JPS605052B2 - How to connect the terminal - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides the following steps in the manufacturing process of an automated coil device:
This invention relates to an improvement in the method of connecting the ends of electric wires wound around a bobbin to terminals.

In the manufacturing process of a coil device, until now there has not been a method suitable for automation that connects both ends of a wire wound around a bobbin, at the beginning and end of the winding, to a terminal provided on a shield on the bobbin.

This is because electric wires usually have an insulating coating made of enamel, polyester, or the like, so when attempting to make a solder connection, for example, it is necessary to remove this coating, which is difficult to automate. Incidentally, attempts have been made to peel off the insulation coating of the electric wire and to connect the electric wire and the terminal using electric welding. In this method, for example, the coil is passed through a coil device having the structure shown in FIG. 1, and the manufacturing method is as described below. That is, the electric wire 3 is wound around the cylindrical winding portion 11 of the forming bobbin 1 . At this time,
The winding start end 31 of the wire 3 is connected to a terminal 2 which is shielded from a protrusion 13 provided on the outer surface of a flange portion 12 formed at both ends of the winding portion 11. This connection is made using the tongue piece 2 provided on terminal 2.
This is done by locking the winding start end 31 of the electric wire 3 on the wire 1 and then bending the tongue piece 21 to hold the winding start end 31 in place. There are known methods for winding the electric wire 3, such as fixing the forming bobbin 1 and rotating the forming bobbin 1, but the former case is suitable. After winding the electric wire 3, the winding end 32 is connected to another terminal 2. This connection method is the same as that for the winding start end 31. Note that the notch 14 provided in the flange portion 12 can be used to start winding, to draw the winding end ends 31 and 32 into the winding portion 11, and to draw them out from the winding portion 11 for better workability. The coil device configured in this way is
Although not shown, the winding start and winding end 31, 3 of the electric wire 3
The terminal 2, which is held by the tongue piece 21, is held between the upper side of the tongue piece 21 and the back side of the terminal 2 by welding electrodes, and is energized and welded. That is, the insulation coating of the electric wire 3 is heated by the current flowing through the tongue piece 21, and the insulation is destroyed by burning. Further, by further energizing, the core wire of the electric wire 3 and the terminal 2 including the tongue piece 21 are welded together. According to this method, the manufacturing of the coil device can be almost completely automated, but the problem with this method lies in the continuous welding of the wire 3 and the terminal 2.

For example, when looking at coil devices used in fluorescent lamp ballasts, the diameter of the wire is about 0.35 mm.
The problem is that the mechanical strength of the welded part may be insufficient. This mechanical strength is great if the wire 3 is not crushed, but in that case, there is a risk of problems with the electrical connection with the terminal, and if the wire 3 is crushed enough, the electrical connection will not be possible. Optimum conditions are difficult to find, as although there is no problem with this, there is a risk that the strength may be insufficient. In view of the above-mentioned circumstances, the present invention proposes a terminal connection method that provides reliable electrical connection and sufficient mechanical strength.

In FIGS. 2 and 3, 4 is solder that is applied to cover the welded part where the electric wire 3 is held between the tongues 21 and electrically welded. This solder 4 supplements the electrical connection and mechanical strength of the welded part. ing. Such solder 4 can be applied automatically since the position of the welded portion of the terminal 2 in the coil device is determined. For example, in a coil device where the terminals 2 are treated with varnish, such as insulation treatment in a ballast for a fluorescent lamp, the solder 4 is used to expose the conductive part on the terminal 2 after the insulation treatment is completed. The varnish that has been covered has been scraped off, but this method is only possible after applying solder 4. Further, as shown in FIG. 3, if the solder 4 applied to the terminal 2 in advance is used for connection with the external lead wire 5, work efficiency is improved compared to soldering the external lead wire 5 with solder. good. Therefore, as in the present invention, if the solder 4 can be applied for the purpose of assisting the electrical connection or supplementing the mechanical strength of the welded portion, it is possible to kill two birds with one stone. Figure 4 shows terminal 2
This is an improved shape, and a side wall 22 is formed to surround the tongue piece 21 that clamps the electric wire 3 to prevent the flow of solder.

Having such a side wall 22 is convenient because the solder does not flow when applying solder to cover the welded portion. In addition to forming the side wall 22 as in this embodiment, a rib may be provided to prevent the solder from flowing. As explained above, in the present invention, the end of the electric wire wound around the bobbin is electrically welded by holding it with the tongue of the terminal attached to the bobbin as a shield, and solder is applied to cover the welded part. Even if the electrical connection or mechanical strength between the wire and the terminal is insufficient by welding alone, this can be sufficiently compensated for. Furthermore, this solder has the effect of increasing work efficiency in soldering connections with external lead wires.

[Brief explanation of drawings]

Figure 1 is a perspective view of the coil device that is the premise of the present invention;
The figure is a side view of the main part showing the state of connection of the coil terminal according to the present invention, partially in section. FIG. 3 is a side view of the main part, partially in section, showing the state of connection with the external lead wire. FIG. 1 is a perspective view of main parts showing another embodiment of the invention, in which 1 is a molded bobbin, 2 is
21 is a terminal, 22 is a side wall, 3 is an electric wire, 4 is solder, and 5 is an external lead wire. O / Zuzai Z Zuzai J Zuzai Zuzai

Claims (1)

[Scope of Claims] 1. Winding an electric wire around a bobbin having a terminal implanted therein, and locking the end of the electric wire to a tongue piece formed on the terminal,
A method for connecting a coil terminal, characterized in that after electric welding is performed while the wire is held between the tongues, solder is applied to cover the welded portion. 2. A method for connecting a coil terminal according to claim 1, characterized in that a terminal is used in which a solder flow stopper is formed so as to surround the tongue piece.