JP2990484B2 - Coil device and method of assembling the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to an electric motor,
More specifically, a coil device applied to an ignition coil, a solenoid valve, and the like, and an assembling method thereof, are described in more detail. Each lead wire taken out as a winding start end and a winding end end of a coil wound on a bobbin member is correspondingly used. The present invention relates to a coil device which is connected to a pair of terminals and is assembled by molding with an electrically insulating resin including a terminal connection portion, the coil device being provided with means for preventing disconnection of a lead wire which is easily generated by molding, and an assembling method thereof. .

[0002]

2. Description of the Related Art A schematic configuration of a conventional coil device of this kind will be described with reference to FIGS. 5 to 7. The coil device is provided on a bobbin 71 around which a coil 91 is wound, through a main body. A terminal fixing portion 72 integrally formed with a pair of terminal mounting holes 73 and a pair of lead wire retaining grooves 74 cut from the side and having a U-shaped cross section is provided. A lead wire connecting portion 82 provided with a locking tongue piece 83 for crimping and crimping a lead wire 92 of the coil 91 is connected to the lead wire connecting portion 82 via a stepped end surface 85 and is not shown. An electric connection portion 84 connected to an external terminal is provided.

In the case of this conventional example, each terminal 8 is inserted into a terminal mounting hole 73 of the terminal fixing portion 72.
In a state where 1 is press-fitted and fixed at a predetermined position, first, the respective lead wires 92 at the winding start end and the winding end end of the coil 91 wound around the bobbin 71 are taken out through a lead groove (not shown) and the like. , Respectively, in the lead wire locking groove 74.

Next, the terminal portions of the lead wires 92 are arranged at positions corresponding to the inner bottom portions of the locking tongue pieces 83, and are strongly caulked until the pressure is biased, and then heated by energization. The terminal portion of the lead wire 92 and the terminal 81 are fused in such a manner that the terminal portion of the lead wire 92 and the terminal 81 are fixed in a conductive state, and then the main portion including the fusing connection portion is molded with an electrically insulating resin 101 to be waterproof. The coil device is obtained by preventing rust.

[0005]

However, in the above-mentioned conventional coil device, each terminal 81 of the terminal portion of the lead wire 92 is provided.
In order to smoothly perform the wiring and the fusing connection, each lead wire 92 wired between the locking holding portion in the lead wire locking groove 74 and the caulking portion by the locking tongue piece 83 is connected. Since a certain amount of tension is applied, and each end portion is strongly pressed at the crimped portion, each lead wire 92 is flattened in the vicinity of the portion where the pressurized connection is applied, and the strength is inevitably reduced. Occurs.

Further, the lead wire 92 is heated by fusing processing, and the electrical insulating resin 1 after fusing connection is connected.
Due to the temperature stress caused by the mold No. 01, there is a problem that stress is concentrated near the flattened and weakened connection portion and disconnection easily occurs. In order to avoid the disconnection, for example, in the one disclosed in JP-A-5-190348, in order to avoid the disconnection, the fusing connection portion and the vicinity of the connection portion are covered with a cover so that the molding resin does not flow. Thus, the effect of distortion due to the difference in thermal expansion coefficient is prevented. However, the one disclosed in this publication has a problem in that the cost is increased due to an increase in the number of parts of the cover, and that the workability of attaching the cover is difficult.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a coil capable of effectively preventing a lead wire from being broken near a connection portion due to molding of an electrically insulating resin. It is an object of the present invention to provide an apparatus and an assembling method thereof.

[0008]

In order to achieve the above object, a coil device according to the present invention has a structure in which a bobbin member on which a coil is wound and a bobbin member are provided integrally with the bobbin member. While holding and holding the lead wire, a terminal fixing portion having a terminal mounting hole for inserting a terminal, and a terminal inserted into the terminal mounting hole and connecting the lead wire, further comprising the terminal and the terminal In a coil device for molding a connection portion with a lead wire and the coil with an electrically insulating resin, the coil device has an insertion position regulating means for regulating an insertion position of the terminal in the terminal mounting hole in a stepwise manner. The terminal is biased to the final position in a state where the lead wire is connected to the terminal provided at the initial position of insertion by the restricting means.

Further, in the above-mentioned coil device according to the present invention, the insertion position regulating means communicates with the insertion side hole provided at the required width or diameter and has a smaller width than the insertion side hole. It is provided between the anti-insertion side hole provided in the small diameter and the terminal, a lead wire connecting portion for electrically connecting a lead wire and an electrical connecting portion for connecting an external terminal, and is continuous with the lead wire connecting portion. And a press-fit fixing portion having a size that is continuous with the step end surface and substantially coincides with the required width or diameter of the insertion-side hole, and press-fits the terminal into the insertion-side hole of the terminal mounting hole. With the fixing portion inserted, a gap is created between the step end surface and the insertion side hole end surface, and the press-fit fixing portion is biased from the insertion side hole to the non-insertion side hole to eliminate the gap. The present invention may be characterized in that it is configured to obtain the same.

The method of assembling a coil device according to the present invention includes a bobbin member on which a coil is wound, a terminal fixing portion provided integrally with the bobbin member and having a terminal mounting hole formed therein, and A terminal comprising a press-fit fixing portion provided between a lead wire connecting portion for electrically connecting the lead wire and an electric connecting portion for connecting an external terminal, and press-fitting the terminal into the terminal mounting hole. Electrically connecting the terminal portion of the lead wire to the lead wire connection portion, including a portion corresponding to the gap length caused by the insertion, and displacing by a portion corresponding to the gap length, A biasing step of giving the lead wire connected to the lead wire connecting portion an extra length corresponding to the gap length.

[0011]

The lead wire taken out of the coil is locked and held in the lead wire locking groove. On the other hand, when the press-fitting fixing portion of the terminal is inserted into the insertion-side hole portion of the terminal mounting hole, a gap is formed between the step end surface and the insertion-side hole portion end surface. After connecting the lead wire latched and held to the stop groove, the terminal is biased to press-fit the press-fitting fixing portion from inside the insertion-side hole portion to inside the counter-insertion-side hole portion. An extra length corresponding to the gap length is given to the lead wire between the lead wire retaining groove and the lead wire connecting portion. As a result, stress concentration due to temperature stress or the like in the mold that is subsequently performed is avoided.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a coil device and an assembling method according to the present invention will be described below with reference to FIGS.

FIG. 1 is a longitudinal sectional view showing a schematic configuration of a coil device according to an embodiment of the present invention. FIG. 2 shows a configuration of a bobbin member in FIG. 1, and FIG. Longitudinal sectional view showing the bobbin member in a wound state,
(B) is a sectional view taken along line AA of (a), and (c) is an enlarged sectional view taken along line BB of (b). 3A and 3B show a process of assembling the terminal in FIG. 1, wherein FIG. 3A is a plan view showing a state before the terminal is biased at the time of fusing connection, and FIG. 3B is a plan view showing a state after the terminal is biased. is there.

In each of these figures, the bobbin member 1
As shown in FIGS. 2A and 2B, a main body 1 is provided with flanges 13 and 14 at both ends in the axial direction and a plunger (not shown) can be received in the hollow shaft hole 12a. The main body 12 has a terminal fixing portion 17 integrally protruding from one side (an upper side in the figure) of the peripheral surface of one flange portion 13 via a holding portion 15, and an inner surface of the flange portion 13. A lead wire lead-out groove 16 is formed from the side to the holding portion 15.

A pair of flat terminal mounting holes 18, 19 for fitting a set of terminals 31, 32 having the shape of a flat plate with a cross section to be described below are provided in the terminal fixing portion 17 in the axial direction. At the same time, a pair of lead wire retaining grooves 20, 21 are formed in a shape cut from both side surfaces. The terminal mounting holes 18 and 19 are inserted into the insertion side holes 18a each having a horizontal width W1 and an axial length L slightly larger than the tapered step holes 18c and 19c formed in the substantially middle portion. , 19a and the non-insertion side holes 18b, 1 provided in the horizontal width W2 slightly smaller than the step holes 18c, 19c.
9b is provided on both sides, and a partition wall 22 is provided between the terminal mounting holes 18 and 19 and protrudes outward.

On the other hand, as shown in FIGS. 3A and 3B, the terminals 31 and 32 are connected to lead wire connecting portions 33 and 3 provided at one end.
4 are provided with locking tongue pieces 35 and 36 bent in a U-shape at one edge thereof.
The terminal mounting holes 18, 19 are separated by step end faces 37, 38.
Are formed at locations corresponding to. The press-fit fixing portions 39 and 40 are connected to the insertion-side holes 18a,
A horizontal width W11 substantially equal to the horizontal width W1 of 19a,
In addition, it is provided with a length L + ΔL longer than the axial length L (see FIGS. 2C and 3A). Further, the terminals 31 and 32 are connected to the press-fit fixing portions 39 and 40 and are electrically connected to the electrical connection portions 43 and 44 via tapered step surfaces 41 and 42 formed corresponding to the tapered step holes 18c and 19c. Is extended. The electrical connection 4
Reference numerals 3 and 44 denote external terminals (not shown) for electrical conduction, and a horizontal width W2 substantially equal to the horizontal width W2.
1 and have the required length.
The insertion-side holes 18a and 19a and the anti-insertion-side holes 18b and 19b, together with a stepped end surface of the terminal and a press-fitting fixing portion described later, become clear in the description of the assembly process of the coil device. The terminal mounting hole 18,
An insertion position regulating means for regulating the insertion for stepwise insertion into the inside 19 is formed.

Here, assembling of the coil device firstly
With the coil 51 wound around the main body 12 of the bobbin member 11, the terminal fixing portion 1 provided on the bobbin member 11 is provided.
7, the insertion side holes 18a,
The terminals 31 and 32 are pushed in as expected from the 19a side to be inserted.

In this case, the terminals 31 and 32 are
As can be seen in (a), each of the electrical connection portions 4344 protrudes outward by a required length through the non-insertion side holes 18b and 19b (see FIG. 2 (c)), and the press-fit fixing portion 39, Numeral 40 is inserted into the insertion side holes 18a, 19a, and the tapered step surfaces 41, 42 on the distal end side are brought into contact with the corresponding tapered step holes 18c, 19c. Further, the respective lead wire connecting portions 33 and 34 are separated from each other by the partition wall 22.

In this state, the press-fit fixing portion 39,
40 is set to a length L + ΔL which is longer by an amount corresponding to ΔL with respect to the axial length L of the insertion side holes 18a, 19a, so that the step end surfaces 37 of the terminals 31, 32,
38, and the respective terminal mounting holes 18, 19 of the terminal fixing portion 17.
A gap corresponding to ΔL is generated between the end face 17a and the end face 17a.

Next, a lead wire 52 corresponding to the winding start end of the coil 51 wound around the main body 12 is drawn out from the lead wire lead-out groove 16 and engaged with one lead wire locking groove 20 of the terminal fixing portion 17. Similarly, the lead wire 53 corresponding to the winding end of the coil 51 is pulled out from the lead wire lead-out groove 16 and pulled out of the other lead wire locking groove 2.
1 and the terminal portions 52a, 53a of these lead wires 52, 53 are lightly tensioned at a length corresponding to the gap corresponding to the ΔL, in other words, while the lead wires 52, 53 , 53 are pulled out by natural wiring operation without regard to the wiring length, and the terminal portions 52a, 53a are inserted and supported by the locking tongue pieces 35, 36.

The corresponding portions of the locking tongues 35, 36, into which the terminal portions 52a, 53a are inserted, are caulked by pressing the terminal portions 52a, 53a as shown in the prior art example of FIG. After that, each terminal portion 52a, 53
By melting the coating of a, the terminal portions 52a and 53a are fused.

Subsequently, the terminals 31, 32 are biased so as to eliminate the gap corresponding to ΔL, and as shown in FIG. 3B, the tapered step surfaces 4 of the terminals 31, 32 are formed.
1, 42 and press-fit fixing portions 39, 40 having a horizontal width W11.
Is the tapered step hole 18 of the terminal mounting holes 18, 19.
c and 19c, it is press-fitted and fixed in the non-insertion side holes 18b and 19b having a smaller width W2. As a result, as the gap ΔL provided between the stepped end faces 37, 38 and the end faces of the terminal mounting holes 18, 19 is eliminated, the lead wires 52, 53, which have been lightly tensioned between them, are bent. As a result, extra lengths 52b and 53b are generated. As a result, each of the lead wires 52 and 53 is affected by the thermal effect of the resin molding performed in the next step and, consequently, the effect of stress concentration due to the difference in the coefficient of thermal expansion in each part.
This is alleviated by the formation of 53b, and disconnection can be prevented.

Thereafter, the coil device is connected to the terminals 31, 3
The housing 64 surrounds the two electrical connections 31 and 32.
Is formed by molding, the housing 64
A space 62 which is a region including the fusing connection formed by the above process is filled with a mold of an electrically insulating resin 63 of the same quality as the housing 64. As a result, the fusing connection portion of the coil device is made waterproof and rustproof, and the assembly is completed as a desired product.

In the resin molding, a primary mold including a housing excluding a fusing connection portion is provided.
The reason why the molding is divided into two moldings with the secondary mold for the fusing connection part is that the influence of the heat on the extra length parts 52b, 53b of the lead wires 52, 53 to be embedded in the resin is reduced. It is based on minimizing as much as possible, and if necessary, only one molding may be performed.

Next, a modification of the coil device according to the present invention will be described with reference to FIG. In this modified example, the configuration of the terminal and the terminal mounting hole is different from that of the embodiment in which the terminal is press-fitted into the terminal mounting hole. Therefore, only the changed portions will be described here, and the same portions will be denoted by the same reference numerals and description thereof will be omitted. 4A and 4B are plan views of each aspect in a terminal mounting process. FIG. 4A shows an initial state of terminal insertion in which lead wires are connected, and FIG. The state is shown.
The terminal 31A has substantially the same shape as that of the previous embodiment. On the other hand, the terminal mounting hole 18 of the terminal fixing portion 17 into which the terminal 31A is inserted is provided in the same structure as that of the previous embodiment. However, in the correspondence between the two, the terminal 31A has an axial length L1 of the press-fit fixing portion 39A reaching from the step end surface 37 to the tapered step surface 41 and an axial length L of the insertion side hole 18a of the terminal fixing portion 17. Match. Therefore, as shown in FIG.
When the tapered step surface 41 is completely inserted into the terminal mounting hole 18, the tapered step surface 41 of the terminal mounting hole 18 is
Clash with c. Therefore, the terminal 31A is press-fitted into the insertion-side hole 18a by the action of the plate thickness and the horizontal width W11 (see FIG. 3A) in the temporary mounting state shown in FIG. 4A. In this state, the electrical connection portion 43 is temporarily held in a state in which the electrical connection portion 43 is pressed into the non-insertion side hole portion 18b. At this time, the gap ΔL provided between the terminal 31 and the end face of the terminal mounting hole 18 described in the previous embodiment can be set by automatic assembly.

In the coil assembling process according to the above modification, as in the previous embodiment, when the lead wire 52 is locked to the terminal fixing portion 17 in the terminal temporarily mounted state shown in FIG.
The terminal portion 52 a is lightly stretched and fused to the locking tongue piece 35 of the lead wire connection portion 33. Then, terminal 3
1A is gently inserted so that the stepped surface 37 comes into contact with the end face of the terminal mounting hole 18 and the tapered stepped surface 41 comes into contact with the tapered stepped hole 18c. As a result, the extra length portion 52 b is easily formed on the lead wire 52 between the locking tongue piece 35 and the terminal fixing portion 17. Thereafter, the coil device is assembled by a mold of an electrically insulating resin (not shown). That is, in this modified example, since the step of press-fitting the terminal into the terminal fixing portion is not involved, assembly in automation can be ensured with high accuracy.

In each of the above embodiments, a so-called male tab terminal having a flat cross section has been described as a terminal, but the present invention can be applied to a so-called round pin type terminal having a circular cross section. The effect is obtained. In each of the above embodiments, the lead wire is described as being fused.
The present invention may be, of course, simply performed by crimping connection by crimping the locking tongue piece or soldering.

[0028]

As described above, according to the coil device and the method of assembling the same according to the present invention, the terminal of each lead wire taken out of the coil wound on the bobbin member is connected to the terminal. Since the extra length is formed before being molded with the electrically insulating resin, it is possible to reduce the thermal effect associated with the molding and thereby alleviate the stress concentration. Disconnection can be prevented. Also, the lead wire is locked and held in the lead wire locking groove and the terminal is biased, so that a certain extra length is always automatically formed. As a result, there is no special consideration for the wiring of the lead wire. It is possible to perform a predetermined assembling operation without performing the operation.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view showing a schematic configuration of a coil device according to an embodiment of the present invention.

2A and 2B show the bobbin member of FIG. 1, wherein FIG. 2A is a longitudinal sectional view of the bobbin member wound with a coil, and FIG. 2B is a sectional view of the bobbin member taken along the line AA of FIG. , (C)
It is an expanded sectional view of the BB line part of the above (b) in the same bobbin member.

3A and 3B are diagrams illustrating a mounting state of the terminal and a process of assembling the terminal of FIG. 1; FIG. 3A is a plan view illustrating a correspondence between a terminal and a terminal mounting hole and illustrating a mode at the time of fusing connection;
(B) is a plan view showing an aspect after fusing connection of the terminal.

FIG. 4 is a plan view showing a correspondence between a terminal and a terminal mounting hole according to a modified example of the present invention, wherein FIG. 4A is a plan view of a terminal in a provisionally inserted state, and FIG.

FIG. 5 is a cross-sectional view showing a schematic configuration of a conventional coil device.

FIG. 6 is a plan view showing a main part of the terminal in the related art.

FIG. 7 is a sectional view taken along the line DD in FIG. 6;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 Bobbin member 12 Main part 12a Hollow shaft hole part 13, 14 Flange part 15 Holding part 16 Lead wire lead-out groove 17 Terminal fixing part 18, 19 Terminal mounting hole 18a, 19a Insertion side hole 18b, 19b Non-insertion side hole 18c , 19c Tapered step hole 20, 21 Lead wire locking groove 22 Partition wall 31, 32 Terminal 33, 34 Lead wire connection 35, 36 Locking tongue 37, 38 Step end face 39, 40 Press-fit fixing part 41, 42 Tapered step surfaces 43, 44 Electrical connection portion 51 Coil 52, 53 Lead wire 52a, 53a Terminal portion of lead wire 52b, 53b Extra length portion of lead wire 61 Electrically insulating resin of primary mold 62 Space 63 Secondary mold Electrical insulating resin

Claims (5)

(57) [Claims] 1. A bobbin member on which a coil is wound, and a terminal provided integrally with the bobbin member, the terminal wire having a terminal mounting hole for engaging and holding a lead wire taken out from the coil and for inserting a terminal. In a coil device having a fixed portion and a terminal inserted into the terminal mounting hole and connecting the lead wire, and further molding a connection portion between the terminal and the lead wire and the coil with an electrically insulating resin, A state in which the terminal has an insertion position regulating means for regulating an insertion position in the terminal mounting hole in a stepwise manner, and the lead wire is connected to the terminal provided at an initial position of insertion by the insertion position regulating means. Wherein the terminal is biased to a final position. 2. The coil device according to claim 1, wherein a lead wire locking groove for locking and holding the lead wire is extended in the terminal fixing portion along the mounting hole. 3. The insertion position restricting means communicates with the insertion side hole provided at a required width or a required diameter and the opposite insertion side provided at a smaller width or a smaller diameter than the insertion side hole. A stepped end face provided between the hole and the terminal, a lead wire connecting portion for electrically connecting the lead wire and an electrical connecting portion for connecting an external terminal, and a step end face continuous with the lead wire connecting portion; A state in which the press-fit fixing portion of the terminal is inserted into the insertion-side hole portion of the terminal mounting hole, the press-fit fixing portion having a size continuous with the end face and substantially matching the required width or required diameter of the insertion side hole portion. A gap is created between the step end face and the end face of the insertion side hole, and the press-fit fixing portion is biased from the insertion side hole to the opposite insertion side hole so that the gap can be eliminated. The coil device according to claim 1, wherein: 4. A bobbin member on which a coil is wound, a terminal fixing portion provided integrally with the bobbin member and having a terminal mounting hole, and a lead for electrically connecting a lead wire taken out from the coil. A terminal comprising a press-fit fixing portion provided between the wire connecting portion and the electrical connecting portion for connecting the external terminal.After inserting the press-fit fixing portion of the terminal into the terminal mounting hole,
Electrically connecting a terminal portion of the lead wire to the lead wire connection portion including a portion corresponding to the gap length generated by the insertion, and displacing the lead wire connection portion by the portion corresponding to the gap length. A biasing step of providing the connected lead wires with an extra length corresponding to the gap length. 5. The method according to claim 4, further comprising, after the biasing step, a molding step of providing at least an extra length of the lead wire at the lead wire connecting portion and embedding a region to be connected with an electrically insulating resin. A method for assembling the coil device described in the above.