JP2000091146A - Wire connecting structure of electric or electronic component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce steps and to improve a working environment without fear of a disconnection by disposing a wire near an end of a terminal, melting an end of the terminal, and electrically and mechanically connecting the wire to the terminal. SOLUTION: Ends 3A, 3B of a wire 3 are respectively entangled with two terminals 5A, 5B protruding from an upper surface of a terminal block 4. Ends of the terminals are melted to form melted parts 6A, 6B. The ends 3A, 3B of the wire 3 are respectively electrically and mechanically connected to the terminals 5A, 5B. A neck (a partly narrowed part of an intermediate part) is provided near an end of the terminal 5A protruding on the block 4. The ends of the wire are entangled with the neck and melted by using a melting means, and the both are electrically and mechanically connected. The end of the terminal 5A is formed in a mushroom shape. The wire is entangled with a stem near a beveled top of the terminal 5A, the top is melted to enclose the entangled part of the end of the wire to be effectively connected to the terminal.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wire connection structure for an electric or electronic component having a wire connected to a terminal portion, and more particularly to a wire connection structure for connecting a wire terminal of an electronic component to a terminal portion. is there.

[0002]

2. Description of the Related Art A conventional wire connection structure of a coil component as an electronic component will be described with reference to FIGS.

As shown in FIG. 15, a conventional coil component 50 has a drum-shaped magnetic core 51 and plate-like (rectangular cross-section) terminal portions 53a, 54a provided on the lower end surface of the magnetic core 51.
And a coil portion 52 made of a wire with a coating (urethane coating or polyimide coating) wound on a magnetic core 51. Wire ends 52a and 52b of the coil portion 52 are entangled with the terminal portions 53a and 54a, respectively. It is.

[0006] As shown in the bottom view of FIG. 16, the terminal portion is provided with plate-shaped terminals 53, 54, 55, 56 divided into four on the bottom surface of the flange portion of the magnetic core 51. The terminals
A pair of terminal portions protruding in the orthogonal direction are formed, one of the terminal portions 53a, 54a, 55a, 56a is entangled with the wire terminal, and the other terminal portions 53b, 54b, 55b, 56b.
Are used as external connection terminals, and constitute a transformer.

The ends of the terminal portions 53a, 54a, 55a, 56a to which the wire terminals are entangled are bent upward so as to be higher than the bottom surface.

A manufacturing process of a transformer as a coil component having such a structure will be described with reference to a series of process diagrams shown in FIG.

[0007] The terminal portion 53 to which the wire terminal is entangled
a, 54a, 55a, and 56a are soldered. In this case, after a solder flux is applied, a solder dip treatment is performed with, for example, a lead-containing solder layer (for example, the temperature condition is set to melt the urethane coating. Temperature of 400 ° C,
After a time of 2 sec), the terminal portions 53a, 54a,
55a and 56a are soldered to wire ends entangled therewith. Thereafter, cleaning is performed using a cleaning material such as methylene chloride in order to remove unnecessary solder, flux, and the like attached to the periphery during the solder processing, and the cleaning process is performed.

[0008]

However, in the case of a conventional wire connection structure, for example, eutectic solder (liquidus temperature 183 ° C.) or tin (Sn) rich solder (liquidus temperature 220 ° C.) is used as a solder material. When C) is used, there is a problem that a so-called copper crack of a wire end occurs, and the wire end becomes thin (wire thinning phenomenon), and when a wire having a small diameter is used, a disconnection accident occurs.

Further, in the case of the conventional wire connection structure, a solder flux is also required, and a cleaning step is indispensable, resulting in an increase in the number of steps.

In the case of the conventional wire connection structure, the wire end with the coating can be entangled with the terminal portions 53a, 54a, 55a and 56a and can be soldered only when the coating is a urethane coating having a low melting point. In the case of a polyimide coating or the like having a melting point, a step of peeling off the coating of the wire terminal is required in advance, and also in this case, there is a problem that the number of steps is increased.

When mounting this kind of coil component on a printed circuit board of an electronic device, reflow soldering using a lead-free high-temperature type solder material has been increasing in order to cope with environmental problems that have been increasing in recent years. For connection inside the coil component, it is necessary to use a higher temperature type solder material.
For this reason, a high-temperature solder must be used, but in the case of such a high-temperature solder (liquidus temperature of 250 ° C. or higher), a lead-containing solder material is used. There were also issues.

Such a problem is not limited to the coil component,
This applies to all electric and electronic components having a structure in which a wire is connected to a terminal portion.

[0013] The present invention has been made in view of the above circumstances, has no fear of wire breakage, can provide a highly reliable connection state, and can reduce the manufacturing cost by reducing the number of steps. It is another object of the present invention to provide a wire connection structure for electric and electronic components that can also improve the working environment.

[0014]

According to the first aspect of the present invention,
In a wire connection structure for an electric / electronic component having a wire connected to a terminal portion, the wire is disposed near a tip of the terminal portion, and the tip of the terminal portion is melted.
The wire is electrically and mechanically connected to the terminal portion.

According to a second aspect of the present invention, a narrow portion is provided near a tip of the terminal portion according to the first aspect, and the wire is entangled with the narrow portion. .

According to a third aspect of the present invention, the terminal of the first aspect is formed in a mushroom-shaped cross section, and the wire is entangled with a stem near the umbrella of the mushroom. The umbrella portion is melted and covers the binding portion of the wire.

According to a fourth aspect of the present invention, a wire insertion hole is provided near the tip of the terminal portion according to the first aspect, and the wire is inserted through the wire insertion hole. is there.

According to a fifth aspect of the present invention, a V-shaped notch is provided near the tip of the terminal according to the first aspect, and the wire is inserted through the notch. It is.

According to a sixth aspect of the present invention, the terminal of the first aspect is bent at the tip, and the wire is disposed at the bent portion.

[0020]

Embodiments of the present invention will be described below.

(Embodiment 1) FIGS. 1 to 9 show a first embodiment of the present invention. FIG. 1 (a) shows a coil device 1 as an example of electric and electronic components. A coil 3 made of a wire is wound around a bobbin 2 having a square flange portion, and has a square terminal block 4. The bobbin 2 is provided with a square hole 4A into which a magnetic core (not shown) is inserted.

On the upper surface of the terminal block 4, two conductive (for example, metal) square terminal portions 5A and 5B are arranged so as to protrude with an interval therebetween. These terminal portions 5A, 5
The other end of B protrudes from the side of the terminal block 4 through the terminal block, and is used as an external connection terminal.

The two terminal portions 5A and 5B protruding from the upper surface of the terminal block 4 are connected to the terminals 3 of the wire 3 respectively.
A and 3B are entangled (FIG. 1 (b)), and the tips of the terminal portions are melted to form fused portions 6A and 6B (FIG. 1).
(C)), the wire terminals 3A, 3B and the terminal portions 5A,
5B is electrically and mechanically connected.

By the way, in this embodiment, an inductor is used as the coil device, so that only two terminals are used.
It goes without saying that a total of four terminals are provided, two on the secondary coil side and two on the secondary coil side.

Next, with reference to FIG. 1B and FIGS. 2 to 9, the wire connection structure before the formation of the fusion parts 6A and 6B will be described in detail.

FIG. 1B shows a case where a wire terminal 3A is tangled and disposed near the tip of the square terminal 5A.

FIGS. 2 and 3 show an example in which a constricted portion (a portion where an intermediate portion is partially thinned) 7 is provided in the vicinity of the tip of a terminal portion 5A protruding on the terminal block 4. FIG. Is a constricted portion 7 formed by a notch from both side surfaces of the terminal portion 5A, and FIG. 3 is a constricted portion 7 formed by a notch directed laterally from one side surface. Wire 3A in this constriction
After the tip is entangled, the electrical and mechanical connection between the two is performed by melting using a melting means such as melting by laser light described later.

According to the structure in which the constricted portion 7 is provided,
Since it is easy to entangle the wire end with the constricted portion, positioning becomes easy, and when melting, the effect is obtained that the distal end of the constricted portion is melted and melted into the wire to perform a reliable connection. .

FIGS. 4 and 5 show the terminal portion 5A formed with a mushroom-shaped tip. FIG. 4 shows a flat top surface, and FIG.

With such a mushroom shape, a wire is entangled with the stem near the umbrella portion of the mushroom. However, positioning when the wire is entangled becomes easy. Since the molten portion wraps around the entangled portion of the wire tip, an effect that the connection is further ensured can be obtained.

FIGS. 6 and 7 show a terminal portion 5A provided with a wire insertion hole 9 near the front end thereof.
FIG. 7 shows a case in which the wire ends 3A are merely inserted into the insertion holes 9 to arrange the wire ends 3A.

In either case, the insertion hole is filled during melting, and the wire ends are pushed from the surroundings.
The effect that the connection between the wire terminal and the terminal is easy and reliable is obtained.

In particular, in the case of FIG. 7, since the wire terminal 3A is simply inserted into the insertion hole 9, an effect that is extremely convenient in automatic assembly can be obtained.

FIG. 8 shows a configuration in which a V-shaped notch 10 cut out from the upper end of the terminal portion 5A is provided, and the wire terminal 3A is sandwiched in the bottom of the V-shaped notch 10. Also in this case, since it is sufficient to simply insert the wire terminal, an effect is obtained that it is suitable for automatic assembly as in the case of FIG.

FIG. 9 shows the tip 5C of the terminal 5A.
Is bent, and the wire end 3A is sandwiched in the gap formed by the bending. Also in this case, the arrangement of the wire terminals becomes easy. In addition, the connection is completed because the bent portion completely wraps the wire during melting.
As the means for arranging the wires, entanglement, insertion, pinching, and the like have been described as examples. However, the wires can be arranged near the terminal end using a jig and connected.

Next, a manufacturing process of the coil device according to the embodiment will be described. In the melting step, various local heating means such as laser melting, plasma melting, and arc melting may be used, but with an electric method such as arc melting. Since a ground (ground) is required, it is considered preferable to use laser melting that does not need to consider such grounding. Therefore, in the following description, the case of laser melting will be described. In addition, since local heating can be performed, the heating position, the heating temperature, and the like can be freely controlled in accordance with the material, dimensions, and the like to be heated.

First, as shown in FIG. 1A, a predetermined number of turns of a wire 3 as a coil are wound around a body of a synthetic resin bobbin 2 having a square body and a flange. Square pins 5A and 5B as square terminal portions made of a conductive material such as iron or copper are planted on the terminal block 4 of the flange portion at the other end of the terminal block. Project over As the wire, a polyimide-coated wire, a polyester-coated wire, a urethane-coated wire, or the like is used.

Next, as shown in FIG. 1B, a wire terminal 3A is entangled in the vicinity of the tip of the square terminal portion 5A, or a "constricted portion" or "constricted portion" as shown in FIGS. The terminals 3A and 3B of the wire are entangled, inserted, or used with a jig, etc., in the terminal portion formed with any of the "mushroom-shaped portion", "hole", "notch", and "bent portion". Are arranged according to the method described above.

Thereafter, as shown in FIG. 1 (c), a laser beam is irradiated to melt the terminal end portion of the terminal portion where the wire terminal is disposed, thereby forming a fused portion 6A. Are electrically and mechanically connected. Square terminal part 5
Connection between B and the wire terminal 3B is performed in the same manner.

The laser melting is performed, for example, as follows.

The laser light source irradiates the tip of the terminal with a spot light having a diameter of, for example, about 0.4 mm, and irradiates the tip of the terminal for about 5 msec to partially melt the area of the tip of the terminal. I do.

According to the wire connection structure for the coil component 1 of the first embodiment, the vicinity of the distal ends of the terminal portions 5A and 5B is used as a wire placement portion, where the wire terminals 3A and 3B are disposed. Is melted by a laser beam to electrically and mechanically connect the wire terminals 3A and 3B to the terminal portions 5A and 5B. Therefore, since the soldering process as in the conventional example is not employed, copper There is no possibility that the wire 3 is broken due to the above, and the wire terminal 3A and the terminal portion 5A, and the wire terminal 3B and the terminal portion 5B are each melted and connected reliably, so that a highly reliable connection state can be obtained. it can.

Further, the terminal portion is irradiated with a laser beam at 1000 ° C.
Wire 3 using a high-melting-point coating material such as a polyimide-coated wire in order to perform a melting treatment at a high temperature as described above.
In this case, the coating of the wire terminals 3A and 3B of the wire 3 is melted at the same time, so that the step of removing the coating of the wire terminals 3A and 3B becomes unnecessary. At this time, since it is melted by local heating, there is an advantage that heat does not affect the wire winding portion.

Further, the soldering process including the flux application and the cleaning process as in the conventional example become unnecessary, and the manufacturing cost can be reduced by reducing the number of steps. Also, since lead-free solder is not used, the working environment can be improved,
The adverse effect on the surrounding environment can be prevented.

When the present inventor conducted an experiment, the tensile strength of the wire connection according to the present invention was compared with the wire connection according to the present invention by the solder in the same coil device, and the tensile strength of the wire connection according to the present invention was 400 ° C.
C, 3 sec), wire breakage (breakage due to copper cracking) occurred at 60 g at a wire diameter of 0.08 mm and wire breakage at a wire diameter of 0.04 mm.
A good result of 20 g was obtained with a wire diameter of 00 g and a wire diameter of 0.04 mm.

Next, another embodiment will be described.

(Embodiment 2) FIG. 10 shows a second embodiment, in which the wire connection structure of the present invention is applied to a transformer using a vertically placed drum core. This has the same basic structure as that shown in FIGS. 15 and 16 as the conventional example.

This transformer has a drum-type magnetic core 12 having flanges at both ends, and a primary winding and a secondary winding are wound around a body of the drum core 12 in a vertical position. The four terminals are joined to the bottom of the terminal block 14, and the ends of the terminals are bent upward in an L-shape to form bent ends 15A, 15B, 15A ', 15B'. 1 (b) and the wire arrangement as shown in FIG. 2 to FIG.
B, 13A ', and 13B' are respectively arranged, and are melted by laser melting, and the melted portions 16A, 16B, 16A ',
16B '.

(Embodiment 3) FIG. 11 shows a third embodiment, in which a wire 23 is wound between a pair of upstanding terminal plates 24A and 24B formed by bending a lead frame. The drum-shaped magnetic core 22 is sandwiched between the
Terminal portions 25A, 25 protruding from the upper ends of A, 24B
The vicinity of the distal end of B is a wire disposition portion as described above, where the wire terminals 23A and 23B are disposed and the terminal portions 25A and 2B are disposed.
By melting the tip of 5B, the melting portions 26A, 26
B is formed.

(Embodiment 4) FIG. 12 shows a fourth embodiment, in which terminal portions 35A and 35A 'are provided on one side in a plate-shaped synthetic resin terminal block 34 and the other side opposite to this. A transformer function section 32 including a coil (wire) 33 is placed on the terminal block 34 having terminal sections 35B, 35B 'implanted therein, respectively, and the terminal sections 35A, 35A', 35B,
The vicinity of the distal end of 35B 'is a wire disposition portion as described above, and wire terminals 33A, 33A', 33B, 33B 'are respectively disposed there, and terminal portions 35A, 35A', 35B, 3 are provided.
5B 'is melted, and the fused portions 36A, 36A', 36
B, 36B '.

(Fifth Embodiment) FIGS. 13 and 14 show a fifth embodiment, in which four terminals formed on a pair of lead frames F are arranged at the center so as to face each other. The tip of the portion 45 is bent upward to form the terminal portion 45A,
A toroidal core 42 around which a wire 43 is wound is disposed between the distal ends of the terminal portions, and a bent end 45A of each of the terminal portions 45 is provided.
, A wire terminal 43A is disposed in the vicinity of the above-mentioned wire disposition portion, and the distal end of the terminal portion 45 is melted to form a fusion portion 46. 48 is an exterior mold.

Each of the second to fifth embodiments also has the same operation as in the first embodiment.
Needless to say, it has an effect. In particular,
As in the transformer of FIG. 10, when the protruding tip of the terminal joined to the terminal block bottom is bent upward and the tip is used as a fusion part, there is also an advantage that the fusion part does not hinder the mounting of the substrate.

The present invention is not limited to the above-described embodiment, but may be applied to electric parts such as capacitor parts and resistance parts, and electronic parts as long as it has a structure for connecting wires and terminals. Is also widely applied.

[0054]

According to the first aspect of the present invention, it is possible to obtain a highly reliable connection state without copper cracks and the like and no reduction in strength. Since there is no cleaning step, the number of steps can be reduced. It is possible to provide a wire connection structure that can reduce the cost and can improve the working environment because it does not use a cleaning step or lead.

According to the second aspect of the present invention, in addition to the same effects as the first aspect of the invention, the wire ends are easily tied, positioning is easy, and the constricted portion melts into the wire. The effect that a reliable wire connection can be performed is obtained.

According to the third aspect of the present invention, in addition to the effect of the first aspect of the present invention, since the umbrella portion is melted in a form enclosing the wire locking portion, the effect that the connection is further ensured is obtained. can get.

According to the fourth aspect of the present invention, in addition to the effect of the first aspect of the present invention, since the tip of the wire is inserted into the insertion hole, positioning is easy, and the wire is pressed from the periphery of the wire during melting. , The effect that connection is secure,
Further, since it is only necessary to insert the tip end of the wire into the wire insertion hole, an effect that it is suitable for automatic assembly can be obtained.

According to the fifth aspect of the invention, the same effect as the fourth aspect of the invention can be obtained.

According to the sixth aspect of the present invention, since the wire is completely wrapped in the bent portion, an effect that the connection by the melting process is further ensured can be obtained.

[Brief description of the drawings]

FIG. 1 is a perspective view showing one embodiment of a wire connection structure of the present invention.

FIG. 2 is an explanatory view of a main part of a wire connection structure applied to an embodiment of the present invention.

FIG. 3 is an explanatory view of a main part of a wire connection structure applied to an embodiment of the present invention.

FIG. 4 is an explanatory view of a main part of a wire connection structure applied to an embodiment of the present invention.

FIG. 5 is an explanatory view of a main part of a wire connection structure applied to an embodiment of the present invention.

FIG. 6 is an explanatory view of a main part of a wire connection structure applied to one embodiment of the present invention.

FIG. 7 is an explanatory view of a main part of a wire connection structure applied to an embodiment of the present invention.

FIG. 8 is an explanatory view of a main part of a wire connection structure applied to an embodiment of the present invention.

FIG. 9 is a perspective view of a main part of a wire connection structure applied to one embodiment of the present invention.

FIG. 10 is a perspective view showing a second embodiment of the present invention.

FIG. 11 is a perspective view showing a third embodiment of the present invention.

FIG. 12 is a perspective view showing a fourth embodiment of the present invention.

FIG. 13 is a plan view showing a fifth embodiment of the present invention.

FIG. 14 is a side view showing a fifth embodiment of the present invention.

FIG. 15 is a side view showing a conventional wire connection structure.

FIG. 16 is a bottom view showing a conventional wire connection structure.

FIG. 17 is a diagram showing a conventional wire connection process.

[Explanation of symbols]

1, 11, 21, 31, 41 Coil device 2, Bobbin 3, 13, 23, 33, 43 Wire 3A, 3B, 13A, 13B, 13A ', 13B', 2
3A, 23B, 33A33B, 33A ', 33B', 4
3A Wire terminal 4, 14, 24, 34, 44 Terminal block 5A, 5B, 15A, 15B, 15A ', 15B', 2
5A, 25B, 35A35B, 35A ', 35B', 4
5A terminal part 6A, 6B, 16A, 16B, 16A ', 16B', 2
6A, 26B, 36A36B, 46 Fused portion 12, 22, 32, 42 Magnetic core

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Ryuji Yoshida 1-13-1, Nihonbashi, Chuo-ku, Tokyo TDC Corporation F-term (reference) 5E043 EA06 EB05 5E062 FF04 FG02 FG05 FG12 5E070 AB02 EA04 EA06 EA10

Claims (6)

[Claims] 1. A wire connection structure for an electric or electronic component having a wire connected to a terminal, wherein the wire is disposed near a tip of the terminal, and the tip of the terminal is melt-processed. A wire connection structure wherein a wire is electrically and mechanically connected to the terminal portion. 2. The wire connection structure according to claim 1, wherein a constricted portion is provided near a tip of the terminal portion, and the wire is entangled with the constricted portion. 3. A terminal portion of the terminal portion is formed in a mushroom shape, the wire is entangled with a stem near the umbrella portion of the mushroom shape, and the umbrella portion is melt-processed to entangle the wire. The wire connection structure according to claim 1, wherein the wire connection structure covers the portion. 4. The wire connection structure according to claim 1, wherein a wire insertion hole is provided near a tip of the terminal portion, and the wire is inserted into the wire insertion hole. 5. The wire connection structure according to claim 1, wherein a V-shaped notch is provided near a tip of the terminal, and the wire is inserted through the notch. 6. A tip of the terminal portion is bent,
The wire connection structure according to claim 1, wherein the wire is disposed at the bent portion.