201025372 六、發明說明： 【發明所屬之技術領域】 本發明係關於一種製造一線圈總成的方法及裝置，特別是 一環形線圈總成的方法及裝置。 【先前技術】 隨著科技的發展，各式的電子裝置已成為現代化社會不可或缺 ® 的要素，由於電子裝置須由外界提供一特定電壓使其正常運作， 因此用以供應該特定電壓之相關電性元件也廣泛地被使用。上述 之電性元件係可為一電感元件’電感元件包含至少一線圈納成， 用以將由外部輸入之交流電源，藉由線圈總成的相互電性感庳， 轉換為特定之直流電源而輸出，供電子裝置正常運作及被使用。 習知一種用於電感元件之線圈總成，包含一環型鐵芯，其可為 一金屬材質，環型鐵芯用以纏繞預定圈數之銅線，造成特定之阻 ®抗，以作為電性感應作用之主要元件。上述之線圈總成其金屬材 質之環型鐵芯，需要額外藉由其他設備製造提供（例如一成型模 具）’且由於在不同的電感元件中，除了線圈總成需要形成特定的 阻抗以外’更需與其他電子零件減配合，讀供蚊之輸出電 壓。基於上述之原因，+同電感元件之線圈總成所纏繞的銅線圈 數因而產生差異’且藉⑽繞銅線之金屬環型鐵芯之尺寸也將有 所不同即母上述線圈總成需要提供特定之金屬環型鐵芯供其 纏繞鋼線’亦即需要額外準備相關之特定生產設備（例如一出成 型模具）’用以製造該金屬環型鐵芯。 3 201025372 由上述可知，習知具有金屬環型鐵芯之線圈總成，其只能供以 特定單一之線圈總成使用，而當欲生產其他尺寸之線圈總成時， 製造金屬環型鐵芯之設備無法共用，造成生產成本無法有效降 低。因此，提供一可製造各式尺寸之線圈總成的方法及設備，以 增加線圈總成應用之彈性，並同時有效控制生產成本，增加產品 市場競爭力，乃為此一業界亟待努力之目標。 【發明内容】 本發明之一目的在於提供一線圈總成的製造方法，該製造方法 可製造用以取代傳統金屬環狀鐵芯之線圈總成。 本發明之另一目的在於提供製造一線圈總成的設備，該設備包 含一繞線早元及一加熱單元。 為達上述目的，該製造方法係利用該繞線單元以纏繞一繞線組 於繞線官心上，最後藉由加熱之方式將穿置有該繞線管芯之一 套s疋型’使該套管緊密地包覆該繞線組以形成該線圈總成。 由於上述之線圈總成具有一撓性材質之管芯因此適可將該管 。f曲成環型’用以取代傳統之金屬環型鐵过。此外，繞線管 長度係依照實際繞線組之圈數多募以及具有該線圈總成的 電ί裝置之尺寸等因素而決定。藉此，於製造不同尺寸及繞線圈 數之線圈〜成時’可不必額外準備相應各不同線圈總成尺寸之金 屬哀里鐵心’藉此可增加生產效率同時降低生產成本。 :、讓本發月之上述目的、技術特徵和優點能更明顯易懂，下文 201025372 係以較佳實施例配合所附圖式進行詳細說明 【實施方式】 本發明之實施例如第i圖所示，一用以製造一線圈總成之 置1’包含一繞線單元 裝 平π la及一加熱單元lb。繞線單元Ia — 本體η及-緊固器13’緊固器13可旋轉地固定於本體，： ❹ 以失持—繞線管芯12,而本體Η具有-致動器（圖未示出），用用 以轉動緊固器13轉動，並連同轉動繞線管芯12。藉此，如第3Α 圖及第3Β圖所示，將—繞線組3纏繞於繞線管芯12上。 …單7L lb實質上係騎具有—預定外型之模具，透過—加孰 器"未示出），適以加熱穿置有繞線管芯12之一套管41，賊 （如第4圖所示）’其中繞線管芯係為可撓之材質。於本實 知例中’預定外型係、呈現—環型，撓性材質之管芯係可弯曲地容 Utl lb中。更特別地是，本加熱單元ib模具上之環型 側壁15係為可調整側壁，亦即該模具上之環型可依據線圈之尺寸 而作不同圓弧尺寸的調整，以因應不同線圈尺寸加熱套管4卜 本發明更提出一線圈總成的製作方法，如第2圖所示，第一步 驟2!係纏繞一繞線組於一繞線管芯上；其次，第二步驟a係穿 ，該繞線㈣於-套管中；最後，第三步驟_、將穿置有該繞線 官芯之該套管定型。 詳細來說，請同時參照第3A圖及第3B圖，本實施例的第一步 驟21係纏繞—·繞線組3於繞線管芯12上，更進-步來說，本實 201025372 施例係將繞線組3纏繞於長度範圍介於70-100毫米之繞線管芯12 上，其中，繞線管芯12係為一矽膠材質之可撓柱狀體，而繞線組 3較佳地由材質為銅之一金屬導線所構成，而其線徑係為34AWG (American wire gauge) ° 其次，繞線組3係由二繞線層組成，首先將前述之金屬導線纏 繞於繞線管芯12上以形成一第一繞線層31，接著於第一繞線層 31上繼續纏繞，以形成一第二繞線層33。於其他實施例中，繞線 管芯12之長度以及構成繞線組3之金屬線之材質及線徑並不以此 為限，繞線管芯12之材質亦可為其他具有撓性之高分子材料。 更詳細而言，如第3A圖所示，於纏繞繞線組3之前可先於繞線 管芯12之一第一端32環繞一膠帶36以作為定位之用，其次，藉 由繞線單元la使繞線管芯12旋轉，由繞線管芯12之第一端32 至與第一端32相對之一第二端34之一方向X纏繞一第一金屬 線，以形成第一繞線層31，第3A圖中之纏繞圈數係用於示意， 並非代表實際圈數，實際上纏繞第一金屬線（即形成第一繞線層 31)之步驟係纏繞第一金屬線約400圈於繞線管芯12上。同時， 可於第二端34環繞一膠帶36’，以界定出繞線層3之範圍。接著， 如第3B圖所示，相似地，自繞線管芯12之第二端34至與第一端 32之一方向Y(即方向X之反方向）纏繞一第二金屬線，以形成 第二繞線層33，第3Β圖中之纏繞圈數係用於示意，並非代表實 際圈數，其中纏繞第二金屬線（即形成第二繞線層33)之步驟係 纏繞第二金屬線約400圈於繞線管芯12上。 需注意的是，於本實施例中，以方向X纏繞第一金屬線於繞線 201025372 以方向Y纏繞第二金屬線於繞線管芯12，201025372 VI. Description of the Invention: [Technical Field] The present invention relates to a method and apparatus for manufacturing a coil assembly, and more particularly to a method and apparatus for a toroidal coil assembly. [Prior Art] With the development of technology, various electronic devices have become an indispensable factor in modern society. Since electronic devices must be supplied with a specific voltage to operate normally, they are used to supply the voltage. Electrical components are also widely used. The electrical component may be an inductive component. The inductive component includes at least one coil, and the externally input AC power source is converted into a specific DC power source by the mutual electrical connection of the coil assembly. The electronic device is in normal operation and used. A coil assembly for an inductive component, comprising a ring-shaped iron core, which can be made of a metal material, and the ring-shaped iron core is used to wrap a predetermined number of copper wires to cause a specific resistance to act as a sexy The main component of the role. The above-mentioned coil assembly is made of a metal ring-shaped core, which needs to be additionally manufactured by other equipment (for example, a molding die)' and because in different inductance elements, except that the coil assembly needs to form a specific impedance, It is necessary to reduce the matching with other electronic components and read the output voltage of the mosquito. For the above reasons, the number of copper coils wound by the + coil assembly of the inductive component is different, and the size of the metal ring core wound by the (10) copper wire will also be different, that is, the above-mentioned coil assembly needs to be provided. The specific metal ring core is used to wrap the steel wire 'that is, it is necessary to additionally prepare the relevant specific production equipment (for example, a molding die) to manufacture the metal ring core. 3 201025372 It can be seen from the above that a coil assembly having a metal ring type iron core can be used only for a specific single coil assembly, and when a coil assembly of another size is to be produced, a metal ring core is manufactured. The equipment cannot be shared, resulting in an inefficient reduction in production costs. Therefore, it is an urgent need of the industry to provide a method and a device for manufacturing coil assemblies of various sizes to increase the flexibility of the application of the coil assembly, and at the same time effectively control the production cost and increase the competitiveness of the product market. SUMMARY OF THE INVENTION An object of the present invention is to provide a method of manufacturing a coil assembly which can manufacture a coil assembly for replacing a conventional metal annular core. Another object of the present invention is to provide an apparatus for manufacturing a coil assembly comprising a winding early element and a heating unit. In order to achieve the above object, the manufacturing method utilizes the winding unit to wind a winding group on the winding core, and finally, by heating, a set of s-shaped type of the winding core is placed. The sleeve tightly wraps the winding set to form the coil assembly. Since the above-mentioned coil assembly has a flexible material wick, it is suitable for the tube. The f-ring into a ring type is used to replace the traditional metal ring type iron. Further, the length of the bobbin is determined according to factors such as the number of turns of the actual winding group and the size of the electric device having the coil assembly. Thereby, in the manufacture of coils of different sizes and winding numbers, it is possible to increase the production efficiency and reduce the production cost without additionally preparing the metal cores of the respective different coil assembly sizes. The above-mentioned objects, technical features and advantages of the present invention can be more clearly understood. The following is a detailed description of the preferred embodiments in conjunction with the drawings. [Embodiment] The embodiment of the present invention is shown in FIG. A device 1A for manufacturing a coil assembly includes a winding unit for π la and a heating unit lb. The winding unit Ia - the body η and the fastener 13' fastener 13 are rotatably fixed to the body, such as: 失 to lose the winding ferrule 12, and the body Η has an actuator (not shown) ), used to rotate the fastener 13 to rotate, and to rotate the wound core 12 together. Thereby, the winding group 3 is wound around the winding core 12 as shown in Figs. 3 and 3D. ...single 7L lb essentially rides a mold with a predetermined shape, through a twister "not shown, suitable for heating a sleeve 41 of the wound core 12, such as the fourth The figure shows that 'the winding core is a flexible material. In the present example, the predetermined preform, the present-ring type, and the flexible material of the core are bendably accommodated in Utl lb. More specifically, the annular side wall 15 of the heating unit ib mold is an adjustable side wall, that is, the ring shape on the mold can be adjusted according to the size of the coil to adjust the size of the coil to be heated according to different coil sizes. Casing 4, the present invention further proposes a method for fabricating a coil assembly. As shown in Fig. 2, the first step 2! is to wind a winding group on a wound core; secondly, the second step a is worn. The winding (four) is in the sleeve; finally, the third step is to shape the sleeve through which the winding core is placed. In detail, please refer to FIG. 3A and FIG. 3B at the same time, the first step 21 of the embodiment is winding—the winding group 3 is on the winding core 12, and further, the step is 201025372. For example, the winding group 3 is wound on a winding core 12 having a length ranging from 70 to 100 mm, wherein the winding core 12 is a flexible column of a silicone material, and the winding group 3 is The ground is made of one metal wire made of copper, and its wire diameter is 34AWG (American wire gauge) ° Secondly, the winding group 3 is composed of two winding layers, firstly winding the aforementioned metal wire around the winding. The die 12 is formed with a first winding layer 31, and then wound on the first winding layer 31 to form a second winding layer 33. In other embodiments, the length of the wound core 12 and the material and diameter of the metal wires constituting the winding group 3 are not limited thereto, and the material of the wound core 12 may be other high flexibility. Molecular material. In more detail, as shown in FIG. 3A, before the winding of the winding group 3, a tape 36 may be wrapped around the first end 32 of the winding core 12 for positioning, and secondly, by the winding unit. La rotates the wound core 12, and a first metal wire is wound from the first end 32 of the wound core 12 to a direction X opposite the first end 32 of the first end 32 to form a first winding The number of windings in layer 31, FIG. 3A is used for illustration, and does not represent the actual number of turns. Actually, the step of winding the first metal wire (ie, forming the first winding layer 31) is about 400 turns of the first metal wire. On the wound core 12 . At the same time, a tape 36' can be wrapped around the second end 34 to define the extent of the winding layer 3. Next, as shown in FIG. 3B, similarly, a second metal line is wound from the second end 34 of the wound core 12 to a direction Y (ie, the opposite direction of the direction X) of the first end 32 to form The second winding layer 33, the number of windings in the third drawing is for illustration, not representing the actual number of turns, wherein the step of winding the second metal wire (ie, forming the second winding layer 33) is wound around the second metal wire. About 400 turns are made on the wound core 12. It should be noted that, in this embodiment, the first metal wire is wound in the direction X at the winding 201025372, and the second metal wire is wound in the direction Y in the winding die 12,
管芯12後，接續地， 即第一金屬線與第二_ 實施例中，金®始 本實施例於纏繞繞線組3於繞線管芯】2之後，更包含利用一繞 線測試儀（圖未不出）以確認各繞線層31及33之繞線圈數是否 步驟，同時亦包含利用一磁性分析儀（爪叫⑽^ (圖未不出）以及一多功能量測儀（multimeter)(圖未示出）分 別確認繞線組3之電感值以及電阻值之步驟。 參閱第4圖及第5圖’完成上述之第一步驟21後，以第二步驟 22將纏繞有繞線組3之繞線管芯12穿置於一套管41之中，以形 成線圈總成半成品4’，接著實施第三步驟23將穿置有繞線管芯 12之套官41定型。於本實施例中，套管41可為一熱縮套管，穿 置有繞線管芯12之套管41係利用加熱單元lb以加熱方式定型。 上述加熱步驟係將線圈總成半成品4,置於加熱單元lb，於本實施 例中，加熱單元lb實質上係為具有複數個環型侧壁15之模具， 適以分別谷置複數個線圈總成羊成品4’。藉此，使繞線管芯12藉 由加熱而彎曲定型，而套管41亦藉由加熱收縮而緊密包覆於繞線 組3，形成線圈總成4。 參閱第5圖及第6圖，藉由加熱定型後之線圈總成4更包含使 繞線管怒12之一相對端32、34配合地相互固接之一步驟。上述 之固接步驟係可設置一連接組43於繞線管芯12之第一端32上（如 201025372 第5圖所示），於此實施例t，繞線管芯12係—^管，同時連 接組43之外露部分亦可同時插置於第二❸4,而形成環型外型之 -線圈總成5。於其他實施例中，連接組们可為其他之構型，繞 線管芯12亦相應而設計’並不以此為限。 51、53於第一繞線層31以 線圈總成5更包含分別連接二引線After the die 12, successively, that is, the first metal wire and the second embodiment, the gold alloy embodiment is used to wind the winding group 3 after the winding die 2, and further includes using a winding tester. (not shown) to confirm whether the number of windings of each of the winding layers 31 and 33 is a step, and also includes using a magnetic analyzer (claw (10) ^ (not shown) and a multimeter (multimeter) (not shown) the steps of confirming the inductance value and the resistance value of the winding group 3 respectively. Referring to FIG. 4 and FIG. 5 'After completing the first step 21 described above, the winding is wound in the second step 22 The wound core 12 of the group 3 is placed in a sleeve 41 to form a coil assembly semi-finished product 4', and then a third step 23 is performed to shape the sleeve 41 through which the wound core 12 is placed. In the embodiment, the sleeve 41 can be a heat shrinkable sleeve, and the sleeve 41 penetrating the wound core 12 is heated by the heating unit 1b. The heating step is to place the coil assembly semi-finished product 4, The heating unit 1b is substantially a mold having a plurality of annular side walls 15 in the embodiment. The plurality of coil assemblies are respectively placed in the valley 4'. The bobbin 12 is bent and shaped by heating, and the sleeve 41 is also tightly wrapped around the winding group 3 by heat shrinkage to form a coil. Assembly 4. Referring to Figures 5 and 6, the coil assembly 4 by heat setting further includes a step of cooperatively fixing one of the opposite ends 32, 34 of the bobbin wreck 12 to each other. In the following steps, a connection group 43 can be disposed on the first end 32 of the winding die 12 (as shown in FIG. 5 of 201025372). In this embodiment t, the winding core 12 is connected to the tube, and the connection group is simultaneously connected. The exposed portion of the 43 can also be inserted into the second crucible 4 at the same time to form a loop-shaped outer coil assembly 5. In other embodiments, the connection groups can be of other configurations, and the winding core 12 is correspondingly The design 'is not limited to this. 51, 53 in the first winding layer 31 with the coil assembly 5 further includes two leads respectively connected
及第二繞線層33之步驟。於本實施例中，第一金屬線與第二金屬 線係分別用以形成第一繞線層31以及第二繞線層33，而第一金屬 線與第二金屬線係實質上為同一金屬線，其中引線5卜53係分別 與該金屬線之三端連結，於上述之連結處亦可以—膠帶％將二引 線51、53與線圈總成5固定。 综上所述，本發明提出一線圈總成之製造方法及裝置其中線 圈總成具有-繞線管芯，將金屬線纏繞於繞線管芯之上而形成繞 線組，並將-套管包覆於繞線組，而繞㈣芯適可_曲，並藉由 加熱而使之定型。藉此係、可改善習知線圈總成之製作方法，將傳 統之金屬環形鐵芯用以本發明之可彎曲之繞線管芯取代，同時， 繞線管芯之長度亦可依實際應用而定。藉此，可不必依據不同尺 〇 寸之線圈總成，而提供特定之金屬環形鐵芯，可有效降低裝置成 本，並提升生產之效率。 上述實施例僅為例示性說明本發明之原理及其功效，以及闡釋 本發明之技術特徵，而非用於限制本發明之保護範疇。任何熟悉 本技術者之人士均可在不違背本發明之技術原理及精神的情況 下，可輕易完成之改變或均等性之安排均屬於本發明所主張之範 圍。因此，本發明之權利保護範圍應如後述之申請專利範圍所列。 8 201025372 【圖式簡單說明】 第1圖係為根據本發明之一線圈總成之製作裝置示意圖； 第2圖係為根據本發明之一線圈總成之製作方法流程圖； 第3A圖係為根據本發明之一實施例，纏繞一第一繞線層於一繞 線管芯示意圖； 第3B圖係為根據本發明之一實施例，纏繞一第二繞線層於一繞 線管芯示意圖； 第4圖係為根據本發明之一實施例，利用一加熱單元使一線圈 半成品定型之示意圖； 第5圖係為根據本發明之一線圈示意圖；以及 第6圖係為根據本發明之一具有二引線之一線圈示意圖。And the step of the second winding layer 33. In this embodiment, the first metal line and the second metal line are respectively used to form the first winding layer 31 and the second winding layer 33, and the first metal line and the second metal line are substantially the same metal. The wire, wherein the lead wires 5 and 53 are respectively connected to the three ends of the metal wire, and the two wires 51 and 53 may be fixed to the coil assembly 5 at the above-mentioned joints. In summary, the present invention provides a method and apparatus for manufacturing a coil assembly in which a coil assembly has a bobbin core, and a metal wire is wound around the bobbin to form a winding group, and a bushing Wrapped around the winding set, and wrapped around the (four) core, and shaped by heating. By this, the conventional coil assembly can be improved, and the conventional metal toroidal core can be replaced by the flexible winding core of the present invention, and the length of the wound core can also be applied according to the actual application. set. In this way, it is possible to provide a specific metal toroidal core without depending on the coil assembly of different sizes, which can effectively reduce the cost of the device and increase the efficiency of production. The above-described embodiments are merely illustrative of the principles and effects of the present invention, and the technical features of the present invention are not intended to limit the scope of the present invention. Any change or equivalent arrangement that can be easily accomplished by anyone skilled in the art without departing from the spirit and scope of the invention is within the scope of the invention. Therefore, the scope of protection of the present invention should be as set forth in the appended claims. 8 201025372 [Simplified illustration of the drawings] Fig. 1 is a schematic view showing a manufacturing apparatus of a coil assembly according to the present invention; Fig. 2 is a flow chart showing a manufacturing method of a coil assembly according to the present invention; According to an embodiment of the present invention, a first winding layer is wound on a winding core; FIG. 3B is a schematic diagram of winding a second winding layer on a winding core according to an embodiment of the present invention. Figure 4 is a schematic view showing the shaping of a coil semi-finished product by a heating unit according to an embodiment of the present invention; Figure 5 is a schematic view of a coil according to the present invention; and Figure 6 is a diagram according to the present invention. A schematic diagram of a coil with one of the two leads.
【主要元件符號說明】 I a :繞線單元 II :本體 13 :緊固器 3 :繞線組 32 :第一端 34 :第二端 1 :裝置 1 b :加熱單元 12 :繞線管芯 15 :環型側壁 31 :第一繞線層 33 :第二繞線層 201025372 36、36’ ：膠帶 4’ ：線圈總成半成品 43 :連接組 51、53 :引線 4 :線圈總成 41 :套管 5 :線圈總成 55 :膠帶 ❹ Λ 10[Description of main component symbols] I a : Winding unit II: Main body 13: Fastener 3: Winding group 32: First end 34: Second end 1: Device 1 b: Heating unit 12: Winding die 15 : annular side wall 31: first winding layer 33: second winding layer 201025372 36, 36': tape 4': coil assembly semi-finished product 43: connection group 51, 53: lead 4: coil assembly 41: casing 5: Coil assembly 55: Tape ❹ Λ 10