TW201805970A - Apparatus and method of making coil component wherein the method includes peeling insulation films with different tensions - Google Patents

Abstract

The invention provides apparatus and methods of making coil components which can prevent wires from being disconnected during the peeling of insulation film of wires. The method includes a winding step and a peeling step. The winding step includes winding wires around the core under a state that a first tension is temporarily applied on wires. The peeling step includes peeling insulation films of the wires connected to a first electrode and a second electrode with laser. In addition, the peeling includes applying a second tension less than the first tension on the wires.

Description

Coil component manufacturing method and coil component manufacturing device

The present invention relates to a coil component manufacturing method and a coil component manufacturing device, and more particularly to a coil capable of preventing breakage of a wire when peeling off an insulation coating film of a wire (wire) formed by covering an conductor such as a copper wire with an insulating coating film Part manufacturing method and coil part manufacturing device.

Conventionally, as a method of winding a lead wire of a coil component around a core, there is a method described in Japanese Patent Application Laid-Open No. 2009-224599 (Patent Document 1). In this wire winding method, the insulating coating film covering the conductor is peeled off while the wire is being wound around the core, and the conductor and the electrode portion after the insulating coating film is peeled off are bonded.

[Prior technical literature]

[Patent Literature]

Patent Document 1: Japanese Patent Application Laid-Open No. 2009-224599

In addition, it has been found that if the above-mentioned conventional method of winding a lead wire of a coil component around a core is actually used, the lead wire may be broken when the insulating coating film is peeled off.

Therefore, an object of the present invention is to provide a coil component manufacturing method and a coil component manufacturing apparatus capable of preventing disconnection of a lead wire when the insulating coating film of the lead wire (electric wire) is peeled off.

In order to solve the above problems, the coil component manufacturing method of the present invention is a coil component manufacturing method for manufacturing a coil component. The coil component includes a core, a wire wound around the core, and a conductor covered with an insulating coating film, and provided on the core. The coil electrode manufacturing method includes a first electrode that is bonded to a leading end of the lead wire and a second electrode that is provided on the core and bonded to a terminal end of the lead wire. In the state of the lead wire, the lead wire is wound around the core; in the peeling step, at least a part of the insulating coating of the lead wire is performed in a state where a second tension smaller than the first tension is added to the lead wire. And peeling by laser irradiation; and a bonding step of bonding a start end of the lead wire to the first electrode, and bonding a terminal end of the lead wire to the second electrode.

Here, "in a state where the first tension is applied to the above-mentioned lead wire at least temporarily" includes a case where the peeling step is performed after all the winding steps are completed, and the first tension is added to the wire in all of the winding steps. Happening.

According to the coil component manufacturing method of the present invention, at least a part of the insulation coating of the wire is irradiated with the laser to peel off at least a part of the insulating coating of the wire in a state where a tension smaller than that applied to the wire when the wire is wound around the core is applied to the wire .

Therefore, since the tension on the lead wire can be relaxed when the insulating cover film is peeled off by laser irradiation, even if at least a part of the insulating cover film is peeled off and the break resistance tension of the lead wire is reduced, the breakage of the lead wire can be prevented.

In addition, in one embodiment of the method for manufacturing a coil part, The stripping step includes: a leading end stripping step, before the winding step, performing laser irradiation on the leading end of the wire bonded to the first electrode to peel off the insulating coating film on the leading end of the wire; and terminal stripping In the step, after the winding step and before the bonding step, the terminal of the lead wire bonded to the second electrode is irradiated with laser to peel off the insulating coating film of the terminal end of the wire.

According to the above embodiment, the starting end and the terminal of the wire are stripped before the bonding step. Therefore, the first electrode of the coil component and the start end of the lead wire and the second electrode of the coil component can be joined to the terminal end of the wire at the same time. Therefore, it is possible to further shorten the step work time (production interval time) required for bonding the lead wire to the electrode.

In one embodiment of the method for manufacturing a coil component, the winding step includes an operation completed by winding the wire before the core is wound around a final turn of the core. In the bonding step, After the wire is wound around the final turn of the core, the terminal of the wire is bonded to the second electrode.

According to the above embodiment, the winding operation is completed by the winding operation immediately before the final winding operation of the winding operation of the wire toward the core. Therefore, even if the wire diameter of the wire is changed, there is a margin in the winding space. Therefore, even if the wire diameter is changed, the insulating coatings of the wires are not rubbed against each other and damaged when the wires are wound around the core.

In one embodiment of the method for manufacturing a coil component, the insulating coating film is peeled over the entire circumference in the circumferential direction of the wire.

According to the above embodiment, since the wire is peeled over the entire circumference in the circumferential direction of the wire The insulating coating film does not cause residues caused by the insulating coating film when the peeled wire is bonded to the electrode. Therefore, the connection reliability between the lead and the electrode can be ensured.

In addition, in one embodiment of the method for manufacturing a coil part, after the laser is irradiated to the lead wire bonded to each of the first electrode and the second electrode, and approximately half of the circumferential direction of the lead wire is peeled off, the insulation coating is performed. The film is reversed by the peeling side, and laser irradiation is performed again toward the remaining side of the insulating coating film, and the remaining insulating coating film is peeled off, so that the insulating coating film is peeled over the entire circumference in the circumferential direction of the wire.

According to the above-mentioned embodiment, after a part of the lead wire connected to each of the first electrode and the second electrode is irradiated with laser light and approximately half of the circumferential direction of the lead wire is peeled off, the peeled side of the insulating coating film is reversed. Laser irradiation was performed again on the remaining side of the insulating coating film, and the remaining insulating coating film was peeled off. As a result, the tension is relaxed even when the lead wire having the reduced breaking resistance tension is reversed, so that it is possible to prevent the lead wire from being broken due to the reverse operation. In addition, since one laser irradiation unit can be used to perform peeling over the entire circumference, the cost can be further reduced.

In addition, in one embodiment of the method for manufacturing a coil component, laser irradiation is performed from two directions facing each other with the lead wires connected to the first and second electrodes interposed therebetween, so as to extend through The insulating coating is peeled off all around. Here, the optical axis of the laser irradiated from the two opposite directions may or may not be coaxial. The optical axes of the lasers may be parallel to each other and staggered by a predetermined distance. The optical axes of the lasers may intersect at non-parallel angles (angles other than 180 ° such as 179 °).

According to the above-mentioned embodiment, laser irradiation is performed from two directions facing a part of the lead wire connected to each of the first electrode and the second electrode, so that the insulating coating is peeled over the entire circumference of the lead wire. . Therefore, since laser irradiation is performed from two directions at the same time, Since the entire peeling is performed, the step time (production interval time) required for peeling the insulating coating film can be further reduced.

The coil component manufacturing device of the present invention is a coil component manufacturing device for manufacturing a coil component. The coil component includes a core, a wire wound around the core and a conductor covered with an insulating coating film, and A first electrode bonded at the start end and a second electrode provided at the core and bonded to the terminal of the lead wire, the coil component manufacturing apparatus includes a tension applying mechanism that applies a first tension to the lead wire and is smaller than the first tension A second tension of the nozzle; the nozzle driving unit pulls the wire from the nozzle in a state where the first tension is added to the wire at least temporarily; and a laser irradiation unit in a state of adding the second tension to the wire Next, at least a part of the insulating coating film of the lead wire is irradiated with laser to peel it off.

According to the coil component manufacturing apparatus of the present invention, the tension applying mechanism applies a first tension to the lead wire and a second tension smaller than the first tension. The nozzle driving unit pulls the lead wire from the nozzle in a state where the first tension is applied to the lead wire. The laser irradiation unit applies laser irradiation to at least a part of the insulating coating film of the lead wire with a second tension applied to the lead wire.

Therefore, at least a part of the insulation coating film of the lead wire is irradiated with the laser beam to be peeled off in a state where a smaller tension is applied to the lead wire than when the lead wire is wound around the core. This makes it possible to relax the tension on the lead when the insulation coating is peeled off by laser irradiation, so that even if at least a part of the insulation coating is peeled off, the break resistance of the lead is reduced, and the break of the lead can be prevented. .

In one embodiment of the coil component manufacturing apparatus, the laser irradiation section peels off the insulating coating film over the entire circumference in the circumferential direction of the lead wire.

According to the above-mentioned embodiment, since the insulating coating film is peeled over the entire circumference of the conductive wire in the circumferential direction, no residue caused by the insulating coating film is generated when the conductive wire and the electrode are peeled after the insulating coating film is peeled off. Therefore, the connection reliability between the lead and the electrode can be ensured.

In addition, in one embodiment of the coil component manufacturing apparatus, the laser irradiation section includes a first laser irradiation section and a second laser irradiation section, and the first laser irradiation section and the second laser irradiation section are clamped. The wires are arranged opposite to each other so that laser irradiation is performed at the same time to peel the wires all around. Here, the optical axes of the lasers of the first laser irradiating portion and the second laser irradiating portion that are oppositely disposed may be coaxial with each other or may not be coaxial. The optical axes of the lasers may be parallel to each other and staggered by a predetermined distance. The optical axes of the lasers may intersect at non-parallel angles (angles other than 180 ° such as 179 °).

According to the above-mentioned embodiment, laser irradiation is performed from two directions facing a part of the lead wire connected to each of the first electrode and the second electrode, so that the insulating coating is peeled over the entire circumference of the lead wire. . Therefore, since laser irradiation is performed simultaneously from two directions to perform peeling over the entire circumference, the step work time (production interval time) required for peeling the insulating coating film can be further reduced.

According to the coil component manufacturing method and the coil component manufacturing apparatus of the present invention, the tension on the lead wire can be relaxed when the insulation coating film is peeled off by laser irradiation, so that the breakage of the lead wire can be prevented when the insulation coating film is peeled off.

1‧‧‧coil part manufacturing device

10‧‧‧ Core

11‧‧‧The first crotch

12‧‧‧ second crotch

13‧‧‧ core core

14‧‧‧first electrode

15‧‧‧Second electrode

18‧‧‧ Nozzle

19‧‧‧ the first wire insertion hole

20‧‧‧Second wire insertion hole

21‧‧‧first lead

22‧‧‧Second Lead

30‧‧‧Tension imparting mechanism

31‧‧‧ substrate

32, 57‧‧‧ bracket

35‧‧‧hysteresis brake

36‧‧‧Main pulley

37‧‧‧ tension arm

38‧‧‧Guide pulley

39‧‧‧ fulcrum

40‧‧‧ Potentiometer

41‧‧‧Bolt for tension adjustment

42‧‧‧ Grip

45‧‧‧tension spring

50‧‧‧ movable film

51‧‧‧Tension switching cylinder

52‧‧‧Piston rod

55‧‧‧stop

61‧‧‧Guide

62, 63‧‧‧Guide pulley

64‧‧‧ core support

65‧‧‧Fixture

70‧‧‧Core Drive Department

80‧‧‧laser irradiation section

90‧‧‧ Nozzle driving unit

100‧‧‧Control Department

The long axis of the L‧‧‧ core.

FIG. 1A is a schematic perspective view showing a state where the first lead wire 21 and the second lead wire 22 are fixed to the jig 65 of the coil component manufacturing apparatus 1 according to the embodiment of the present invention.

FIG. 1B is a top view of the core 10 of FIG. 1A.

FIG. 2 is a block diagram showing the components of the coil component manufacturing apparatus 1 of FIG. 1A.

FIG. 3 is a schematic diagram showing a configuration of the tension applying mechanism 30 of FIG. 2.

FIG. 4 is a plan view showing a first step of the coil component manufacturing method of the coil component manufacturing apparatus 1 of FIG. 1A.

FIG. 5 is a plan view showing a second step of the coil component manufacturing method of the coil component manufacturing apparatus 1 of FIG. 1A.

FIG. 6 is a graph illustrating the resistance of a lead wire wound around a core of a coil component.

Hereinafter, the present invention will be described in detail through the illustrated embodiments. It should be noted that the inventors provide drawings and the following description in order for those skilled in the art to fully understand the present disclosure, but it is not intended to limit the subject matter described in the scope of the patent application through these contents.

(Specific problem discovered by the inventor alone)

Conventionally, when manufacturing a coil component used in a mobile device such as a mobile phone, when a conductor is bonded to an electrode portion, a part of the entire circumference of the insulation coating film is peeled off, and the thermal insulation and laser welding are applied to the coil part. The peeled portion is bonded to the electrode portion. Here, the insulating coating film of the portion that has not been peeled off throughout the week is vaporized by thermocompression bonding or laser welding, and does not remain as a residue of the joint portion.

In recent years, the demand for coil parts for vehicles is increasing. In the case of manufacturing this coil component, a heat-resistant insulating coating film is used as the insulating coating film covering the conductor. Therefore, the insulating coating film of the portion that has not been peeled off throughout the week is not vaporized by thermal compression bonding or laser welding, and remains as a residue in the joint portion.

In order to eliminate such a problem, when joining a conductor covered with a heat-resistant insulating coating film to an electrode portion, it is adopted that the insulating coating film is peeled over the entire circumference (peel-off), and the peeled part This method is bonded to the electrode portion.

However, the inventors have newly discovered that when at least a part of the lead wire is peeled off, a new problem arises that the lead wire is easily broken. In particular, when the wire is wound around the core, in order to prevent the wire from being loosened, it is necessary to wind the wire with a certain degree of tension. If the state where the tension is added is maintained, the wire is covered throughout the entire circumference of the wire. When the insulating coating is peeled off, for example, the possibility of disconnection is very high during peeling. The inventors have newly discovered that when the entire circumference of the wire is stripped, the possibility of the wire being broken is increased.

In addition, it is expected that the above-mentioned problems will become more significant with the recent reduction in the size of wires.

Focusing on the problems described above, in this embodiment mode, it is provided to apply a strong first tension to the wire when the wire is wound around the core, and to peel off at least a part of the insulating coating of the wire. The wire is added with a second tension that is smaller than the first tension and is smaller than the breaking resistance of the wire (conductor) after being stripped, so that a coil component manufacturing method and a coil component manufacturing device that prevent the wire from being broken. Hereinafter, a coil component manufacturing method and a coil component manufacturing apparatus according to this embodiment will be described using FIGS. 1 to 5.

FIG. 1A shows a state where the first lead 21 and the second lead 22 are fixed to the present invention. A schematic perspective view of the state of the clamp 65 of the coil component manufacturing apparatus 1 according to the embodiment. FIG. 1B is a plan view of the core 10 of FIG. 1A. As shown in FIGS. 1A and 1B, the coil component manufacturing apparatus 1 includes a core support portion 64 that supports the core 10 of the coil component, and a nozzle that supplies the first lead 21 and the second lead 22 and winds the leads 21 and 22 around the core 10. 18. In addition, two nozzles 18 are provided, and each of the nozzles 18 includes a first wire insertion hole 19 and a second wire insertion hole 20. The first conductive wire 21 passes through the first conductive wire insertion hole 19. A second wire 22 is passed through the second wire insertion hole 20.

The coil component manufacturing apparatus 1 of FIG. 1A rotates the core 2 by rotating the axis of the core portion 13 of the drum-type core 10 as a rotation axis, thereby winding the first wire 21 over substantially the entire core portion 13 of the core 10. The second wire 22 is used to manufacture a coil part of a double-strand structure. The coil component is, for example, a common mode choke coil.

The core 10 includes a core core portion 13, a first flange portion 11 provided at one end of the core core portion 13, and a second flange portion 12 provided at the other end of the core core portion 13. As a material of the core 10, for example, materials such as alumina (non-magnetic body), Ni-Zn-based ferrite (magnetic body, insulator), and resin are used.

The core portion 13 has a rectangular parallelepiped shape, for example. The shape of the first crotch portion 11 and the shape of the second crotch portion 12 are, for example, rectangular flat plates. A first electrode 14 and a second electrode 15 are respectively provided on the bottom surface of the first crotch portion 11 and the bottom surface of the second crotch portion 12. The material of the first electrode 14 and the second electrode 15 is, for example, Ag. The starting end of the first lead 21 is bonded to the first electrode 14 of the first crotch 11 of the core 10. The starting end of the second wire 22 is bonded to the second electrode 15 of the first crotch 11 of the core 10. The terminal of the first lead 21 is bonded to the first electrode 14 of the second crotch 12 of the core 10. The terminal of the second wire 22 is bonded to the second electrode 15 of the second crotch 12 of the core 10. and, The first lead 21 and the second lead 22 are applied with tension through a tension applying mechanism 30 described later. The core 10 is provided on the XY plane so that the long-axis L direction connecting the first crotch portion 11 and the second crotch portion 12 coincides with the Z direction. The first electrode 14 and the second electrode 15 are each bonded to an electrode of a mounting substrate (not shown).

The first lead 21 and the second lead 22 are spirally wound around the winding core portion 13, and copper wires covered with insulation are used. For example, the insulating cover film is formed of polyamidoimide (AIW), which is a heat-resistant material. The first lead 21 is wound around the core 10 to form a primary-side coil. The second lead 22 is wound around the core 10 to form a secondary coil.

The core support portion 64 is configured as one first crotch portion 11 capable of holding the core 10. In addition, the core support portion 64 is configured to be supported by a rotating device (not shown), and rotates around the axis of the core portion 13 of the core 10 supported by the core support portion 64 as a rotation axis. When the first lead wire 21 and the second lead wire 22 are wound around the core portion 13 of the core 10, the core 10 is rotated while the core support portion 64 is supported, so that the core 10 also uses the axis of the core portion 13 as The first lead wire 21 and the second lead wire 22 drawn from the nozzle 18 are rotated around a rotating shaft, and are wound around the winding core portion 13.

In addition, a clamp 65 is provided in the core support portion 64. The clamp 65 holds one end of the first lead 21 and the second lead 22 respectively drawn from the nozzle 18, and the first lead 21 and the second lead held by the clamp 65. One end of 22 is fixed to the core support portion 64. Therefore, when the nozzle 18 is moved as described later, one end of the first lead 21 and the second lead 22 are fixed. Therefore, as the nozzle 18 moves, the first lead 21 and the second lead 22 are pulled out from the nozzle 18 respectively. .

In addition, the coil component manufacturing apparatus 1 includes a cutter (not shown) that cuts the first lead 21 and the second lead 22, and the cutter can be moved in any direction in a three-dimensional direction.

FIG. 2 is a block diagram showing the components of the coil component manufacturing apparatus 1 of FIG. 1A. The coil component manufacturing apparatus 1 shown in FIG. 1 includes a control unit 100, a tension applying mechanism 30, a core driving unit 70, a laser irradiation unit 80, and a nozzle driving unit 90. The control unit 100 controls the tension applying mechanism 30, the core driving unit 70, the laser irradiation unit 80, and the nozzle driving unit 90 to perform the following operations.

The tension applying mechanism 30 of FIG. 2 applies a predetermined tension corresponding to each step of manufacturing the coil component to the lead wire supplied to the core 10 of the coil component based on a signal from the control unit 100. For example, the control unit 100 controls the tension applying mechanism 30 in a step of peeling the insulation coating film of the lead wire over the entire circumference, and applies a tension less than the breaking resistance of the conductor to the lead wire supplied to the core 10 of the coil component.

The core driving unit 70 drives a rotation device (not shown) that supports the core support portion 64 based on a signal from the control unit 100 and rotates the core 10 supported by the core support portion 64.

The laser irradiation unit 80 irradiates the laser toward the first lead 21 and the second lead 22 arranged near the core 10 according to a signal from the control unit 100, and the first lead 21 and the second lead 22 are insulated and covered. The side surface to which each electrode was bonded was peeled off in the film. That is, the laser irradiation part 80 is a peeling unit which irradiates a laser beam to a lead wire and peels an insulation coating film. Here, the laser irradiation unit 80 can irradiate a range of 300 mm angle while scanning the laser, and the first and second lead wires 21 and 22 are arranged in the 300 mm angle laser irradiation range to irradiate the laser respectively. In addition, a single irradiation time is about several milliseconds, and even if a plurality of peelings are performed by successively irradiating a plurality of times, the time taken as a whole is within about 1 second. The laser irradiation unit includes, for example, a laser oscillator and an optical system that guides a laser to an irradiation position.

In addition, two laser irradiation portions 80 may be disposed so as to face each other with the laser processing point interposed therebetween, or the laser may be disposed at a position such as the lower side of the processing point (the bottom surface side of the coil component manufacturing apparatus 1) and the like. Irradiation section 80.

Here, when the laser irradiation portions 80 are arranged at two locations across the processing point, each laser irradiation portion 80 is simultaneously irradiated toward a part of the first lead 21 and the second lead 22 disposed at the processing point, respectively, and Peel off all week. Accordingly, since laser irradiation is performed from both directions to perform peeling over the entire circumference, the step work time (production interval time) required for peeling the insulating coating film can be further reduced.

In addition, in a case where the laser irradiation section 80 is arranged at one place, the laser irradiation section 80 performs laser irradiation toward a part of the first lead wire 21 and the second lead wire 22, and After approximately half of the circumferential direction is peeled off, the peeled side of the insulating coating film is reversed so that the remaining side of the insulating coating film faces the laser irradiation section 80, and the laser irradiation is performed again to peel off the remaining insulating coating film. Thereby peeling is performed for the whole week. Accordingly, since the tension is relaxed even when the lead wire having the reduced breaking resistance tension is reversed, it is possible to prevent the lead wire from being broken due to the reverse operation. In addition, since the entire circumference can be peeled off by using one laser irradiation portion, the cost can be further reduced.

In addition, the irradiated laser is a second harmonic generation (SHG) laser, and the wavelength of this laser is about 532 nm. Therefore, the insulating coating film of each of the first lead 21 and the second lead 22 made of polyimide and imine made of a heat-resistant material has a good absorptivity, and heating can be performed only with the insulating coating as the target, which can efficiently perform the heating. Remove the insulation coating. The insulating coating can be removed at the interface position with each of the first lead 21 and the second lead 22 most appropriately.

The nozzle 18 is supported by a nozzle driving section 90 that pulls out the first lead 21 and the second lead 22 from the nozzle 18 based on a signal from the control section 100. In addition, the nozzle driving section 90 moves the nozzle 18 in an arbitrary direction in the three-dimensional space based on a signal from the control section 100.

FIG. 3 is a schematic diagram showing a configuration of the tension applying mechanism 30 of FIG. 2. The first lead wire 21 and the second lead wire 22 are pulled out from the bobbin 71 and guided to the nozzle 18 via the tension applying mechanism 30 described below, and are supplied from the nozzle 18 to the core 10 supported by the core support portion 64.

The tension applying mechanism 30 in FIG. 3 includes, for example, a base plate 31, a main pulley 36 attached to a hysteresis brake 35, a tension arm 37 including a guide pulley 38, a potentiometer 40, a tension adjusting bolt 41, a tension spring 45, and a movable The tension switching cylinder 51 and the stopper 55 of the sheet | seat 50 are comprised. The first lead 21 and the second lead 22 drawn from the bobbin 71 are guided by the guide piece 61 and are introduced to the back side of the substrate 31, are wound around the main pulley 36 via the guide pulleys 62 and 63, and are provided under tension The guide pulley 38 at the tip of the arm 37 reaches the nozzle 18. The main pulley 36 is assembled in an electromagnetic brake portion of the hysteresis brake 35.

The tension arm 37 is rotatably provided on the substrate 31 with the support shaft 39 as a fulcrum, and a potentiometer 40 is provided on the support shaft 39. The potentiometer 40 detects the tension of the wire 5 based on the rotation angle of the tension arm 37, and controls the operation of the hysteresis brake 35 based on the detection result.

The tension adjusting bolt 41 is provided on the base plate 31 through the brackets 32 and 32 in a state parallel to the base plate 31, and a gripper 42 for manual rotation is attached to one end. The tension switching air cylinder 51 is attached to a nut (not shown) screwed onto the bolt 41 via a bracket (not shown), and is located directly above the bolt 41. A movable piece 50 is fixed to the front end of the piston rod 52 of the air cylinder 51, and a spiral tension spring is set between the movable piece 50 and the base end 37a of the tension arm 37. 45. On the other hand, the stopper 55 is provided on the substrate 31 via the bracket 57 and faces the movable piece 50.

The movable piece 50 is set to the position A when the air cylinder 51 is not operating. When the air cylinder 51 operates, the piston rod 52 advances to the position B, and the movable piece 50 is set at the position B. That is, the movable piece 50 is set at any one of the positions A and B according to the setting state of the operation or non-action of the cylinder 51. When it is set at the position A, the tension spring 45 is strongly stretched, At the position B, the tension of the tension spring 45 decreases, and the tension applied to the first and second wires 21 and 22 via the tension arm 37 is changed according to the situation. In other words, the tension applying mechanism 30 can switch the tension of the first lead 21 and the second lead 22 in two steps: large and small. For example, in this embodiment, the tension when the movable piece 50 is set at the position B is set to 70% or less of the tension when the movable piece 50 is set to the position A and is smaller than the conductor break resistance tension.

In the tension applying mechanism 30 configured as described above, the tension arm 37 is always applied with a counterclockwise rotation force by the tension spring 45 and is balanced with each other at the angle shown in FIG. 3. In the winding operation, if the tension of the first lead wire 21 and the second lead wire 22 increases, the tension arm 37 bends clockwise and rotates against the tension spring 45. If it is a slight increase in tension, it is absorbed by the bending and rotation. If the above tension is applied to the first lead 21 and the second lead 22, the potentiometer 40 detects it, and the hysteresis brake 35 operates according to the detection result to release or weaken the braking of the main pulley 36. Thereby, the first lead 21 and the second lead 22 are drawn out, and the amount of increase in the tension on the first lead 21 and the second lead 22 is eliminated.

On the other hand, in the winding step to the core portion 13 of the core 10, the air cylinder 51 is controlled to be inoperative, the movable piece 50 is set to the position A, and the tension of the tension spring 45 is strongly stretched to act on The tension of the first lead 21 and the second lead 22 is increased. In contrast, in Lee In the step of peeling off the insulation coatings of the first and second wires 21 and 22 by laser irradiation, the air cylinder 51 is controlled to operate, and the movable piece 50 is set at the position B to act on the first wire 21 The tension of the second lead 22 is reduced. In this way, the tension is automatically switched in accordance with each step of the winding operation, thereby preventing damage and disconnection of the first lead wire 21 and the second lead wire 22.

In addition, when the first lead wire 21 and the second lead wire 22 are set in the coil component manufacturing apparatus 1 again, the bolt 41 is rotated and the initial position A of the movable piece 50 is changed, so that the first lead wire 21 and the second lead wire 22 can be adjusted. Material and wire diameter. In addition, for example, in order to change the tension, a solenoid can be used instead of the air cylinder 51 or another driving mechanism that can switch the movable piece 50 to a plurality of positions. The potentiometer 40 may be replaced with another sensor that detects the tension of the first lead 21 and the second lead 22.

Next, a coil component manufacturing method will be described. In the method of manufacturing a coil part, two first wires 21 and second wires 22 are wound around the core 10 at the same time, and are respectively bonded to the first electrode 14 and the second electrode 15. This step will be described in detail below.

First, the movable piece 50 is set to the position A in the tension applying mechanism 30, and a first tension is applied to the first lead 21 and the second lead 22.

Next, as shown in FIG. 1A, one first crotch portion 11 of the core 10 is clamped and fixed by the core support portion 64. Here, the core 10 can be rotated around the axis of the core portion 13 of the core 10 as a rotation axis.

Next, as shown in FIG. 1A, the first conductive wire 21 and the second conductive wire 22 are respectively drawn from the first conductive wire insertion hole 19 and the second conductive wire insertion hole 20 of the nozzle 18, and the first conductive wire 21 and the second conductive wire One end of the lead wire 22 is held by a clamp 65 and fixed to the core support portion 64.

Next, the movable piece 50 is set to the position B in the tension applying mechanism 30, A second tension (<first tension) is applied to the first lead 21 and the second lead 22. Here, the tension applied to the first lead 21 and the second lead 22 is temporarily relaxed. As described above, for example, the second tension is set to be 70% or less of the first tension and less than the breaking resistance of the conductor (the same applies hereinafter).

Next, as shown in FIG. 4, while maintaining the state where the tension applied to the first lead 21 and the second lead 22 is relaxed, each of the first electrode 14 and the second electrode 15 which are connected to the first crotch portion 11 is joined. The insulation coating film of the peeling part 200 is peeled off all around. In detail, the peeling part 200 which is a part of the 1st lead 21 and the 2nd lead 22 is moved to the laser irradiation range, and laser irradiation is performed, and the insulation coating film of the peeling part 200 is peeled all around. In addition, as will be described in detail later, the exposed copper wires (conductors) are respectively bonded to the first electrode 14 and the second electrode 15 of the first crotch portion 11.

Next, the movable piece 50 is set to the position A in the tension applying mechanism 30, and a first tension is applied to the first lead 21 and the second lead 22.

Next, the peeling portions 200 of the first lead wires 21 and the second lead wires 22 are respectively disposed in the vicinity of the first electrode 14 and the second electrode 15 of the first crotch portion 11.

Next, the first lead 21 and the second lead 22 are wound around the core portion 13 of the core 10 (winding step). Specifically, as shown in FIG. 5, while rotating the core 10 and the core support portion 64 around the axis of the core portion 13 of the core 10 supported by the core support portion 64 as the rotation axis, the nozzle 18 is directed toward the core 10. The core portion 13 is moved in the axial direction, so that the first conductor 21 and the second conductor 22 are wound around the core portion 13 as a whole. Then, the rotation operation of the core support part 64 is completed at the timing when the winding operation before the last winding operation is completed, and the winding step is ended. Therefore, even if the wire diameters of the wires used for the first lead 21 and the second lead 22 are changed, there is still room for winding. Therefore, when the first conductive wire 21 and the second conductive wire 22 are wound, the insulating coatings of the conductive wires do not rub against each other. And damage.

Next, the movable piece 50 is set to the position B in the tension applying mechanism 30, and a second tension (<first tension) is applied to the first lead 21 and the second lead 22. Here, the tension applied to the first lead 21 and the second lead 22 is temporarily relaxed.

Next, as shown in FIG. 5, while maintaining the state where the tension applied to the first lead 21 and the second lead 22 is relaxed, each of the first electrode 14 and the second electrode 15 connected to the second crotch portion 12 is bonded. The insulation coating film of the peeling part 201 is peeled off all around. Specifically, the peeling portion 201 is moved to a laser irradiation range, and laser irradiation is performed to peel off the entire insulating coating film of the peeling portion 201. Therefore, since the tension on the lead wire can be relaxed when the insulating cover film is peeled off by laser irradiation, even if at least a part of the insulating cover film is peeled off and the break resistance tension of the lead wire is reduced, the breakage of the lead wire can be prevented. In addition, since the insulating coating film is peeled over the entire circumference in the circumferential direction of the lead wire, residues caused by the insulating coating film are not generated when the peeled wire is bonded to the electrode. Therefore, the connection reliability between the lead and the electrode can be ensured.

In addition, as will be described in detail later, the exposed copper wires (conductors) are respectively bonded to the first electrode 14 and the second electrode 15 of the second crotch portion 12.

In addition, the insulation coating film may be peeled off by applying laser irradiation to the peeling portion 200 of the first lead 21 and the second lead 22 used when the next coil component is continuously manufactured after the laser irradiation is performed toward the peeling portion 201. Here, the peeling part 200 is a region closer to the nozzle than the peeling part 201 among the first lead 21 and the second lead 22. This can further shorten the step work time (production interval time) required for peeling.

Next, the start and end of the first wires 21 and 22 are respectively bonded to the first electrode 14 and the second electrode 15 by thermocompression bonding and laser welding. Here, the tension applying mechanism In 30, the movable piece 50 is set at the position A, and a first tension is applied to the first lead 21 and the second lead 22.

Next, a final loop winding operation is performed. That is, the first lead wire 21 and the second lead wire 22 are wound only once around the winding core portion 13 of the core 10.

Next, the peeling portions 201 of the first lead 21 and the second lead 22 are arranged near the first electrode 14 and the second electrode 15 of the second crotch portion 12, respectively.

Next, the peeling portions 200 and 201 of the first lead 21 and the second lead 22 are bonded to the first electrode 14 and the second electrode 15 by thermocompression bonding and laser welding, respectively. Here, these joinings may be performed simultaneously or sequentially. When the bonding is performed at the same time, it is possible to further reduce the step working time (production interval time) required for bonding the lead to the electrode.

Finally, the cutter (not shown) is sequentially moved toward the vicinity of the first crotch 11 and the second crotch 12 of the core 10, and one end (starting end) and the other end of each of the first lead 21 and the second lead 22 are respectively moved. The (terminal) section is cut off. Thereby, a coil component is manufactured.

In addition, in this embodiment, the winding operation to the core in the winding step is performed in a state where a strong tension (first tension) is applied, but the present invention is not limited to this. For example, during the winding of the first lead 21 and the second lead 22 to the core 10, the control unit 100 may control the core 10 to perform a one to several times while maintaining the weak tension (second tension) in the peeling step. After that, a strong tension (first tension) is applied to the winding.

In this way, when the first lead wire 21 and the second lead wire 22 are wound around the core 10, it is possible to prevent disconnection in the peeling part 200 where the insulating coating film is peeled off. That is, as shown in FIG. 6, in the peeling part 200 from which the insulation coating film was peeled off, compared with the lead wire covered with the insulation coating film over the entire circumference, the breaking resistance is reduced. However, if the second tension is applied for about 1 to several times, After winding, the first lead 21 and the second lead 22 are wound to the core 10 with the first tension added, and the first tension is not directly applied to the peeling portion 200 after the reduction of the break resistance is reduced. It is possible to prevent disconnection in the peeling portion 200.

Here, for example, FIG. 6 shows an example of the breaking resistance of a wire covered with an insulation coating film having a thickness of 0.005 mm over the entire circumference of a copper wire having a diameter of 0.05 mm. As shown in this example, when the wire-breaking tension of a wire covered with an insulating coating film is set to 100, for example, the wire-breaking resistance of a conductor (copper wire) with which the insulating coating film is peeled over the entire circumference is broken. The tension is about 50.

In addition, the insulating coating film of the peeling part 200 of the first lead 21 and the second lead 22 and the insulating coating film of the peeling part 201 of the first lead 21 and the second lead 22 are peeled in different steps, but the present invention It is not limited to this. These peeling processes can be processed in one step, for example. That is, the laser irradiation is continuously performed in one step to separate the insulating coating films. In this way, the laser can be continuously irradiated in the same step to separately peel a part of the wire. Therefore, compared with the case where each of the wires is peeled in each step, the step operation time (production interval) required to peel the insulating coating film can be further shortened time).

In addition, a description has been given of a configuration in which the coil component manufacturing apparatus 1 rotates the core 2 with the axis of the core portion 13 of the core 10 as the rotation axis, and the first conductor 21 and the second conductor 22 are wound around the core portion 13. However, the present invention is not limited to this. For example, instead of this structure, the nozzle 18 may be made to revolve around the core 10 to wind the first lead 21 and the second lead 22 around the core portion 13 of the core 10.

In addition, the present invention is not limited to the above-described embodiments, and design changes can be made without departing from the gist of the present invention.

In the above embodiment, two wires are wound around the core, but 1 may be wound. Three or more wires are wound around the core.

In the above embodiment, the nozzle is moved in the long axis direction of the core, but the core may be moved in the long axis direction of the core with respect to the nozzle.

1‧‧‧coil part manufacturing device

10‧‧‧ Core

11‧‧‧The first crotch

12‧‧‧ second crotch

13‧‧‧ core core

14‧‧‧first electrode

15‧‧‧Second electrode

18‧‧‧ Nozzle

19‧‧‧ the first wire insertion hole

20‧‧‧Second wire insertion hole

21‧‧‧first lead

22‧‧‧Second Lead

64‧‧‧ core support

65‧‧‧Fixture

Claims (9)

A coil component manufacturing method is a coil component manufacturing method for manufacturing a coil component. The coil component includes a core, a wire wound around the core, and a conductor covered with an insulating coating film, and provided on the core and connected to the core. The first electrode bonded at the beginning and the second electrode provided at the core and bonded to the terminal of the lead are characterized in that the coil component manufacturing method includes a winding step of applying a first tension to the lead at least temporarily. In a state where the wire is wound around the core; in a peeling step, laser is applied to at least a part of the insulating coating of the wire in a state where a second tension smaller than the first tension is added to the wire And peeling by irradiation; and a bonding step of bonding the leading end of the lead to the first electrode and bonding the end of the lead to the second electrode. For example, the method for manufacturing a coil part according to item 1 of the patent application, wherein the peeling step includes a starting end peeling step, and before the winding step, the starting end of the wire bonded to the first electrode is irradiated with laser light to Peeling off the insulating coating on the leading end of the wire; and a terminal peeling step, after the winding step and before the bonding step, laser irradiation is performed on the terminal of the wire bonded to the second electrode to peel off the wire. Terminal insulation coating. For example, the method for manufacturing a coil part in the scope of patent application item 2, wherein, The winding step includes an operation completed before the wire is wound around a final turn of the core, and in the bonding step, the wire is wound after the wire is wound around the final turn of the core. The terminal is bonded to the second electrode. The method for manufacturing a coil part according to any one of claims 1 to 3, wherein in the stripping step, the insulating coating is peeled over the entire circumference in the circumferential direction of the wire. For example, in the coil component manufacturing method described in item 4 of the scope of the patent application, in the peeling step, laser irradiation is performed on the conductive wire bonded to each of the first electrode and the second electrode, and the circumferential direction of the conductive wire is roughly After half peeling, reverse the peeled side of the insulating coating film, and then irradiate the laser with the remaining side of the insulating coating film again to peel off the remaining insulating coating film, so that the insulation is peeled over the entire circumference of the wire in the circumferential direction. Covering film. For example, in the method for manufacturing a coil component according to item 4 of the patent application, in the peeling step, laser irradiation is performed from two directions facing each other with a wire bonded to each of the first electrode and the second electrode, so that The insulating coating film is peeled over the entire circumference of the wire in the circumferential direction. A coil component manufacturing device is a coil component manufacturing device for manufacturing a coil component. The coil component includes a core, a wire wound around the core and a conductor covered with an insulating coating film, and a core provided on the core and connected to the core. The first electrode bonded at the beginning and the second electrode provided at the core and bonded to the terminal of the lead are characterized in that the coil component manufacturing device includes: A tension applying mechanism that applies a first tension and a second tension smaller than the first tension to the lead; a nozzle driving unit that pulls out the lead from the nozzle while the first tension is added to the lead; and a thunder The radiation irradiating unit peels off the insulating coating film of the lead wire bonded to the first electrode and the second electrode while applying the second tension to the lead wire. For example, in the coil component manufacturing apparatus according to claim 7, the laser irradiated portion peels off the insulating coating film over the entire circumference in the circumferential direction of the lead wire. The coil component manufacturing device according to item 8 of the scope of the patent application, wherein the laser irradiation section includes a first laser irradiation section and a second laser irradiation section, the first laser irradiation section and the second laser irradiation section The wires are arranged opposite to each other so that the wires are simultaneously irradiated to peel off the wires all around.