JPH07297064A - Manufacture of resin mold ignition coil - Google Patents

Abstract

PURPOSE:To provide a method of manufacturing a resin mold ignition coil whose primary cord can be connected after resin is cast. CONSTITUTION:A primary coil and a secondary coil which are wound around the outer periphery of a core via a bobbin are built in a case, in which resin is cast-molded from the aperture to embed the coils. Both ends of the primary coil are connected with the respective primary coil terminal metal fittings 7 having press terminal insertion holes 7d. The metal fittings 7 are previously retained by bobbin flange 2a in the case before resin is cast-molded. At the time of cast molding of resin, each of the primary coil terminal metal fittings is also embedded. A press terminal 15 is previously connected with the end portion of each primary cord 14 to be connected with each of the primary coil terminal metal fittings 7. Before resin is cured, each of the press terminals 15 is forcibly inserted into the press terminal insertion hole 7d of the corresponding primary coil terminal metal fitting 7 in the resin, and connected with the hole.

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 resin mold type ignition coil in which each coil is molded with resin in a case.

[0002]

2. Description of the Related Art In a conventional resin-molded ignition coil of this type, the primary coil is directly soldered and connected to both ends of the winding start and end of the primary coil or the collar of the primary coil bobbin. Part supports two primary coil terminal fittings, the end of the primary coil on the side corresponding to these primary coil terminal fittings and the end of the primary cord are connected by soldering, and each primary cord is inside the case. It is pulled out of the resin cast into.

In any case, each primary cord should be submerged in the resin inside the case so that the connecting portion between the end of the primary coil and the end of the primary cord does not come out of the resin inside the case. ing. This is to prevent the leak from the exposed connecting portion if the connecting portion is exposed to the outside of the resin in the case.

Such a resin mold type ignition coil is
It is often used for outboard motors and other equipment that requires waterproofing and vibration resistance.

Such a resin mold type ignition coil is
A primary coil wound around the outer circumference of the iron core via a bobbin and 2
The secondary coil is assembled in a case, and a resin is cast into the case from its opening to embed the primary coil and the secondary coil for manufacture. In this case, the end of the primary coil and 1
Since the connection part with the end of the next cord needs to be embedded in the resin, it was necessary to connect the primary cord to the primary coil before casting the resin.

[0006]

However, if the primary cord is connected to the primary coil before casting the resin,
The resin is scattered on the primary cord during casting, and the primary cord is contaminated with the resin. If the primary cord is long, the primary cord cannot be stored in the vacuum casting chamber. there were. Further, if the primary code is long, there is a problem that the workability of assembly is poor.

An object of the present invention is to provide a method of manufacturing a resin mold type ignition coil in which the primary cord can be connected after the resin is cast.

Another object of the present invention is to provide a method of manufacturing a resin mold type ignition coil which can surely connect the primary cord after the resin is cast.

Another object of the present invention is to provide a method of manufacturing a resin-molded ignition coil which can support the primary coil terminal fitting without any hindrance.

Another object of the present invention is to provide a resin-molded ignition coil capable of protecting the drawn-out portion of the primary cord from the resin even if the primary cord is connected after the resin is cast. It is to provide a manufacturing method.

[0011]

According to the present invention, a primary coil and a secondary coil wound around a bobbin around an outer periphery of an iron core are incorporated in a case, and a resin is poured into the case through an opening thereof. A method of manufacturing a resin-molded ignition coil, which is manufactured by embedding the primary coil and the secondary coil in a mold, is an object of improvement.

In the present invention, both ends of the primary coil are connected to respective primary coil terminal fittings having press-fit terminal insertion holes, and these primary coil terminal fittings are preliminarily placed in the case before the resin is cast. It is supported by a support. When casting the resin, the respective primary coil terminal fittings are also embedded. Press-fit terminals are connected in advance to the ends of the respective primary cords connected to the respective primary coil terminal fittings. Before the resin is cured, the press-fit terminals are press-fitted into the press-fit terminal insertion holes of the corresponding primary coil terminal fittings in the resin through the openings of the case so that the press-fit terminals correspond to each other. To each of the primary coil terminal fittings.

In this case, a plurality of saw-toothed protrusions may be provided on the inner circumference of the press-fitting terminal insertion hole in the primary coil terminal fitting so as to be pressed against the outer circumference of the press-fitting terminal.

Further, the support body of the primary coil terminal fitting is used as the collar portion of the bobbin, and the collar portion is provided with a press-fit terminal escape hole corresponding to the press-fit terminal insertion hole of the primary coil terminal fitting. You can

A reinforcing tube may be fitted in advance to the primary cord, the press-fit terminal may be inserted into the resin, and then the base end portion of the reinforcing tube may be embedded in the resin.

[0016]

In this way, the primary coil terminal fitting is provided with the press-fitting terminal insertion hole, and the primary coil terminal fitting is previously supported by the support body in the case before the resin is cast. Later, press-fit terminals that are connected in advance to the end of the primary cord are pressed into the press-fit terminal insertion holes of the corresponding primary coil terminal fittings in the resin before the resin hardens, and the press-fit terminals are made compatible. By connecting to the primary coil terminal metal fitting, the primary cord can be connected after the resin is cast.

In this case, if a plurality of saw-tooth projections for press-contacting the outer circumference of the press-fit terminal are provided on the inner circumference of the press-fit terminal insertion hole in the primary coil terminal fitting, these saw-tooth teeth are pressed when the press-fit terminal is press-fit. Since the protrusions bite into each other, the electrical connection between the primary coil terminal fitting and the press-fit terminal can be reliably performed even in the resin.

Further, if the support of the primary coil terminal fitting is used as the collar portion of the bobbin and a press-fitting terminal escape hole is provided in the collar portion in correspondence with the press-fitting terminal insertion hole of the primary coil terminal fitting, the press-fitting terminal escape hole is formed. It is possible to prevent the collar portion of the bobbin from interfering with the insertion of the press-fit terminal into the terminal insertion hole.

Further, a reinforcing tube is fitted in advance to the primary cord, the press-fit terminal is inserted into the resin, and then the base end of the reinforcing tube is embedded in the resin. Even if the method is to connect after casting,
It is possible to protect the lead-out portion of the next cord.

[0020]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a method of manufacturing a resin mold type ignition coil according to the present invention will be described below in detail with reference to FIGS. In this embodiment, as shown in FIG. 4, the primary coil bobbin 2 around which the primary coil 1 is wound is mounted on the outer circumference of the iron core 3. The secondary coil 4 is wound and the secondary coil bobbin 5 is attached.
Is attached to the outer circumference of the primary coil 1.

In this case, as shown in FIG. 1, two pairs of terminal metal fitting positioning projections 6 facing each other in a circular arc shape are formed on the upper edge of the collar portion 2a in the upper part of the primary coil bobbin 2. Is integrally formed in advance to project.

A primary coil terminal fitting having a linear coil terminal wire connecting portion 7a and a disc-shaped press-fit terminal connecting portion 7b integrally formed at one end thereof in the terminal fitting positioning protrusion 6 The press-fitting terminal connecting portions 7b of 7 are fitted and positioned. This primary coil terminal fitting 7 is shown in FIG.
As shown in FIG. 7, a coil terminal wire retaining portion 7c is provided at the other end of the coil terminal wire connecting portion 7a, and a press-fit terminal inserting hole 7d is provided at the center of the press-fit terminal connecting portion 7b. Has a structure in which a slit portion 7e is provided on the press-fit terminal connecting portion 7b on the opposite side.

Collar portion 2 on the upper part of the primary coil bobbin 2.
As shown in FIGS. 1 and 6, a press-fit terminal escape hole 8 is provided in advance in a corresponding to the press-fit terminal insertion hole 7d of the press-fit terminal connecting portion 7b positioned by the terminal metal fitting positioning projection 6.

When the press-fit terminal connecting portion 7b of the primary coil terminal fitting 7 is fitted into the terminal fitting positioning protrusion 6 for positioning, the coil terminal wire 1a of the primary coil 1 is previously attached to the coil terminal wire connecting portion 7a. Wrap and connect by soldering.

Numeral 9 designates a high-voltage cord-connecting cylindrical body projecting from the collar portion 2a in the upper part of the primary coil bobbin 2.
Reference numeral 0 is a screw-shaped high-voltage terminal projecting from the collar portion 2a in the high-voltage cord connection cylinder 9, and 11 is an iron core through hole provided in the collar portion 2a for inserting the iron core 3.

On the upper collar portion 5a of the secondary coil bobbin 5,
As shown in FIG. 4, the secondary coil terminal fitting 12 is provided in advance by embedding the base portion thereof at the time of molding, and after the secondary coil 4 is wound around the secondary coil bobbin 5, the secondary coil terminal fitting 12 is attached to the secondary coil terminal fitting 12. Coil terminal wire 4 of the secondary coil 4
Wrap a and connect by soldering. Although not shown, the soldered connection portion of the coil terminal wire 4a is electrically connected to the base portion of the high voltage terminal 10 by contact or soldering.

As described above, the bobbin 2 is provided on the outer periphery of the iron core 3.
The primary coil 1 and the secondary coil 4 which are wound via 5 are incorporated in the case 13. The case 13 has a bottomed structure having an opening 13a at the top, and a hole (not shown) through which the iron core 3 passes is provided at the bottom. Iron core 3
Has a length such that both ends thereof are vertically projected from the case 13 when assembled in the case 13.

As shown in FIG. 1, press-fit terminals 15 are preliminarily connected to the ends of the primary cords 14 which are respectively connected to the respective primary coil terminal fittings 7. Press-fit terminal 15
Has a constricted portion 15b behind its head portion 15a. A reinforcing tube 16 is fitted in advance to the primary cord 14.

In this state, the case 13 as shown in FIG.
A resin 17 is cast from the opening 13a into the inside by a nozzle to embed the primary and secondary coils 1 and 4 and the bobbins 2 and 5.

Before the resin 17 hardens, each press-fit terminal 15
6 through the openings 13a of the case 13 into the press-fitting terminal insertion holes 7d of the respective primary coil terminal fittings 7 in the resin 17 as shown in FIG. Connect to the coil terminal fitting 7.

After inserting each press-fitting terminal 15 into the resin 17, the base end portion of the reinforcing tube 16 is, as shown in FIG.
It is embedded in the resin 17.

When the press-fit terminal 15 is connected to the primary coil terminal fitting 7 in this manner, the connecting portion can be embedded in the resin 17. Further, the base end portion of the reinforcing tube 16 can also be embedded in the resin 17.

After that, the resin 17 is cured, and as shown in FIG.
It becomes the same figure when it is connected to the primary coil terminal fitting 7 before the casting of 7. Thereafter, although not shown, a high-voltage cord is screwed into the high-voltage terminal 10 having a screw shape in the high-voltage cord connection cylinder 9 to connect.

FIG. 7 shows another example of the primary coil terminal fitting 7 used in the present invention. In the inner periphery of the press-fitting terminal insertion hole 7d of the primary coil terminal fitting 7 of this embodiment, a plurality of serrated projections 7f for press-contacting the outer periphery of the press-fitting terminal 15 are provided.
Is projected.

As described above, when a plurality of serrated projections 7f for press-contacting the outer circumference of the press-fit terminal 15 are provided on the inner circumference of the press-fit terminal insertion hole 7d in the primary coil terminal fitting 7, the press-fit terminal is formed. At the time of press-fitting 15, the serrated protrusions 7f bite into the primary coil terminal fitting 7 and the press-fit terminal 1.
It is possible to reliably make the electrical connection with 5 even in the resin 17.

[0036]

As described above, according to the method of manufacturing the resin mold type ignition coil according to the present invention, the following excellent effects can be obtained.

In the present invention, the primary coil terminal fitting is provided with a press-fitting terminal insertion hole, and the primary coil terminal fitting is previously supported by the support in the case before the resin is cast. After the mold, the press-fit terminal that is connected in advance to the end of the primary cord is connected to the corresponding one in the resin before the resin is cured.
Since the press-fit terminal is press-fitted into the press-fit terminal insertion hole of the secondary coil terminal fitting to connect the press-fit terminal to the corresponding primary coil terminal fitting, after the resin is cast, the primary cord is connected and the connecting portion is provided in the resin. be able to. Therefore, various problems associated with the primary cord being connected to the primary coil terminal fitting before the resin is cast can be avoided.

Further, by providing a plurality of serrated projections for press-contacting the outer circumference of the press-fit terminal on the inner circumference of the press-fit terminal insertion hole in the primary coil terminal fitting, these serrated teeth are pressed when the press-fit terminal is press-fitted. The protrusions will bite in, 1
The electrical connection between the secondary coil terminal fitting and the press-fit terminal can be reliably performed even in the resin.

By using the support of the primary coil terminal fitting as the collar portion of the bobbin, and providing the press-fitting terminal escape hole in the collar portion in correspondence with the press-fitting terminal insertion hole of the primary coil terminal fitting, It is possible to prevent the collar portion of the bobbin from interfering with the insertion of the press-fit terminal into the press-fit terminal insertion hole.

A reinforcing tube is fitted in advance to the primary cord, the press-fit terminal is inserted into the resin, and the base end portion of the reinforcing tube is embedded in the resin, so that the primary cord is made into resin. Even with the method of connecting after casting, it is possible to protect the primary cord lead-out portion from the resin.

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of a main structure of a bobbin collar and an end structure of a primary cord used in a method for manufacturing a resin mold type ignition coil according to the present invention.

FIG. 2 is a perspective view showing an example of a primary coil terminal fitting used in this embodiment.

FIG. 3 is a perspective view showing a state of the primary coil terminal fitting set on the bobbin collar portion in the present embodiment.

FIG. 4 is a perspective view showing a process of incorporating an iron core, a primary coil, and a secondary coil in a case in this embodiment.

FIG. 5 is a perspective view showing a state where resin is cast into a case in the present embodiment.

FIG. 6 is a longitudinal sectional view of an essential part of an ignition coil formed by the method of this embodiment.

FIG. 7 is a perspective view showing another example of the primary coil terminal fitting used in this embodiment.

[Explanation of symbols]

 1 Primary coil 1a Coil terminal wire 2 Primary coil bobbin 2a Collar part 3 Iron core 4 Secondary coil 4a Coil terminal wire 5 Secondary coil bobbin 5a Upper collar part 6 Terminal metal fitting positioning protrusion 7 Primary coil terminal metal fitting 7a Coil terminal wire connection part 7b Press-fit terminal connection part 7c Coil terminal wire retaining part 7d Press-fit terminal insertion hole 7e Slit part 7f Serrated protrusion 8 Press-fit terminal escape hole 9 High-voltage cord connection cylinder 10 High-voltage terminal 11 Iron core through hole 12 Secondary coil terminal metal fitting 13 Case 13 13a Opening 14 Primary cord 15 Press-fit terminal 15a Head 15b Constriction 16 Reinforcement tube 17 Resin

Claims (4)

[Claims] 1. A primary coil and a secondary coil wound around a bobbin on an outer periphery of an iron core are incorporated in a case, and a resin is cast into the case from an opening portion thereof to form the primary coil. In the method of manufacturing a resin-molded ignition coil, which is manufactured by embedding the secondary coil, both ends of the primary coil are connected to respective primary coil terminal fittings having press-fit terminal insertion holes, and these primary coil terminals are connected. The metal fitting is supported in advance by the support in the case before the resin is cast, and the respective primary coil terminal fittings are also buried when the resin is cast, and are connected to the respective primary coil terminal fittings. The press-fit terminals are connected to the ends of the primary cords in advance, and the press-fit terminals are connected to the corresponding primary coil terminal fittings in the resin through the opening of the case before the resin is cured. Insert it into the press-fit terminal insertion hole. Method for manufacturing a resin mold type ignition coil, characterized by connecting the respective press-fit terminals to respectively press-fitted in the phase corresponding each primary coil terminal fitting. 2. A plurality of serrated protrusions for press-contacting the outer circumference of the press-fit terminal are provided on the inner circumference of the press-fit terminal insertion hole of the primary coil terminal fitting. 1. The method for manufacturing the resin mold ignition coil according to 1. 3. A support for the primary coil terminal fitting is a collar portion of the bobbin, and a press-fit terminal escape hole is formed in the collar portion in correspondence with the press-fit terminal insertion hole of the primary coil terminal fitting. The method for producing a resin-molded ignition coil according to claim 1 or 2, wherein 4. A reinforcing tube is fitted in advance to the primary cord, the press-fit terminal is inserted into the resin, and then the base end portion of the reinforcing tube is embedded in the resin. The method for manufacturing a resin-molded ignition coil according to claim 1, 2, or 3.