JPS58199509A - Manufacture of parts for electrical coil-winding device - Google Patents

Abstract

PURPOSE:To reduce the thickness of the part of a bobbin corresponding to a winding part thereby to eliminate the need for a collar attaching operation, by a method wherein simultaneously with the formation of a bobbin or collars, the collars are secured to the bobbin and vice verse. CONSTITUTION:A mold 1 is provided with a cavity for receiving a ferrite core 2 and cavities for forming collars 3a, 3b. The ferrite core 2 is placed in the mold 1 before a molten resin as a collar material is filled. The molten resin is filled in the mold 1, and after having solidified, the resin is removed from the mold 1 to obtain a winding element constituted by the ferrite core 2 having the collars 3a, 3b secured thereto. The coil wound on the core 2 has terminal lead grooves 3a', 3b'. After the resin material is removed from the mold 1, terminal pins 4a, 4b are erected on the collar 3a.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a small electric winding device such as a transformer or a choke coil.

This type of winder is equipped with a sintered ferrite core, a bobbin and a coil made of an insulating material, and is generally constructed by winding the ferrite core around the bobbin in advance and then inserting the ferrite core into the cylindrical part of the bobbin. There are many.

By the way, in such a winder, there is a gap between the bobbin thicknesses between the wound coil and the iron core, so from the point of view of improving accuracy, the thickness of the bobbin that corresponds to the winding part can be adjusted as much as possible. It is preferable to make it as thin as possible.

However, there is a limit to reducing the thickness of the bobbin formed by the mold, and if the wall thickness is thin, distortion may occur during the winding process, making it difficult to insert the core.

On the other hand, there is a winder that uses a highly insulating nickel-based ferrite core and winds the coil directly around the core, but this winder does not have many terminal pins installed at both ends of the core. An insulating flange is fixed and a terminal pin is implanted in this flange.

However, if the inner body of the winder is small, for example, the length of the iron core is 10 mm or less, the size of the flange in the planar direction is about 4 mm. The work of fixing the parts to the iron core is troublesome, and the work efficiency is very low.

The present invention was developed with the aim of solving the above-mentioned drawbacks, and at the same time as the bobbin or flange is formed, the bobbin or flange is fixed to the iron core, and the winding part is We propose a method for manufacturing wire-wound parts that reduces the thickness of the bobbin and eliminates the need to attach a flange.

Examples of the present invention will be described below.

Figure 1 is a simplified cross-sectional view of the mold for forming the flange.
This forming die 1 is provided with a die hole for placing the ferrite core 2 therein and a die hole for forming the flanges 3α and 3b.

The ferrite iron core 2 is previously placed inside the forming mold 1 as a flange member before being filled with a resin melting material, and then the forming mold 1 is filled with a resin melting material such as a phenol resin.

If the molten resin material is solidified and then die-cut, a wire-wound component with flanges 3α and 3b fixed to the ferrite core 2 is completed, as shown in FIG. In addition, in the same figure, 3α
, 3b are terminal pull-out grooves of the coil wound around the ferrite core 2, and 4α, 4b are terminal pins implanted in the flange portion 3α after die cutting.

Further, the terminal pins 4α, 4b can be fixed at the same time as the flange is formed. That is, the terminal pin 4α is placed on the forming mold 1,
A mold hole is provided to accommodate the terminal pins 4α and 4b.
These pins may be placed in the mold hole so that one end portion of b protrudes into the flange mold hole, and then the resin melting material may be filled.

Figure 3 shows an enlarged view of both ends of the ferrite core 20, showing the flange 3.
This figure shows a wire-wound type part that makes the installation of α and 3b more reliable. This wire-wound part is manufactured in the same manner as above, except that
It is preferable that the ferrite core 2 has a prismatic shape.

Figure 4 is a simplified cross-sectional view of the bobbin forming die.
This forming die 5 is provided with a die hole in which the ferrite core 2 is placed and a die hole for forming the flanges 6α and 6b, as in the above embodiment, however, in this embodiment, the ferrite core 2 The inner diameter of the mold hole is slightly larger than the thickness of the iron core 2.

With this configuration, the melted resin material filled in the forming die 5 enters around the ferrite core 2.

As a result, a film-like bobbin portion 6C is formed around the ferrite core 2 as the flanges 6g and 6b are formed.

FIG. 5 is a partially cutaway perspective view of the wire-wound part manufactured in accordance with the above embodiment, and as can be seen from this drawing, the winding portion 6C of the bobbin 6 is film-like and extremely thin. In addition, the ferrite core 2 is buried inside the bobbin 6, and the ferrite core 2 and the bobbin 6 are integrally fixed. Note that 4α and 4b are terminal pins similar to those shown in FIG. 2, and 6α and 6b are coil terminal extraction grooves.

FIG. 6 shows a modification of the embodiment shown in FIG. 4, in which the ferrite core 2 is exposed from the outer surface of the bobbin collars 6α, 6b. The figure shows a wire-wound part.

Also, in the manufacturing method shown in FIG. 1, the ferrite core 2 is the flange portion 3a, as in this modification.

It can be made to be exposed from the outer surface of 3b.

FIG. 8 shows an example of a rectangular winder component manufactured by the manufacturing method of the present invention, and FIG. 9 shows a longitudinal sectional view of the winder in which this wire-wound component is equipped with a coil.

In these drawings, 7 is a prismatic ferrite core;
8 is a bobbin having flanges 8α and 8b; 9 is a primary coil;
10 is a secondary coil, 11 is an insulating surface member provided between the primary and secondary coils, and 12 is a terminal pin.

In this winder, the ferrite core 7 and the bobbin 8 are integrally fixed, and the cylindrical portion of the bobbin 8 has a film-like thickness. Further, the stepped portion 8C formed between the coil terminal pull-out grooves 8α, 8b and the bobbin cylindrical portion is for preventing damage to the flanges 8α, 8b.

Next, FIG. 10 shows a wire-wound component manufactured using a flanged ferrite core 13, and in this wire-wound component, the core 1
3 is covered with a film-like resin material 14α, and a thick portion 14b for implanting the terminal pin 4 is formed on the outside of the flange.

FIG. 11 shows a wire-wound component manufactured in the same manner as the embodiment shown in FIG. 2
The flange portion is fixed to the iron core 2 so that α is embedded in the flange portions 3α and 3b. Further, by providing the convex portion 2α with an expression portion 2C as shown in FIG. 12, the collar portions 3α and 3b are more securely fixed. In addition, the groove part 2C
may be a circular small hole.

According to the present invention, the flange or bobbin is integrally fixed to the ferrite core at the stage of forming the flange or bobbin, so no work is required to attach the flange or bobbin. 1. The mass production efficiency of winding devices such as transformers and choke coils can be further increased. Further, since the wall thickness of the winding portion of the bobbin can be made much thinner than that of conventional products, there is an effect that the precision of the winder can be improved.

In addition, in the manufacturing method of the present invention, the ferrite core may be cylindrical or prismatic, and the shape of the bobbin collar or collar may be arbitrary.

[Brief explanation of the drawing]

The drawings show embodiments of the present invention, and FIG. 1 is a cross-sectional view schematically showing a mold for forming an insulating collar portion, and FIG. 2 is a perspective view of a winder component manufactured by the mold shown in FIG. Figure 3 is a cross-sectional view of the winding device parts with both ends of the ferrite core enlarged.
4 and 6 are simplified cross-sectional views of the bobbin forming die, FIGS. 5 and 7 are partially cutaway perspective views of winder parts manufactured using the bobbin forming die, and FIG. The figure shows a rectangular winder part manufactured according to the present invention, FIG. 8 (α)
is a front view of the winder component, FIG. 8(h) is a plan view of the component, FIG. 8(c) is a sectional view taken along line A-A in FIG. 8(α),
Fig. 9 is a longitudinal cross-sectional view of the winder, Fig. 10 is a cross-sectional view of a winder component equipped with a flanged ferrite core, and Fig. 11 shows convex portions for fixing the flanges on both end faces of the ferrite core. FIG. 12 is a sectional view of the provided winding device component, and is an enlarged view showing a convex portion on the end face of the core. 1... Flange forming mold 2... Ferrite core 3α,
3b... Flange portion 5... Bobbin forming mold 6... Bobbin 6α, 6h... Flange portion 6c... Winding portion
7°°° Ferrite core 8...Bobbin 8α, 8h
...Flame 13...Ferrite core Figure 1 Figure 3 Port ? Row 3b Figure 4 I)C N5 Figure 8-42-'m yo Figure 11

Claims (2)

[Claims] (1) Insert a sintered ferrite core into a bobbin mold and use it as a bobbin material (7) Resin f6
A method of manufacturing an electric winding device component, in which a bobbin is formed by filling scrap wood and integrally fixing it to a ferrite core. (2) A sintered ferrite core is placed inside an insulating flange forming mold, and then a melted resin material is filled as a flange member, and an electric winding is formed to form a flange that is integrally fixed to the ferrite core. Method of manufacturing wire parts.