JPH10241986A - Method for connecting coil bind-line - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent such accidents and effects as deformation, disconnection, poor insulation, sticking of foreign material, by forming the non-binding part at the tip of a coil binding terminal into umbrella shape, irradiating the non- binding part with a laser beam in the longitudinal direction, and melting the non-binding part so that a binding line is welded with the molten metal. SOLUTION: A non-binding part 4c at the tip of a coil binding terminal 4 is so formed, into umbrella shape, as to be larger in cross-section compared to a binding part 4b at the root of the binding terminal. Relating to the coil binding terminal 4, a tip part of a cylindrical rod terminal is press-worked to easily form the umbrella-like non-binding part 4c and the binding part 4b. When the binding terminal 4 irradiated with a laser beam 5 in the longitudinal direction, a focal point 5a of the laser beam 5 is near the center of the tip of the non-binding part 4c. Under the laser beam 5, the non-binding part 4c is melted toward the longitudinal direction of the terminal 4. Then, a binding line 3a and the binding part 4b of the coil binding terminal 4 are connected with a molten bonding part 4d obtained by melting the non-binding part 4c.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil used for an electromagnet, an electromagnetic relay, or the like, which is used to connect a coil wound around a coil spool to a coil terminal by a laser beam. About the method.

[0002]

2. Description of the Related Art A coil used for an electromagnet or an electromagnetic relay tends to be further reduced in size, higher in reliability and lower in price. On the other hand, coils are trying to meet demands for miniaturization, high reliability, and low cost by using a technique of connecting a stranded wire with a laser. The following method has been proposed as a method for connecting the coil binding wires by using a laser.

[0003] Japanese Utility Model Application Laid-Open No. 4-56302 (known example 1)
The method shown in FIG. 5A and FIG. 5B
A entangled recess 10 is formed at the tip of the terminal, and this coil recess 1 is formed.
While tightly winding the end 11 of the coil winding around 0,
This is a method of welding a winding by a laser beam 12 in a coil portion. In the fusion portion 14 of the binding portion 13, the binding wire is melted in the fusion portion 14 and welded to the terminal 15.

In the method disclosed in Japanese Patent Application Laid-Open No. 4-350915 (known example 2), as shown in FIG. The turning part 17b is formed. The non-wound portion 17b is irradiated with the laser beam 18 to melt the coil terminals, and the coiled wire 16 is welded with the molten metal.

As shown in FIGS. 7 (a) and 7 (b), the method disclosed in Japanese Patent Application Laid-Open No. 63-24914 (FIG. 7) shows that laser beams 20a and 20b are
Is convergently irradiated to dissolve the coating of the coil core wire end, and to weld the coil core wire end 21 to the terminal 22.

In the method disclosed in Japanese Patent Application Laid-Open No. 4-141975 (known example 4), a wire 25 is hooked on a notch 26 on at least one surface of a terminal 24 as shown in FIGS. The molten portion 27 of the terminal 23 is fused to a wire that passes through the side opposite to the side irradiated with the laser beam 26.

[0007]

A first problem of the prior art is that, in any of the known examples, since the cross-sectional area of the terminal tip is equal to that of the terminal base, when a laser beam is irradiated from the longitudinal direction of the terminal. Then, the laser beam irradiates the spool mold, the coil, and the tangled wire to melt, cut, and carbonize. This causes coil disconnection, generation of foreign matter, defective dimensions, and defective insulation. Therefore, all of the known terminals irradiate the laser beam from the direction perpendicular to the longitudinal direction of the terminal.

[0008] The second problem of the prior art is that the method of irradiating the laser beam in any of the known examples is in a direction perpendicular to the longitudinal direction of the terminal, so that there is little effect of shortening the terminal length after welding. Therefore, it is difficult to reduce the size of the coil terminal.

Known example 1 shown in FIGS. 5 (a) and 5 (b)
In order to irradiate the laser beam 12 to the entanglement recess 10 from the direction perpendicular to the terminal 15,
The length is hardly shortened. In addition, the direct binding line 13
There is also a problem of disconnection due to rapid thermal stress since the laser beam is irradiated to the laser beam.

[0010] The known example 2 shown in FIG.
Therefore, the problem of wire breakage as in the known example 1 can be prevented. However, since the laser beam 18 is irradiated from the direction perpendicular to the terminal 19, the effect of shortening the terminal length after welding is small.

A known example 3 shown in FIG.
In a and 20b, only the surface of the terminal 22 and the wire end 21 are melted, and the length of the terminal after welding does not become short.

FIG. 8 shows a known example 4 in which a laser beam 26 is used.
Is configured to melt the binding wire 25 on the side opposite to the irradiation side of
The terminal length after welding does not become shorter.

An object of the present invention is to provide a small coil which is free from accidents and influences such as deformation, disconnection, insulation failure, and adhesion of foreign matter due to laser irradiation on coil spools, coil windings, and tangled wires of the coil during laser irradiation. It is an object of the present invention to provide a method for connecting a tying wire.

[0014]

According to the connecting method of the present invention, the end of the coil winding wound on the coil spool (2 in FIG. 1) is embedded and fixed in the coil spool. In the coil block (1 in FIG. 1) which is wound around the coil binding terminal (4 in FIG. 1) and is welded to the coil binding terminal by a light beam such as a laser, non-entanglement at the tip of the coil binding terminal. The cross-sectional area (4c in FIG. 2) is formed in an umbrella shape with a larger cross-sectional area than the root of the tying terminal, and a laser beam (5 in FIG. 2) is irradiated from the longitudinal direction of the non-tied part to allow The entangled portion is melted, and the molten metal (4d in FIG. 2) ties the entangled wire (FIG. 2).
3a) is welded.

The non-entangled portion at the tip of the coiled terminal (4 in FIG. 3) is compared with the rooted portion (4b in FIG. 3) of the terminal by pressing a flat metal plate. 4c in FIG. 4 and a laser beam (5 in FIG. 4) is radiated from the longitudinal direction of the non-entangled portion to melt the non-entangled portion and tie it with the molten metal. Is welded.

The non-entangled portion at the tip end of the coil-entangled terminal (4 in FIG. 4) is formed to have a larger cross-sectional area than the root of the entangled terminal by pressing a round bar-shaped metal (see FIG. 4). 4c), a laser beam is irradiated from the longitudinal direction of the non-entangled portion (5 in FIG. 4) to melt the non-entangled portion and weld the entangled wire with the molten metal.

[0017]

Next, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 shows the first embodiment of the present invention.
The perspective view of the coil block completed by the connection method of the embodiment is shown. FIG. 2A shows a side view before connection of the coil binding terminal of the present invention, and FIG. 2B shows a side view after connection of the coil binding terminal of the present invention. FIG. 2C is a perspective view of FIG.

Referring to FIG. 1, the coil block 1 comprises:
A coil spool 2 of a molded product made of an insulator such as a synthetic resin, and a coil winding 3 wound on the coil spool
And a coil tying terminal 4 for tying and connecting the coil winding 3
And a coil external connection terminal 4a for connection to the outside. The laser beam 5 is applied from the longitudinal direction of the terminal 4.

Referring to FIGS. 2 (a) and 2 (c), the binding wire 3a at the end of the coil winding passed from the coil connecting wire 3b is fixed to the coil spool 2 embedded and fixed in the coil spool 2. It is wound around the barb 4b. The non-drop portion 4c at the tip of the coil binding terminal has a larger umbrella-shaped cross-sectional area than the binding portion 4b at the root of the binding terminal. The coil binding terminal 4 can easily form the umbrella-shaped non-binding portion 4c and the binding portion 4b by pressing the tip of the cylindrical rod terminal.

The laser beam 5 extends from the longitudinal direction of the binding terminal 4.
Is irradiated, the focal point 5a of the laser beam 5 is set near the center of the tip of the non-entangled portion 4c. The non-entangled portion 4 c is melted in the longitudinal direction of the terminal 4 by the laser beam 5. When the non-entangled portion is melted, the non-entangled portion 4c is formed in an umbrella-like shape with a larger cross-sectional area than the entangled portion 4b at the root of the entangled terminal, and the laser beam is directly applied to the entangled wire 3a. 5 is not irradiated, so that the coil tangling wire 3a, the coil tying wire 3b,
Without irradiating the coil spool 2 and the coil winding 3 with the laser beam 5, coil breakage, foreign matter generation, dimensional defects,
Accidents and effects of poor insulation can be prevented.

Referring to FIG. 2B, the laser beam 5
As a result, the binding wire is welded at the fusion fixing portion 4d of the non-binding portion 4c. For example, as a laser device,
Using a tIndex (GI) type YAG laser, a fiber diameter of 0.2 mm, a voltage of 300 V, and a pulse width of 2.5 ms
Weld at ec. Tie wire 3 made of polyurethane copper wire
a and a binding portion 4b of a coil binding terminal 4 made of phosphor bronze.
Are connected by a fusion-fixed part 4d obtained by melting the non-entangled part 4c.

Since the laser beam 5 is irradiated from the longitudinal direction of the terminal, welding can be performed in a direction to shorten the terminal length.
The size of the binding terminal can be reduced. Further, since a laser beam is irradiated from the longitudinal direction of the terminal, and the cross-sectional area of the non-entangled portion 4c at the tip is larger than the root-entangled portion 4b, a sufficient molten metal can be efficiently supplied. Strong wire joint strength and high joint reliability.

FIG. 3 is a perspective view of a second embodiment of the present invention before connecting the coil binding terminals. Referring to FIG.
The non-entangled portion 4c at the tip of the planar coiled terminal 4 is formed in a disk shape having a larger cross-sectional area than the rooted portion 4b at the root of the terminal. The coil binding terminal 4 can easily form a disc-shaped non-binding portion 4c and a binding portion 4b by pressing a flat metal.

When irradiating the laser beam 5 from the longitudinal direction of the coil binding terminal 4, the focal point 5a of the laser beam 5 is set near the center of the tip of the non-binding portion 4c. The non-entangled portion 4 c is melted in the longitudinal direction of the terminal 4 by the laser beam 5. When the non-entangled portion 4c melts, the non-entangled portion 4c
However, since the cross-sectional area is larger than that of the binding portion 4b at the root of the binding terminal and is formed in a disk shape, and the laser beam 5 is not directly applied to the binding wire 3a, the coil binding wire 3a and the coil crossing wire are formed. 3b, the coil spool 2 and the coil winding 3 are not irradiated with the laser beam 5, and the coil is disconnected and the foreign matter is generated.
Accidents and effects of poor dimensions and poor insulation can be prevented.

FIG. 4 is a perspective view of a third embodiment of the present invention before connecting the coil binding terminals. Referring to FIG.
The non-entangled portion 4c at the end of the coiled terminal of the column-shaped tied terminal 4 has a larger disk-shaped cross-sectional area than the tied portion 4b at the root of the tied terminal. The coil binding terminal 4 can easily form a disc-shaped non-binding portion 4c and a binding portion 4b by pressing a columnar metal.

The laser beam 5 extends from the longitudinal direction of the binding terminal 4.
Is irradiated, the focal point 5a of the laser beam 5 is set near the center of the tip of the non-entangled portion 4c. The non-entangled portion 4 c is melted in the longitudinal direction of the terminal 4 by the laser beam 5. When the non-entangled portion is melted, the non-entangled portion 4c is formed in a disk shape having a larger cross-sectional area than the entangled portion 4b at the root of the entangled terminal, and the laser beam is directly applied to the entangled wire 3a. 5 is not irradiated, so that the coil tie 3a and the coil tie 3
(b) Without irradiating the coil spool 2 and the coil winding 3 with the laser beam 5, accidents and effects of coil disconnection, foreign matter generation, dimensional defects, and insulation defects can be prevented.

[0027]

The first effect of the present invention is as follows:
By irradiating the coil spool, the coil, and the binding wire with a laser beam, it is possible to prevent accidents and effects of coil disconnection, foreign matter generation, dimensional defects, and insulation defects. The reason is that the non-entangled portion at the end of the coil-entangled terminal is formed in an umbrella shape with a larger sectional area than the root of the entangled terminal, and a laser beam or the like is irradiated from the longitudinal direction of the non-entangled terminal. This is because the non-tied portion is melted and the tied wire is welded with the molten metal.

The second effect is that the binding strength of the binding wire is strong,
The reliability of the joining is high. The reason is that the laser beam is radiated from the longitudinal direction of the terminal, so that the laser beam is not directly radiated to the tangled wire, and since the cross-sectional area of the terminal tip is larger than the root, sufficient molten metal can be efficiently produced. Because it can be supplied to

A third effect is that the terminal length becomes shorter after the irradiation with the laser beam, and the size of the binding terminal can be reduced. The reason is that since the laser beam is irradiated from the longitudinal direction of the terminal, welding can be performed in a direction to shorten the terminal length.

[Brief description of the drawings]

FIG. 1 is a perspective view of a coil block completed by a connection method according to a first embodiment of the present invention.

2A to 2C are a side view before connection, a side view after connection, and a perspective view before connection of the coil binding terminal of the present invention.

FIG. 3 is a perspective view showing a state before connecting a coil binding terminal according to a second embodiment of the present invention.

FIG. 4 is a perspective view before connection of a coil binding terminal according to a third embodiment of the present invention.

FIGS. 5A and 5B are a side view before connection and a side view after connection, respectively, showing a conventional embodiment.

FIG. 6 is a perspective view showing a conventional embodiment before connection.

FIGS. 7A and 7B are a perspective view and a partially enlarged view of a conventional embodiment before connection, respectively.

8 (a) to 8 (c) are a plan view before connection, a side sectional view before connection, and a side sectional view after connection showing a conventional embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Coil block 2 Coil spool 3 Coil winding 3a Tying wire 3b Coil connecting wire 4 Coil tying terminal 4a Coil external connection terminal 4b Tying part 4c Non-tying part 4d Melt fixing part 5 Laser beam 5a Focus

Claims (3)

[Claims] An end of a coil winding wound around a coil spool is wound around a coil binding terminal embedded and fixed in the coil spool, and is welded to the coil binding terminal by a laser beam or the like. In the coil block, the non-entangled portion at the tip of the coil-entangled terminal is formed in an umbrella shape with a larger cross-sectional area than the base of the coil-entangled terminal, and the laser beam is irradiated from the longitudinal direction of the non-entangled portion. Irradiating the non-entangled portion and fusing the entangled wire with the molten metal. 2. The non-entangled portion at the tip end of the coil-entangled terminal according to claim 1 is formed by pressing a flat plate-shaped metal to have a larger cross-sectional area than the root of the entangled terminal. A method of connecting a coil binding wire in which a non-linked portion is irradiated by irradiating a laser beam or the like from the longitudinal direction of the portion, and the binding wire is welded with the molten metal. 3. The non-entangled portion at the tip end of the coil-entangled terminal according to claim 1 is formed by pressing a round bar-shaped metal to have a larger cross-sectional area than the root of the entangled terminal. A method of connecting a coil binding wire in which a non-linked portion is irradiated by irradiating a laser beam or the like from the longitudinal direction of the portion, and the binding wire is welded with the molten metal.