JPS60208821A - Manufacture of hollow-core coil - Google Patents

Abstract

PURPOSE:To isolate a coil sufficiently from the level of molten solder, by forming a coil as an intermediate product having lead ends extending long from the coil. CONSTITUTION:An end of a metallic wire 6 is formed into a coil with a smaller number of turns than that of a final diameter as desired. The coil 11, 12 thus formed is cut off from the end of the metallic wire 6. The lead ends 12 and 22 of the cut-off coil 11, 12 are plated with solder. The soldered lead ends 12 and 22 are further wound to form a coil 1 having a final number of turns. In such a manner, the coil 11, 12 can be isolated sufficiently from the level of molten solder 7, so that no problem is caused in the solder plating treatment even if the level has variations.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing an air-core coil used in a tuner of a television receiver or the like.

FIG. 1 shows an example of an air-core coil, where 1 is the air-core coil and 2 is its lead end. The air core coil 1 has a second
As shown in the figure, the lead ends 2 are inserted into the through holes 4 of the printed board 3 and soldered 5. In order to ensure that the soldering 5 is performed smoothly and reliably, the lead ends 2 are coated with a resin coating in advance. It is necessary to remove it and perform solder plating.

Conventionally, as shown in FIG. 3, the coil 1 is formed by winding the end of the metal wire 6 with a winding machine to a desired final number of turns (FIG. 3(a)), and the formed coil 1 is then turned into a wire. 6, the lead end 2 of the separated coil 1 is immersed in molten solder 7 to remove the M fat coating and solder plating (FIG. 4(C)), or As shown in the figure, the metal wire 6 is passed through the molten solder jet 8 in predetermined lengths to remove the resin coating and solder plate the part 6a (Fig. 4(a)), and then the wire 6 is passed through the molten solder jet 8. The coil 1 is shaped using a winding machine so that the solder plated part 6a is exactly on the lead end 2 part of the coil 1 (see figure (b)).
The air-core coil 1 was manufactured by separating the coil from the coil (FIG. 3(C)).

By the way, with the recent miniaturization of electronic devices and the increase in the packaging density of electronic circuits, the air-core coil 1 has changed from the conventional mounting structure as shown in FIG. 2 to the lower edge 1a of the coil 1 as shown in FIG. The printed board 3 is now attached in a state where it is in contact with it, and the thickness of the printed board 3 tends to be reduced. If a mounting structure as shown in FIG. 5 is to be adopted, it will be necessary to shorten the lead end 2 of the coil 1 and solder plate it to near its root. However, in the conventional method shown in FIG. 3, since the molten solder 7 comes into contact with the lower edge 1a of the coil during solder plating, it is impossible to perform solder plating to the base of the lead end 2. Even if the method of immersing the lead end 2 obliquely in the molten solder 7 as shown in , there is a risk that the coil 1 will come into contact with the molten solder 7 due to fluctuations in the liquid level of the molten solder 7 or fluctuations. As a result, the lead ends 2 cannot be sufficiently plated, and assembly to the printed board 3 is sometimes difficult.

In addition, in the conventional method shown in FIG. 4, the lead end 2 can be shortened and the base can be solder plated, but since the solder plating is performed before winding, the solder plated portion 6a is attached to the wire guide of the winding machine, etc. or the solder plated part 6
Errors in the spacing of the plated portion 6a accumulate and the plated portion 6a comes off from the lead end 2 of the coil 1 being molded, so this must be corrected, resulting in poor reliability of the device and poor structure. It has the disadvantage of being complicated, and also has the disadvantage of large losses in solder plating, such as large deterioration of the solder.

This invention solves the problems of the conventional method as described above,
The purpose of this invention is to provide a more rational method that allows solder plating to be performed up to the base of the lead end 2.

That is, as shown in FIGS. 7 and 8, the method for manufacturing an air-core coil of the present invention includes a first step (A) of forming the end portion of the metal wire 6 into a fill shape with a number of turns smaller than the desired final number of turns.
and a second step (B) of separating the formed coil 11.21 from the end of the metal wire 6, and the separated coil 1.
1.3rd step to solder plate the lead end 12.22 of 21.
Step (C) and solder plated lead ends 12, 22
This process consists of a fourth step (D) of further winding the coil 1 to form the coil 1 having the final number of turns.

In the embodiment shown in FIG. 7, the number of turns of the coil 11 as an intermediate product is two times less per part than the number of turns of the fill 1 as the final product. That is, in step (A), a coil 11 is formed as an intermediate product with a number of turns 1/2 times smaller than the desired final number of turns using a winding machine, and in step (I3), this is cut from 9 parts of the wire rod 6 to form a coil 11 known in the art. The solder plating device is then delivered to the handling head of the solder plating equipment. The handling head of the solder plating apparatus has a guide pin 9 and fingers 10 as shown in FIG. 9 (the structure of this handling head 14 itself is known).
The coil 11, which is an intermediate product, has a guide pin 9 inserted into its air core, and is held in a state where it is held between fingers 10 with the lead ends 12 facing in a predetermined direction. In this state, the coil 11 is transferred to the upper part of the molten solder tank, the handling head 14 is rotated 90 degrees, one lead end 12a is immersed in the molten solder 7, and the handling head 18 is immersed in the molten solder 7.
The other lead end 12b is immersed in the molten solder 7 by rotating it 0 degrees (FIG. 7(C)), and then the lead end 12 is wound 90 degrees around the guide pin 9 (FIG. 7(D)). )
) Obtain coil 1 as a final product.

Step (D) of winding the lead end 12 around the guide pin 9
There are various ways to achieve this, examples of which are shown in FIGS. 10 to 14. The method shown in FIG.
After performing the plating process in step 2, the coil 11 is passed between the guide rollers 15 and 15, and J=
, = the lead ends 12 are bent at 90 degrees. In this case, the bent lead ends are slightly returned to the light due to the pack ring phenomenon, so the guide roller 15
The distance between the coils 11 and 15 is narrower than the outer diameter of the coil 11, and the guide rollers 15 and 15 are elastically expanded.
It is best to have a structure that allows the passage of.

In FIG. 10, 16 is an arm that supports the guide roller 15 so as to be able to vibrate freely, 17 is a stopper that defines the interval between the rollers 15 and 15, and 18 is a compression spring that biases the arm 16 against the stopper 17. It is.

In the case shown in FIG. 11, the pressing bodies 19 and 20 are advanced from above and both sides of the coil 11.
Reference numeral 23 in Figure 0, which bends the lead end 12 as shown in (c,), is a driving device such as a solenoid or a pneumatic cylinder.

What is shown in FIGS. 12 and 13 is the guide pin 9.
The pins 24 and 25, which rotate in opposite directions about the axis of the coil 11, are advanced toward the coil 11 held in the handling head 14, and by rotating the pins 24 and 25, the lead end 12 is bent. The 12th
The figure shows a side view of the device, and FIG. 13 shows its operation. In FIG. 12, 26 is a machine frame, 27 is a pneumatic cylinder that advances and retreats the machine frame 26 toward the no. A sleeve 30 is rotatably fitted into the sleeve 29, 31 and 32 are pinions fixed to the sleeves 29 and 30, respectively, and 33 and 34 are fitted to the machine frame 26. Pneumatic cylinders 35 and 36 are racks fixed to the rod ends of pneumatic cylinders 33.34 and meshing with pinions 31.32, respectively, and pins 24.25 are fixed to the tips of sleeves 29.30, respectively. has been done. That is, after operating the pneumatic cylinder 27 to advance the pin 24.25 toward the handling head 14, the pneumatic cylinder 33.34 is operated to rotate the pin 24.25, thereby moving the lead end 12. is bent as shown in FIGS. 13(a) and 13(b).

In the device shown in FIG. 14, a roller 37 is advanced toward the coil 11 held by the handling head, and the handling head is rotated left and right by a predetermined amount, thereby bending the lead ends 12 one by one. It is.

In the method shown in FIG. 14, since an asymmetrical force acts on the coil held by the handling head, the gripping force by the fingers 10 of the handling head 14 is increased to prevent the coil 11 from rotating around the guide pin 9. It is necessary to

In the embodiment shown in FIG. 8, the number of turns of the coil 21 as an intermediate product is approximately 300 degrees smaller than the number of turns of the coil 1 as the final product. If you do this,
There is an advantage that both lead ends 22 can be plated in one operation in step (C,). The bending angle of the lead end 22 in the step (D) after solder plating is larger than that of the first embodiment, but if a method such as the one shown in FIG. 13 is adopted, there will be no problem even if the bending angle is large. do not have.

If the above-regulated method of the present invention is adopted, the lead end 12.2 when the lead end is immersed in the nolander tank.
Since the coils 11 and 2 extend long from the intermediate product coils 11 and 21, the coils 11 and 12 can be sufficiently separated from the liquid level of the molten solder 7 to prevent fluctuations and oscillations in the liquid level. Since the lead end 12.22 after plating is further wound to form the lead end 2 of the coil 1 as the final product without causing any trouble in the solder plating process, the solder plating The lead end 2
It becomes possible to easily reach the root of the . Since the coil is first formed into a coil 11°21 as an intermediate product using a winding machine and then plated, there is no problem with the operation of the winding machine, and the solder-plated part is the final product of the coil. Since there is no fear of the lead end being displaced from the 2 parts of lead 1 and there is no need to inject molten solder into an, the structure of the device is simple and there is little loss of solder.

[Brief explanation of drawings]

Figure 1 is a perspective view showing an example of an air-core coil, Figures 2 and 5 are front views showing the mounting structure of the air-core coil on a printed board, and Figures 3 and 4 are conventional air-core coil manufacturing processes. FIG. 7 is an explanatory diagram showing the first embodiment of the manufacturing process of an air-core coil according to the method of the present invention, FIG. 8 is an explanatory diagram showing the second embodiment, and FIG. 9 is an explanatory diagram showing a solder plating apparatus. Perspective view showing the coil held in the handling head, No. 10
14 to 14 are explanatory diagrams showing means for forming a plated lead end into a coil with the final number of turns. FIG. 10 shows the first embodiment, FIG. 11 shows the second practical example, and 12 and 13 show the third embodiment, and FIG. 14 shows the fourth embodiment. In the figure, 1 is an air core coil, 2 is a lead end, 6 &; is a metal wire 14, 11, 21 is a coil as an intermediate product, (A) is the first process, (B') is the second process, (c) The third step is the third step, and (D) is the fourth step. Agent Patent Attorney Takao Nishi Figure 1 Figure 2 Figure 3 Figure 5 Figure 6 Travel Figure 7 Figure 7 Figure to Figure 11 (a) (b) (C) Figure 12 Figure 14 (a) ) (b) (C) Procedures (Method) 3. Person making the amendment 4.4 Agent ■ 920 Telephone 0762-23-
0417 June 6, 1980 (shipped on June 26, 1982) 6. Subject of amendment Brief description of drawings in the specification column 7
, Contents of the amendment (1) On page 10, line 13 of the specification, ``Explanatory diagram showing...
” and “Figure 7 is...” Add the following sentence.

Claims (1)

[Claims] (1) A first step of forming the end of the metal wire into a coil with a number of turns smaller than the desired final number of turns, a second step of cutting the formed coil from the end of the metal wire, and a second step of cutting the formed coil from the end of the metal wire; A method for manufacturing an air-core coil, comprising a third step of solder-plating the lead end of the coil, and a fourth step of further winding the solder-plated lead end to form a coil with the final number of turns.