TWI459421B - Method and apparatus for producing a coil assembly - Google Patents

Description

Method and device for manufacturing a coil assembly

The present invention relates to a method and apparatus for manufacturing a coil assembly, and more particularly to a method and apparatus for manufacturing a toroidal coil assembly.

With the development of technology, various electronic devices have become an indispensable element of the modern society. Since electronic devices must be supplied with a specific voltage from the outside to operate normally, the relevant electrical components for supplying the specific voltage are also widely used. The ground is used. The electrical component may be an inductive component, and the inductive component includes at least one coil assembly for converting an externally input AC power source into a specific DC power source by mutual electrical induction of the coil assembly. The electronic device is in normal operation and used.

A coil assembly for an inductive component includes a ring-shaped iron core, which may be a metal material, and the ring-shaped iron core is used to wrap a predetermined number of copper wires to cause a specific impedance for electrical induction. The main components. The above-mentioned coil assembly has a metal ring core, which needs to be additionally manufactured by other equipment (for example, a molding die), and since different coil components are required to form a specific impedance, Correspond to other electronic components to provide a specific output voltage. For the above reasons, the number of copper coils wound by the coil assemblies of different inductive components is different, and the size of the metal ring-shaped iron core by which the copper wires are wound will also be different, that is, each of the above-mentioned coil assemblies needs to be provided. A specific metal ring core is used to wrap the copper wire, that is, an additional specific production equipment (for example, a molding die) is required to manufacture the metal ring core.

It can be seen from the above that a coil assembly having a metal ring type iron core can be used only for a specific single coil assembly, and when a coil assembly of another size is to be produced, a device for manufacturing a metal ring type iron core is known. Unable to share, resulting in inefficient production costs. Therefore, it is an urgent need of the industry to provide a method and a device for manufacturing coil assemblies of various sizes to increase the flexibility of the application of the coil assembly, and at the same time effectively control the production cost and increase the competitiveness of the product market.

It is an object of the present invention to provide a method of manufacturing a coil assembly which can be fabricated to replace a conventional metal toroidal core assembly.

Another object of the present invention is to provide an apparatus for manufacturing a coil assembly including a winding unit and a heating unit.

In order to achieve the above object, the manufacturing method utilizes the winding unit to wind a winding group on a winding core, and finally heats a sleeve through which one of the winding cores is shaped, so that The sleeve tightly coats the winding set to form the coil assembly.

Since the above-mentioned coil assembly has a flexible material die, it is suitable to bend the die into a ring shape to replace the conventional metal ring core. In addition, the length of the wound core is determined by factors such as the number of turns of the actual winding set and the size of the electrical device having the coil assembly. Therefore, when manufacturing the coil assembly of different sizes and the number of coils, it is not necessary to additionally prepare the metal ring type cores of the respective different coil assembly sizes, thereby increasing the production efficiency and reducing the production cost.

The above described objects, technical features and advantages of the present invention will become more apparent from the following description.

One embodiment of the present invention is shown in Fig. 1. A device 1 for manufacturing a coil assembly includes a winding unit 1a and a heating unit 1b. The winding unit 1a includes a body 11 and a fastener 13 rotatably fixed to the body 11 for holding a winding core 12, and the body 11 has an actuator (not shown) And to rotate the fastener 13 and rotate the winding core 12 together. Thereby, as shown in FIGS. 3A and 3B, a winding group 3 is wound around the winding core 12.

The heating unit 1b is substantially a mold having a predetermined shape, and is passed through a heater (not shown) to heat the sleeve 41 of the wound core 12 and fix it (for example, Figure 4), wherein the bobbin core is a flexible material. In this embodiment, the predetermined shape is a ring type, and the core of the flexible material is flexibly received in the heating unit 1b. More specifically, the annular side wall 15 of the heating unit 1b is an adjustable side wall, that is, the ring shape on the mold can be adjusted according to the size of the coil to adjust the size of the coil to be heated according to different coil sizes. Sleeve 41.

The present invention further provides a method for fabricating a coil assembly. As shown in FIG. 2, the first step 21 is to wind a winding group on a winding core; secondly, the second step 22 is to pass the winding tube. The core is in a sleeve; finally, a third step 23 is to shape the sleeve through which the wound core is placed.

In detail, referring to FIG. 3A and FIG. 3B simultaneously, the first step 21 of the embodiment is to wind a winding group 3 on the winding core 12, and further, the embodiment will be wound. The group 3 is wound on a wound core 12 having a length ranging from 70 to 100 mm, wherein the wound core 12 is a flexible column of a silicone material, and the winding group 3 is preferably made of a material One of the copper metal wires is formed, and its wire diameter is 34 AWG (American wire gauge).

Next, the winding group 3 is composed of two winding layers. First, the foregoing metal wires are wound on the winding core 12 to form a first winding layer 31, and then continue to be wound on the first winding layer 31. To form a second winding layer 33. In other embodiments, the length of the wound core 12 and the material and diameter of the metal wires constituting the winding group 3 are not limited thereto, and the material of the wound core 12 may be other high flexibility. Molecular material.

In more detail, as shown in FIG. 3A, before the winding of the winding group 3, a tape 36 may be wrapped around the first end 32 of the winding core 12 for positioning, and secondly, by the winding unit. 1a rotates the wound core 12, and a first metal wire is wound from a first end 32 of the wound core 12 to a direction X opposite one of the second ends 34 of the first end 32 to form a first winding The number of windings in layer 31, Fig. 3A is for illustration, and does not represent the actual number of turns. Actually, the step of winding the first metal wire (i.e., forming the first winding layer 31) is about 400 turns of the first metal wire. On the wound core 12 . At the same time, a tape 36' can be wrapped around the second end 34 to define the extent of the winding layer 3. Next, as shown in FIG. 3B, similarly, a second metal line is wound from the second end 34 of the wound core 12 to a direction Y (ie, the opposite direction of the direction X) of the first end 32 to form The second winding layer 33, the number of windings in FIG. 3B is used for illustration, and does not represent the actual number of turns, wherein the step of winding the second metal wire (ie, forming the second winding layer 33) is wound around the second metal wire. About 400 turns are made on the wound core 12.

It should be noted that, in this embodiment, after the first metal wire is wound in the direction X on the winding die 12, the second metal wire is wound in the direction Y in the winding die 12, that is, the first metal wire. It is substantially the same metal wire as the second metal wire system. However, in other embodiments, the number of turns of the metal wire, the number of winding layers formed, and whether the metal wires are substantially the same metal wire are determined according to actual needs, and are not limited thereto.

In this embodiment, after winding the winding group 3 on the winding core 12, a step of using a winding tester (not shown) to confirm whether the number of windings of each of the winding layers 31 and 33 is correct is also included; A step of confirming the inductance value and the resistance value of the winding group 3 by a magnetic analyzer (not shown) and a multi-meter (not shown) is also included.

Referring to FIG. 4 and FIG. 5, after the first step 21 is completed, the winding core 12 wound with the winding group 3 is placed in a sleeve 41 in a second step 22 to form a total coil. The semi-finished product 4' is then subjected to a third step 23 to shape the sleeve 41 through which the wound core 12 is placed. In the present embodiment, the sleeve 41 can be a heat shrinkable sleeve, and the sleeve 41 that is passed through the wound core 12 is heat-set by the heating unit 1b. The heating step is to place the coil assembly semi-finished product 4' in the heating unit 1b. In the embodiment, the heating unit 1b is substantially a mold having a plurality of annular side walls 15 for respectively accommodating a plurality of coil assemblies. Semi-finished product 4'. Thereby, the bobbin core 12 is bent and shaped by heating, and the sleeve 41 is also tightly wrapped around the winding group 3 by heat shrinkage to form the coil assembly 4.

Referring to Figures 5 and 6, the heated coil assembly 4 further includes the step of matingly securing the opposite ends 32, 34 of the wound core 12 to each other. The fastening step described above may be provided with a connection group 43 on the first end 32 of the winding core 12 (as shown in FIG. 5). In this embodiment, the winding core 12 is a hollow tube. At the same time, the exposed portion of the connection group 43 can also be inserted at the second end 34 to form a coil assembly 5 of the ring shape. In other embodiments, the connection group 43 can be in other configurations, and the winding core 12 is designed accordingly, and is not limited thereto.

The coil assembly 5 further includes the steps of connecting the two leads 51, 53 to the first winding layer 31 and the second winding layer 33, respectively. In this embodiment, the first metal line and the second metal line are respectively used to form the first winding layer 31 and the second winding layer 33, and the first metal line and the second metal line are substantially the same metal. The wire, wherein the leads 51, 53 are respectively connected to the two ends of the wire, and the two leads 51, 53 and the coil assembly 5 may be fixed by a tape 55 at the above-mentioned joint.

In summary, the present invention provides a method and apparatus for manufacturing a coil assembly, wherein the coil assembly has a wound core, and a metal wire is wound around the wound core to form a winding group, and a set is The tube is wrapped around the winding set, and the wound core is suitably bendable and shaped by heating. Thereby, the conventional coil assembly can be improved, and the conventional metal toroidal core is replaced by the flexible winding core of the present invention, and the length of the wound core can also be determined according to practical applications. . Thereby, it is not necessary to provide a specific metal toroidal core according to different size coil assemblies, which can effectively reduce the device cost and improve the production efficiency.

The above-described embodiments are merely illustrative of the principles and effects of the present invention, and the technical features of the present invention are not to be construed as limiting the scope of the present invention. Any person skilled in the art can make changes or equal arrangements that can be easily accomplished without departing from the technical spirit and spirit of the invention. Therefore, the scope of protection of the present invention should be as set forth in the appended claims.

1. . . Device

1a. . . Winding unit

1b. . . Heating unit

11. . . Ontology

12. . . Winding die

13. . . Fastener

15. . . Annular side wall

3. . . Winding group

31. . . First winding layer

32. . . First end

33. . . Second winding layer

34. . . Second end

36, 36’. . . tape

4. . . Coil assembly

4’. . . Coil assembly semi-finished product

41. . . casing

43. . . Connection group

5. . . Coil assembly

51, 53. . . lead

55. . . tape

1 is a schematic view showing a manufacturing apparatus of a coil assembly according to the present invention;

Figure 2 is a flow chart showing a method of fabricating a coil assembly according to the present invention;

3A is a schematic view of winding a first winding layer on a winding core according to an embodiment of the invention;

3B is a schematic view of winding a second winding layer on a wound core according to an embodiment of the present invention;

Figure 4 is a schematic view showing the shaping of a coil semi-finished product by a heating unit according to an embodiment of the present invention;

Figure 5 is a schematic view of a coil in accordance with the present invention;

Figure 6 is a schematic view of a coil having one of the two leads according to one of the present inventions.

1. . . Device

1a. . . Winding unit

1b. . . Heating unit

11. . . Ontology

12. . . Winding die

13. . . Fastener

15. . . Annular side wall

Claims (14)

A method of manufacturing a coil assembly, comprising the steps of: winding a winding group on a winding core, the winding core being a flexible material; and inserting the winding core in a sleeve; The sleeve that is placed with the wound core is placed in a mold of a predetermined shape and heated to shrink the sleeve to tightly coat the winding set on the wound core while shaping the sleeve. The manufacturing method according to claim 1, wherein the mold of the predetermined shape is a ring-shaped mold, and a ring-shaped side wall of the ring-shaped mold is adjustable to change a size of the ring-shaped mold. The manufacturing method of claim 1, wherein the step of winding the winding group further comprises: winding a first winding layer on the winding core; and winding a second winding layer on the first winding On the floor. The manufacturing method of claim 3, wherein the step of winding the first winding layer further comprises winding one of the first end of the winding core to one of the second ends opposite to the first end The first metal wire. The manufacturing method of claim 4, wherein the step of winding the first metal wire further comprises the step of winding the first metal wire by about 400 turns. The manufacturing method of claim 4, wherein the step of winding the second winding layer further comprises winding a second metal wire from the second end of the winding core to one of the first ends. The manufacturing method according to claim 6, wherein the step of winding the second metal wire More than one step of winding the second metal wire about 400 turns. The manufacturing method of claim 1, wherein the step of winding the winding group further comprises winding the winding group on the winding core between 70-100 mm in length. The manufacturing method of claim 1, further comprising the step of providing a connection group on the bobbin, such that the opposite ends of the bobbin are cooperatively fixed to each other. The manufacturing method according to claim 3, further comprising the step of respectively connecting the two leads to the first winding layer and the second winding layer. An apparatus for manufacturing a coil assembly, comprising: a winding unit for winding a winding group on a winding core, the winding core is a flexible material; and a heating unit for A sleeve is fixedly placed with the shape of a sleeve of the bobbin and heated to shape the sleeve, the sleeve being contracted and shaped to form the coil assembly. The device of claim 11, wherein the winding unit comprises: a body having an actuator; and a fastener rotatably fixed to the body for clamping the winding core; The body is adapted to rotate the fastener by the actuator to rotate the winding die. The device of claim 11, wherein the heating unit is substantially a mold having a predetermined shape adapted to receive the sleeve through which the winding core is placed. The device of claim 13, wherein the predetermined shape is a ring type.