JPH0883729A - Manufacture of coil part - Google Patents

Abstract

PURPOSE: To enable a large number of insulation cases to be arranged in a small space by a method wherein insulating resin is cast into the insulating cases and cured, and the joints of the insulating cases are cut off to split the insulating cases into pieces. CONSTITUTION: Insulating cases 27 are linked together with thin joints 28, and a coil main body 26 is housed in each of the insulating case 27 through its opening side. The insulating cases 27 are set in a vacuum tank, the tank is exhausted, and insulating resin 29 of epoxy resin or the like is cast into the insulating cases 27 under vacuum. After the insulating cases 27 are filled up with the resin 29, the resin 29 is cured by heating, and the joints 28 of the insulating cases 27 are cut off with a cutting edge 30 to split the insulating cases 27 into unit coil parts. By this setup, a large number of the insulating cases 27 are arranged in a small space, so that a coil part can be enhanced in productivity.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a coil component used in electronic equipment for electrical equipment, industry and consumer.

[0002]

2. Description of the Related Art A conventional method of manufacturing a coil component will be described with reference to FIGS.

First, as shown in FIG. 10, a winding 2 is wound around a bobbin 1 having a plurality of winding grooves 1b divided by a plurality of intermediate collars 1a, and the collars 1c at both ends of the bobbin 1 are wound.
The lead wire 4 of the winding wire 2 is wound around the wiring terminal 3 which is planted in the wire and connected by soldering, and the bobbin 1 is EE or EI.
The magnetic core 5 of the mold is incorporated to form a coil body 6, which is housed in an insulating case 7. The insulating case 7 is filled with an insulating resin 8 in a vacuum as shown in FIG. Manufacturing.

At the time of filling the insulating resin 8, as shown in FIG. 12, individual coil parts 11 are formed by using a casting pallet receiving jig 10 provided with a holding hole 9 having a shape slightly larger than the outer shape of the insulating case 7. The insulating case 7 was filled with the insulating resin 8. A receiving rib 7a is provided above the outer peripheral portion of the insulating case 7 and is held by a receiving jig 10 so that the receiving rib 7 floats above the lower plate 12 of the casting pallet to fill the insulating resin 8.

In the case of the insulating case 7 without such a receiving rib 7a, as shown in FIG. 13, the positioning is performed within the height of the insulating case 7.

Then, as shown in FIG. 11, the filled insulating resin 8 is heated to a predetermined temperature and hardened.

[0007]

In the above-described conventional coil component manufacturing method, the coil component 11 can be simultaneously filled in the vacuum tank for a predetermined time when the insulating resin 8 is filled.
There was a problem that the quantity was limited and productivity was lacking.

In order to improve the productivity, it is sufficient to increase the number of coil parts 11 that can be stored in the vacuum tank at one time, but it is necessary to enlarge the casting pallet, and as a result, the vacuum tank is also enlarged. It is necessary to improve the performance of the vacuum pump of the vacuum tank, and the equipment becomes large in scale, which is disadvantageous in terms of economy.

Further, it is necessary to insert and remove the coil components 11 one by one into and from the holding holes 9 of the receiving jig 10 of the casting pallet, and the holding holes 9 also have a shape larger than the outer shape of the insulating case 7. It is necessary to improve the workability of insertion and removal, so that the holding position of the insulating case 7 varies, and the insulating resin 8 spills from the insulating case 7 depending on the discharge position of the nozzle that fills the insulating resin 8.
There is a drawback that it adheres to the outside of the insulating case 7 and reduces the commercial value.

Since the receiving jig 10 is provided with the holding hole 9, it is necessary to consider the layout of the holding hole 9 and the shape of the receiving jig 10 to secure the strength of the end portion. It has been extremely difficult to increase the number of coil components 11 that can be held on the mold pallet.

As described above, conventionally, it has been difficult to provide a coil component which does not improve productivity and is inexpensive in terms of cost.

An object of the present invention is to eliminate the above-mentioned conventional drawbacks and to provide a method for manufacturing a coil component which is excellent in productivity and advantageous in cost.

[0013]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, according to the present invention, a plurality of coil bodies each having a bobbin around which a winding is wound and a magnetic core incorporated therein are housed in respective insulated case groups. Then, each of the insulating cases is filled with an insulating resin, the filled insulating resin is cured, and then the connecting portion of the insulating case group is cut to separate the individual coil parts.

[0014]

With the above method, a large number of insulating cases can be arranged in a small space, which is advantageous for filling the insulating resin in a vacuum, and the productivity can be improved and the cost can be reduced.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method of manufacturing a coil component according to an embodiment of the present invention will be described below with reference to the drawings.

First, an embodiment of the present invention will be described with reference to FIGS. In FIG. 1, a plurality of intermediate collars 2
A winding 22 such as a copper wire is wound around a bobbin 21 in which a plurality of winding grooves 21c are formed by 1a and both end flanges 21b, and a wiring terminal 23 is planted on both end flanges 21b of the bobbin 21. The lead wire 24 is wound and connected by soldering, and the coil core 26 is constructed by incorporating a magnetic core 25 made of an EE type or EI type ferrite core into the bobbin 21.

A plurality of coil main bodies 26 are housed in an insulating case 27 to which they are connected from the opening surface of the insulating case 27.
This group of insulating cases 27 is made of a resin such as polybutylene terephthalate, and is connected to an adjacent insulating case 27 by a thin connecting portion 28 at the opening surface.

The coil body 26 is housed in each insulating case 27 of the insulating case 27 having such a structure, the insulating case 27 group is set in a vacuum tank, and the insulating case 27 is vacuumed. Insulation resin 29
To fill. The reason why the insulating resin 29 is filled in a vacuum is that the inside can be surely filled and voids are not generated.

When the filling of the insulating resin 29 is completed, the insulating resin 29 is heated and hardened, and the connecting portion 28 of each insulating case 27 is cut by the cutting blade 30 to be separated into individual coil parts.

In FIG. 2, four insulating cases 27 are connected to a connecting portion 28.
FIG. 4 is a top view showing a state in which the coil bodies 26 are respectively housed in the ones connected with each other and the insulating resin 29 is filled.
FIG. 3 is an explanatory view showing the connecting portion 28 in cross section. The thickness of the connecting portion 28 is preferably thin in consideration of later cutting, but the position of each insulating case 27 is firmly determined when the insulating resin 29 is filled. The strength is required, and without this strength, the position of the insulating case 27 is misaligned when the insulating resin 29 is filled with the discharge nozzle, and accurate charging cannot be performed.

Further, the connecting portion 28 after the insulating resin 29 is cured
In order to easily and surely cut the above, a V-shaped groove 31 may be provided in advance on both sides of the center of the connecting portion 28 as shown in FIGS. This is V on either side
The groove 31 may be provided.

Further, as shown in FIGS. 6 and 7, it is possible to easily cut the connecting portion 28 by providing the connecting portion 28 with the window holes 32 at regular intervals.

Further, as shown in FIGS. 8 and 9, the connecting portion 28
Instead of providing the window holes 32 provided at the fixed intervals, the long window holes 32 and the short window holes 32 may be alternately formed.

In the above embodiment, the four insulating cases 27 are connected by the connecting portion 28.
The number can be increased to any number such as 8 pieces, 8 pieces, 10 pieces, etc., and it is preferable to select this quantity in view of the size of equipment such as a vacuum tank and economical efficiency.

Although the cutting of the connecting portion 28 has been described using the cutting blade 30, it is needless to say that the cutting can be performed by using any cutting means such as laser, water flow, polishing, cutter, and hot wire. The cutting means can be selected with reference to the finish of the cut surface and the like.

[0026]

As is apparent from the above embodiments, according to the present invention, a plurality of insulating cases for accommodating the coil body are connected by the connecting portions, so that the insulating resin can be filled using a vacuum tank or the like. A large number of insulating cases can be placed in a small space to rationalize the productivity, save the trouble of attaching and detaching to the casting pallet, the position of each insulating case becomes accurate, and the mistake of filling the insulating resin can occur. It has the effect of significantly increasing productivity and making it significantly advantageous in terms of cost as well, and is of great industrial value.

[Brief description of drawings]

FIG. 1 is a sectional view showing an embodiment of a method for manufacturing a coil component of the present invention.

FIG. 2 is a top view showing a state before being filled with the insulating resin.

FIG. 3 is a sectional view of an essential part showing a state of the connecting part.

FIG. 4 is a cross-sectional view of a connecting portion showing another example.

FIG. 5 is an enlarged sectional view of the same main part.

FIG. 6 is a top view showing still another example.

FIG. 7 is a sectional view of the connecting portion.

FIG. 8 is a top view showing still another example.

FIG. 9 is a sectional view of the connecting portion.

FIG. 10 is a top view of the conventional coil component manufacturing method before being filled with an insulating resin.

FIG. 11 is a sectional view of a coil component obtained by the same method.

FIG. 12 is an explanatory view showing a casting pallet holding the insulating case.

FIG. 13 is an explanatory view showing another conventional casting pallet.

[Explanation of symbols]

 21 bobbin 21a intermediate flange 21b both ends flange 21c winding groove 22 winding 23 wiring terminal 24 lead wire 25 magnetic core 26 coil body 27 insulating case 28 connecting portion 29 insulating resin 30 cutting blade 31 V-shaped groove 32 window hole

Claims (3)

[Claims] 1. A plurality of coil main bodies each having a magnetic core incorporated into a bobbin around which a winding is wound are housed in a group of connected insulating cases, and each insulating case is filled with an insulating resin. A method of manufacturing a coil component, which comprises curing a filled insulating resin and then cutting a connecting portion of an insulating case group to separate into individual coil components. 2. The method for manufacturing a coil component according to claim 1, wherein a V-shaped groove is previously formed on both sides or one side of the cut portion of the connecting portion. 3. The method for manufacturing a coil component according to claim 1, wherein the connecting portion is provided with window holes at regular intervals or at irregular intervals.