JPS634687B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a coil, and its purpose is to create a coil that can be manufactured using only a coil bobbin and a coil winding, and that is thin and has a large Q and inductance. The object of the present invention is to provide a manufacturing method that allows continuous manufacturing.

The first thin coil with simple structure
A printed coil as shown in the figure is known. This coil is formed by forming a spiral coil 102 using conductive foil on an insulating substrate 101. One end 102a of the coil 102 is used as a terminal, and the other end of the coil 102, that is, the center portion 102b is connected to the substrate 102 through a through hole. The conductive foil 103 is connected to the conductive foil 103 on the back side of the conductive foil 103, and the end 103a of the conductive foil 103 is used as the other terminal. This type of coil can be manufactured using the same method as printed wiring boards, so it is inexpensive, but when the magnetic flux passes through the coil 102, eddy currents flow through the conductive foil that makes up the coil 102, causing loss and increasing the Q. Not only is it impossible to increase the inductance, but the inductance of this coil 102 is extremely small.If you try to increase the inductance, you have to stack the coils in multiple layers, which makes wiring between the coils complicated and costly. The drawback was that it also became expensive.

The present invention is intended to eliminate such conventional drawbacks, and embodiments thereof will be described below with reference to FIG. 2 and subsequent drawings. FIGS. 2 and 3 show the coil of the first embodiment, where 1 is an integrally molded resin coil bobbin with flanges 2 at both ends, and 3 is a coil winding. The bobbin 1 has a cylindrical shape with a center hole 4, and the inner peripheral wall of the center hole 4 has a groove 5.
is provided. Further, a winding engagement groove 6 is provided in a part of the outer periphery of the flange portion 2 (at the center position of one side of the square). The coil winding 3 is wound on the bobbin 1 between the flanges 2, and both ends 3a and 3b of the coil winding 3 are engaged with the grooves 6 of the flanges 2 and are bonded, welded, and fitted. A conductor is provided on the peripheral wall of the groove 6 and fixed by a method such as soldering.
Both ends 3a and 3b of the coil winding 3 are used as connection terminals.

According to the coil of this embodiment, the coil can be constructed from only the integrally molded coil bobbin 1 and coil winding 3, and by adjusting the number of turns of the coil, the inductance can be increased, and losses due to eddy current can be increased. Since there are few numbers, Q can also be high. Moreover, by reducing the thickness of the flange portion 2 and the distance between the flange portions, the coil can be made thinner very easily. In this way, a coil that can have a high Q and inductance and can be easily made thin can be provided at a low cost.

In the above embodiments, the bobbin 1 can be made of various materials such as polymer resin materials, magnetic materials, ceramic materials, etc., but for the coil, a material with low moisture absorption characteristics and low high frequency loss etc. is used. This is desirable. Further, the flange portion 2 is not limited to the square shape shown in the figure, but may be of any shape such as a rectangular shape or a round shape, and may also be formed separately and attached to the bobbin.

FIG. 4 shows a second embodiment based on the above embodiment, in which a coil bobbin 1 is provided with flanges 2 at both ends.
An intermediate flange 2a is also provided between the flange portions of the coil bobbin, and a groove 6 is provided at the same position on the outer periphery of the flange portions 2 and 2a. The portions 3c and 3d of the coil winding 3 that are wound and engaged with the grooves 6 of the intermediate flange 2a other than the flange portions located at both ends of the coil bobbin are used as intermediate terminals.

In this second embodiment, the coil bobbin 1 including the intermediate flange portion 2a is integrally formed, but a plurality of coil bobbins 1 of the first embodiment may be arranged in parallel to create a coil with an intermediate terminal having the shape shown in FIG. 4. You can also do it.

Next, a method for continuously manufacturing the coil of the first embodiment or the coil additionally explained in the second embodiment will be explained with reference to FIG. First, the support shaft 7, which is rotatable in the direction of the arrow, is inserted into the center hole 4 of the coil bobbin 1 while the protrusion 8 provided on the outer periphery of the shaft 7 is engaged with the groove 5 of the center hole 4. Coil bobbins 1 are arranged and positioned in parallel. Although the figure shows that there is a gap between the bobbins, this gap is provided to make the figure easier to read and does not need to be provided.

Next, a part of the coil winding 3 is engaged with the groove 6 of the left flange 2 of the left end coil bobbin among the plurality of coil bobbins arranged in parallel. In this state, the shaft 7 is rotated to wind a predetermined number of coil windings around the coil bobbin on the left end side. Next, the shaft 7 is stopped and the coil winding is engaged with the groove in the right flange of the left end coil bobbin and the groove in the left flange of the coil bobbin on the right side of the coil bobbin. Next, the shaft 7 is rotated again to wind a predetermined number of coil windings onto the coil bobbin on the right side. After repeating this series of operations to wind the coil windings on all the coil bobbins and engaging them with the grooves in the right flange of the right-most coil bobbin, remove the coil bobbin from the shaft 7 and place the coil winding between the adjacent coil bobbins. When the coil winding is cut, a coil as shown in FIGS. 1 and 2 is completed. By putting together several coil bobbins and cutting the coil windings on both sides, a coil with an intermediate terminal is completed.

If a conductor is previously provided on the inner wall of the groove 6, the connection can be easily made by winding the coils around the entire plurality of coil bobbins and then immersing them in a solder bath to dip them in solder. As mentioned above, there are various methods of engaging and fixing the coil winding 3 in the groove 6 other than the soldering described above, such as welding, adhesion, and simple zero-fitting. Further, the product number and the like are stamped on the main surface of the flange portion 2 of the coil, and a separate label with the product number and the like is omitted. Further, by filling or coating the coil winding 3 of the coil with wax, epoxy resin, etc., the characteristics of the coil can be stabilized. In addition, the groove 5 of the circular center hole 4 of the coil bobbin 1 and the protrusion 8 of the shaft 7 can be made such that the center hole 4 is a square hole and the shaft 7 is square, or the center hole 4 is provided with a protrusion and the shaft 7 is provided with a groove. can be replaced with another configuration.

Figures 6 and 7 show examples of development.
In the illustrated example, a threaded groove is formed in advance in the center hole 4 of the bobbin 1 of the coil, and a fine adjustment core 9 is inserted into this threaded groove.
is screwed in, and the inductance can be adjusted by adjusting the screwing amount. If the core 9 is made of a magnetic material, the magnetic permeability μ can be increased, and if the core 9 is made of a diamagnetic material, μ or Q can be lowered. In the case shown in FIG. 7, a molded support 11 is bonded to a coil mounting board 10, and this support 11 is inserted into the center hole 4 of the coil to fix the coil.

As explained above, according to the method of manufacturing a coil of the present invention, a coil can be manufactured continuously using at least a coil bobbin and a coil winding, and can be easily made thin and has a large Q and inductance. Can be mass produced. In the coil manufacturing method, the grooves provided on the outer circumferential ends of adjacent flanges of the coil bobbin are aligned parallel to the axis of the shaft when supported and positioned by the support shaft, so that the coil winding is engaged. The work is easy to perform and the winding workability can be improved.

[Brief explanation of the drawing]

Fig. 1 is a plan view showing a conventional coil, Fig. 2 is a plan view of a coil in a first embodiment of the present invention, Fig. 3 is a side view of the same coil, and Fig. 4 is a plan view of a coil according to a first embodiment of the present invention.
FIG. 5 is a side view of the coil in the embodiment. FIG. 5 is a diagram for explaining the method of manufacturing the coil of the first embodiment. FIGS. 6 and 7 are side views showing an example of the coil developed. 1... Coil bobbin, 2... Flange, 3... Coil winding, 4... Center hole, 5... Groove, 6... Groove, 7
...Support shaft, 8...Protrusion.

Claims (1)

[Claims] 1. A plurality of cylindrical coil bobbins each having a flange at both ends and a groove on the outer peripheral end surface of the flange, a support shaft being inserted into the center hole of the coil bobbin, and an engagement provided on the outer periphery of the shaft. The coil winding is positioned by engaging the part with the engaging part provided on the periphery of the center hole, and the coil winding is engaged with the groove in the flange of one of the coil bobbins at one end of the plurality of coil bobbins arranged in parallel. Then, the coil winding is wound between the flanges of the coil bobbin on the one end side, and then the groove of the other flanges of the coil bobbin on the one end side and one of the flanges of the next coil bobbin adjacent thereto. The above coil winding is engaged with the groove of the next coil bobbin, and the coil winding is wound between the flanges of the next coil bobbin. After repeating this series of operations and winding the coil winding on all the coil bobbins, an arbitrary number of coil windings are wound. A method for manufacturing a coil, characterized in that the coil is manufactured by cutting the coil winding at both ends of the integrated coil bobbin. 2. 1 with multiple coil bobbins integrally molded in advance
The coil according to claim 1, characterized in that the coil is manufactured by cutting the coil bobbin at an intermediate flange portion after winding the coil winding around the coil bobbin. Production method.