern forming portion of the photoresist film 51a on the front surface side is removed by photolithography (see FIG. 7A). The photoresist film 51b on the back surface is left as it is (see FIG. 7A). Next, a copper pyrophosphate solution is used as a plating solution, and a copper plating film 52 having a thickness of 60 μm and a width of 120 μm is provided on the exposed aluminum portion 50a by electroplating (see FIG. 7B).

A modified epoxy paint is applied to the aluminum substrate 50 provided with the copper plating film 52 by an electrodeposition coating method to form a paint film 31. At this time, the coating material is deposited on the surface of the copper plating film 52 which is a conductor and does not directly adhere to the photoresist film 51a which is an insulator. Here, the portions of the copper plating film 52 with a small interval are connected as a result of the lateral spread of the coating film 31 (FIG. 7C).
reference). That is, the coils 21 to 23 and the lead wire portion 2
The space between 1b1 to 23b2, the short rings 24 and 25, and the bridge portions 26a to 26d is integrally supported by the paint film 31, as shown in FIG. Then, the paint film 31 is hardened by heat treatment and its strength is increased. This paint film 31 has a soldering temperature of 180 ° C.
It dissolves to some extent. Next, the photoresist film 51
By removing a and 51b and further removing the aluminum substrate 10 with a hot alkaline solution, a flat plate type coil with a lead wire is obtained (see FIG. 7D).

The flat plate type coil 20 formed as described above.
6, each lead wire portion 21b1 to 23b2 was bent at a right angle to the opposite side of the surface on which the paint film 31 was formed, inserted into the through holes 14a to 14c of the ferrite core 10, and the adhesive was applied. The coil portions 21 to 23, the short rings 24 and 25, and the bridge portions 26a to 26d are aligned and inserted into the respective grooves of the ferrite core 10. Then, the lead wire portions 21b1 to 23b2 passed through the back side of the ferrite core 10 are wound around the connection terminals 15a to 15c and further soldered to obtain a rotary transformer component.

As described above, in the flat-plate coil 20 according to the present embodiment, the spirally wound membrane conductor coil is covered with the insulating support film and integrally formed in a flat plane, so that mass productivity is improved. It is excellent and cheaply provided. Further, since the flat plate type coil is very thin, it can be easily attached to the ferrite core, and the thickness of the ferrite core can be made thin, so that the rotary transformer component can be miniaturized. Further, since the lead wire portion is integrally provided at both ends of the membrane conductor coil via the connecting wire portion, it is not necessary to separately provide the lead wire portion, so that the manufacturing cost can be significantly reduced. When inserting the membrane conductor coil into the ferrite core, the lead wire portion can be easily attached to the connection terminal on the back side through the through hole of the ferrite core by bending the lead wire portion from the boundary of the connecting wire portion. it can. Therefore, a rotary transformer component using the flat plate type coil can be provided at low cost and with high reliability. Further, since the coil portion and the lead wire portion are integrated, there is no need to change the design of the ferrite core for the winding coil, which is widely used at present, which is convenient.

Next, a second embodiment of the present invention will be described with reference to the drawings. FIG. 8 is a partial cross-sectional view schematically showing the manufacturing process of the flat-plate coil with lead wire according to the second embodiment. Here, the formation of the photoresist films 51a and 51b and the copper plating film 5 shown in FIGS.
The formation of 2 is the same as in the first embodiment. After providing the copper plating film 52, photoresist films 51a and 51b
Are removed (see FIG. 8C). Then, a photoresist film 32 is newly provided on the front surface side, the photoresist film 32 of only the coil portion, the short ring portion and the bridge portion is left by a photolithography method, and the photoresist film 32 is cured by heat treatment (see FIG. 8D). . Then, the aluminum substrate 10 is removed with a hot alkaline solution to obtain a flat plate type coil with a lead wire (FIG. 8E).
reference). According to the present embodiment, the electrodeposition coating device is unnecessary, and the patterning can be performed only by the photolithography process, and the manufacturing process is simplified.

Next, a third embodiment of the present invention will be described. In the flat-plate coil 20 according to the third embodiment, the connecting portion K of the coil portion 22 and the lead wire portions 22b1 and 22b2 to the connecting portion 22a is continuously expanded in line width as shown in FIG. Both side edges are formed in a curved shape. The other parts are the same as those in the first embodiment, so the description thereof will be omitted. By configuring the connecting part of the lead wire part to the connecting part as described above, when the lead wire part is bent and used, the root part of the lead wire part does not bend at an acute angle, and it has a smooth curved shape. Can be bent. Therefore, it is possible to reliably prevent the strength or damage of the lead wire portion at the root portion, and it is possible to enhance the reliability of the lead wire portion. Further, since the bending position of the lead wire portion can be arranged on the substantially center line of the bridge portion, the lead wire portion can be easily inserted into the through hole 14b of the ferrite core 10 only by gently bending the lead wire portion. it can. Accordingly, since the size of the through hole can be reduced, the electromagnetic characteristics of the rotary transformer can be improved.

Next, a fourth embodiment will be described. Fourth
As shown in FIG. 10, in the flat-plate coil 20 according to the embodiment, the lead wire portions 21b1 to 23b1 are bent in a zigzag shape instead of an arc shape. The curvature of each zigzag waveform is preferably 1.5 times or more the lead wire width. If it is less than 1.5 times, cracks are likely to occur in the zigzag portion when the lead wire portion is straightened. The other parts of the flat-plate coil are the above-mentioned first
The description is omitted because it is similar to the embodiment. Since the lead wire part is bent in a zigzag manner as described above, when the lead wire part is straightened, it can be performed very easily with bare hands as compared with the case of a single arc shape. Since the length of the part can be increased, the handling becomes easier. Therefore, the lead wire portion can be easily passed through the through hole of the ferrite core or the like, and the winding and soldering work of the lead wire portion around the connection terminal can be performed easily and quickly.

The shape and material of the coil and the like are not limited to those shown in each of the above embodiments, but may be appropriately changed and used according to the application of the flat plate type coil.

[Brief description of drawings]

FIG. 1 is a perspective view schematically showing a rotary transformer component to which the present invention is applied.

FIG. 2 is a plan view showing a front surface side of a ferrite core which is a constituent member of the rotary transformer component.

FIG. 3 is a front view schematically showing a flat-plate coil according to an embodiment of the present invention.

FIG. 4 is an enlarged front view showing a bridge portion of the flat plate type coil.

FIG. 5 is a front view showing a part of the flat-plate coil in detail.

FIG. 6 is a perspective view showing a state in which a lead wire portion of the flat plate coil is bent.

FIG. 7 is a cross-sectional view showing a manufacturing process of the flat plate coil.

FIG. 8 is a cross-sectional view showing the manufacturing process of the flat coil according to the second embodiment.

FIG. 9 is an enlarged front view showing in detail a bridge portion of a flat-plate coil according to a third embodiment.

FIG. 10 is a front view showing a flat-plate coil according to a fourth embodiment.

[Explanation of symbols]

10; Ferrite core, 14a to 14c; Through hole, 15
a to 15c; connection terminal, 20; flat plate coil, 21; outer coil, 22; middle coil, 23; inner coil, 2
1a to 23a; connecting portion, 21b1 to 23b2; lead wire portion, 23c; winding wire, 24; outer short ring, 2
5: inner short ring, 24a; permanent magnet, 25; rotating shaft, 26a to 26d; bridge part, 31; paint film, 3
2; photoresist film, 50; aluminum substrate, 51
a, 51b; photoresist film, 52; copper plating.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Hideki Shinohara 3600 Amitsu, Kotomaki, Koichi City, Aichi Tokai Rubber Industry Co., Ltd.

Claims (4)

[Claims] 1. A spirally wound membrane conductor coil, an insulating support film for covering the membrane conductor coil to support and fix it in a plane, and a membrane conductor coil integrally connected to both ends of the membrane conductor coil. A pair of connecting wire portions provided in substantially the same plane as the coil, and a lead wire portion integrally connected to each of the connecting wire portions and extending for a predetermined length along the membrane conductor coil are provided. A flat plate coil with a characteristic lead wire. 2. The flat-plate coil with a lead wire according to claim 1, wherein the line width of the connecting portion of the membrane conductor coil and the lead wire portion to the connecting wire portion is continuously widened, and the same connection is made. A flat plate type coil with a lead wire characterized in that both side edges of the portion are curved. 3. The flat-plate coil with a lead wire according to claim 1 or 2, wherein the lead wire portion is formed in a zigzag shape. 4. A spiral wound film conductor coil, a connecting wire portion connected to both ends of the same film conductor coil, and a lead wire portion connected to the connecting wire portion and extending along the same film conductor coil on a substrate. A conductor film forming step of providing a linear conductor film constituting the insulating film; an insulating support film forming step of forming an insulating support film on the substrate to cover at least the film conductor coil; a substrate removing step of removing the substrate; And a lead wire portion bending step of bending a wire portion at a boundary of the connecting wire.