WIRE COIL ASSEMBLY FOR MATRIX PRINT HEAD AND MANUFACTURING METHOD

Abstract: An assembly including a wire coil carrying bobbin (50) and a printed circuit board (34) having conductors (44) thereon. The bobbin (50) has first and second posts (68, 70) extending through corresponding apertures (40, 42) in the printed circuit board (34). Each post (68, 70) has first and second grooves (72, 74) extending along it and each end (82) of the coil wire (80) extends along and within said first groove (72), across the tip (84), and along and within said second groove (74) of the respective post (68, 70) and is soldered to the reverse side of the printed circuit board. Assembly is accomplished in one operation wherein a single aperture in the printed circuit board serves both as an aperture for the post and as an aperture for the wire end.

Description: WIRECOILASSEMBLYFORMATRIXPRINTHEADANDMANUFACTURINGMETHOD Tpπhnical Field The present invention relates to an assembly including a coil wire-carrying member and a printed circuit board, and to a method of securing a wire coil carrying member to a printed circuit board. Such method and assembly are particularly useful in the manufacture of wire matrix print heads, more particularly print heads in which a plurality of wires are caused to be propelled against a record medium by respective clapper-type, solenoid actuated, print wire drivers for printing dot matrix characters in accordance with external control signals. Background Art In wire matrix print heads of this kind, the solenoids are arranged or grouped in a manner to drive the respective print wires a precise distance form a rest or non-printing position to an impact or printing position. The print wires are generally engaged by the clapper members or armatures which are caused to be moved such precise distance when the solenoid coil is energized and wherein the armature normally oper- ates against the action of a return spring. It has been quite common to provide an arrangement or grouping of such solenoids in a circu¬ lar configuration to take advantage of reduced space available in the manner of locating the print wires in that area from the solenoid to the front tip of the print head adjacent the record media. In this re¬ spect, the actuating ends of the print wires are spaced in accordance with the circular arrangement and the operating or working ends of the print wires are closely spaced in vertically-aligned manner adjacent ζXT-^ l O PI the record media. The availability of narrow or compact actuators permits a narrower print head to be used and thereby reduces the width of the printer because of the reduced clearance at the ends of the print line. The print head can also be made shorter because the narrow actuators can be placed in side-by- side manner closer to the record media for a given amount of wire curvature. The print head, with the wire elements aligned in a vertical line, is supported on a print head carriage which is caused to be moved or driven in a horizontal direction for printing in line manner. The method according to the invention may be advantageously used in the manufacture of wire matrix print heads of the above type, wherein a printed circuit board serves as a support for, and provides electrical connections to, the solenoid coils for actuating the print wire drivers. A method of securing an electrical component such as a coil form to a printed circuit board, is described in U.S. Patent No. 3,486,224. The form, which is of thermoplastic material, has mounting feet thereon which are pressed through holes in the circuit board. The coil ends are passed through separate holes in the circuit board in contact with appropriate circuit elements on the reverse side of said board and are soldered to these elements. Concurrently, the ends of the mounting feet are fused to form rivet-like heads permanently securing said component to said board. Disclosure of the Invention It is an object of the present invention to provide a simplified assembly and method of assembly of a wire coil carrying member and a printed circuit board. Thus, according to the invention, there is provided an assembly including a wire coil carrying member and a printed circuit board having conductors thereon, in which said wire coil carrying member has first and second posts extending through corresponding apertures in the printed circuit board, and in which the ends of the coil wire pass through, and are sol¬ dered to, conductors of said printed circuit board, characterized in that each post has first and second grooves extending along it, and in that each end of the coil wire extends along and within said first groove, across the tip, and along and within said second groove of the respective post. According to another aspect of the invention, there is provided a method of securing a wire coil carrying member to a printed circuit board having conductors thereon, including the steps of providing said wire coil carrying member with first and second posts, passing said posts through corresponding aper- tures in the printed circuit board and passing the ends of the coil wire through, and soldering them to, conductors of said printed circuit board, character¬ ized by the steps of providing each post with first and second grooves therealong, placing one end of the coil wire into and along said first groove, across the tip and into and along said second groove of said first post, and placing the other end of the coil wire into and along said first groove, across the tip and into and along said second groove of said second post prior to passing said posts through the corresponding apertures in said printed circuit board. It will be appreciated that the method according to the invention has the advantage that it facilitates assembly, since assembly is accomplished in one operation wherein a single aperture in the printed circuit board serves both as an aperture for the post and as an aperture for the wire end. Brief Description of the Drawings Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:- Fig. 1 is a perspective view showing certain parts of a print head in exploded manner; Fig. 2 is a top plan view showing one embodiment of a coil bobbin; Fig. 3 is a sectional view taken along the line 3-3 of Fig. 2; Fig. 4 is a sectional view showing the bobbin wound coil and circuit board assembly; Fig. 5 is an enlarged view of the coil wiring connection with the circuit board; Fig. 6 is a top plan view showing another embodiment of the coil bobbin; and Fig. 7 is a sectional view taken along the line 7-7 of Fig. 6. Rest Mode for Carrying Out the Invention Fig. 1 is an illustration, in exploded manner, of several of the parts included in the pres¬ ent invention and wherein a backplate 18, of circular shape and having spaced apertures or windows 20 there¬ in, carries a plurality of U-shaped magnetic core members 22 each of which comprises inner and outer poles 24 and 26. A hole 27 is provided in the back¬ plate 18 for a ground connection. An insulating spacer 28 of paper or like material is provided next to the backplate 18 and has a lower portion 30 and a plurality of apertures or windows 32 for receiving the pole portions 24 and 26 of the core members 22. Next is a printed circuit board 34 likewise of similar shape as the spacer 28 and having a lower portion 36 and including a plurality of apertures or windows 38 therein corresponding generally in location and size with the windows 32 in the spacer 28. Each of the three elements, i.e., the backplate 18, the spacer 28 and the circuit board 34 includes a central aperture therein for receiving a member for fastening the three elements in a wire matrix print head, the details of which are disclosed in an international application in the name of the present applicant filed on the same day as the present application and entitled "Wire Matrix Print Head." A pair of copper-lined holes 40 and 42 are positioned adjacent each window 38 in the printed circuit board 34 and copper runs or conductors 44 extend on one side (the back side in Fig. 1) of the board from certain ones of such holes 40 and 42 to copper-lined holes 46 formed in a row along the lower portion 36. A second row of copper-lined holes 48 is positioned just below the holes 46 for connecting with other ones of the holes 40 and 42 on the other side (the front side in Fig. 1) of the circuit board, which front side includes a copper coating or plating there¬ on, schematically indicated 45, for connecting the common or neutral portion of each circuit. The con¬ struction of the copper runs or conductors on a print¬ ed circuit board 34 is well-known, as are the connec- tors typically used to connect with the conductors on the circuit board. Fig. 2 shows a top view of a coil bobbin 50 which is secured to the circuit board 34. The bobbin 50 is made of a plastic material such as nylon or the like and includes flange ends 52 and 54 (Fig. 3) which may be considered to be somewhat rectangular-shaped and connected by a hollow rectangular-shaped central body portion 56. The flange 54 has a slightly raised portion 58 on the surface thereof and the flange 52 has a smaller and slightly raised portion 60. as best seen in Fig. 3. There are three pads 62, 64 and 66 (Fig. 2) on the outer surface of the flange 52 for providing a seating plane with the surface of the circuit board 34 when in place and supported thereby. Additionally, the three pads 62, 64 and 66 provide space between the surfaces of the circuit board 34 and bobbin 50 to enable flushing of any liquids or materi¬ als used in assembling the parts. A pair of posts 68 and 70, integral with the flange 52, are positioned at two corners of the flange 52 and extend outwardly from the pads 64 and 66. Each of the posts 68 and 70 has opposed grooves 72 and 74. with the outside groove 72 extending through the flange 52. Fig. 4 is a section of the assembly of a bobbin 50 and a circuit board 34 taken through the post 68 and the pad 62. The assembly includes in excess of 200 turns of copper magnet wire 80 wound on the bobbin in coil form. The coil wire 80 is wrapped with several layers of tape 90 in well-known manner. The ends of the wire 80 are placed in the grooves 72 and 74 of the posts 68 and 70 and then the wound bobbin 50 is attached to the circuit board 34 with the posts 68 and 70 extending through the respective holes 40, 42 in the circuit board. As best understood from Fig. 5, each end 82 of the coil wire 80 is disposed in and along the one groove 72, across a tip 84 of the respective posts 68 and 70, and then in and along the other groove 74. After the wire ends 82 are seated in the grooves 72, 74 of the respective posts and the pads 62, 64, 66 of the bobbin 50 are placed firmly against the surface of the circuit board 34 with the posts 68 and 70 extending through the respective holes 40, 42, a portion of solder 86 is placed, as in a wave soldering or like operation, across the wire ends 82 on the tip 84 of the posts 68, 70 and over the copper lining, designated as 88, in and adjacent each hole 40, 42 in the circuit board 34. The backplate 18 carries the core members 22 secured thereto as by pressing same through the windows 20. The insulating spacer'28 is placed adjacent the backplate 18 with the core member poles 24 and 26 extending through the windows 32 of the spacer 28, through the windows 38 of the circuit board 34, and with outer pole 26 of core member 22 extending through the hollow body portion 56 of the bobbin 50 (Fig. 4) . It should be noted that the backplate 18 is made of aluminum, the core members 22 are made of silicon iron and the circuit board 34 is epoxy glass. Figs. 6 and 7 illustrate a different arrangement for certain structure of the coil bobbin 50. The flange ends 52 and 54 are the same shape and size as the ends shown in Figs. 2 and 3, however the central body portion 56 is enlarged slightly to better accommodate the outer pole 26 in the assembly of parts. The flange 54 includes the slightly raised portion 58 on the surface thereof and the flange 52 also has the raised portion 60. There are four square pads 92 arranged in symmetrical manner on the flange 52 for providing a seating plane with the surface of the circuit board 34 and holding the flange 52 in a stable condition when mounting the bobbin 50 on the circuit board 34. Further, the pads 92 provide space between the surfaces of the circuit board 34 and bobbin 50 to enable flushing of any liquids or materi¬ als used in the soldering operation. The posts 68 and 70, integral with the flange 52, are positioned along a centerline thereof. Each of the posts 68 and 70 has the opposed grooves 72 and 74 with the outside groove extending through the flange 52. It is thus seen that herein shown and described is a wire matrix print head solenoid assem¬ bly having a plurality of print wire actuating coils directly connected with and supported from a printed circuit board.

Claims: CLAIMS * 1. An assembly including a wire coil carrying member (50) and a printed circuit board (34) having conductors (44) thereon, in which said wire coil-carrying member (50) has first and second posts (68. 70) extending through corresponding apertures (40, 42) in the printed circuit board (34), and in which the ends (82) of the coil wire (80) pass through, and are soldered to, conductors of said printed circuit board (34) , characterized in that each post (68, 70) has first and second grooves (72, 74) extending along it, and in that each end (82) of the coil wire (80) extends along and within said first groove (72) , across the tip (84) , and along and within said second groove (74) of the respective post (68, 70) . 2. An assembly according to claim 1. characterized in that said wire coil-carrying member is a bobbin (50) including a plurality of raised portions (62, 64, 66) on one flange end (52) thereof for providing a seating plane with one surface of said printed circuit board (34) . 3. An assembly according to claim 2, characterized in that one of the grooves (74) in each of said first and second posts (68. 70) is arranged to continue as an aperture through the said flange. end (52) of said bobbin (50) . 4. An assembly according to claim 2, characterized in that said bobbin (50) is generally rectangular in shape and said first and second posts (68- 70) are located on respective corners of said one flange end (52) of said bobbin (50) . 5. An assembly according to claim 2 , characterized in that said bobbin (50) is generally rectangular in shape and said first and second posts (68, 70) are located on respective sides of said one flange end (52) of said bobbin (50) . OMPI IPO 6. An assembly according to claim 1, characterized in that one major surface of said print¬ ed circuit board (34) has a copper coating (45) there¬ on, said conductors (44) being runs of copper extend- ing on the other major surface of said printed circuit board (34) terminating at individual copper lined apertures (40, 42). 7. A wire matrix print head including a plurality of assemblies claimed in any one of claims 1 to 7, characterized in that said printed circuit board (34) serves as a support for, and provides electrical connections to, the coils (80) of a plurality of electromagnetic actuating means (22, 24, 50) for the print wires. 8. A method of securing a wire coil carrying member (50) to a printed circuit board (34) having conductors (44) thereon, including the steps of providing said wire coil carrying member (50) with first and second posts (68, 70) , passing said posts (68, 70) through corresponding apertures (40, 42) in the printed circuit board (34, and passing the ends (82) of the coil wire (80) through, and soldering them to, conductors of said printed circuit board (34) , characterized by the steps of providing each post (68, 70) with first and second grooves (72. 74) therealong, placing one end (82) of the coil wire (80) into and along said first groove (72) , across the tip (84) and into and along said second groove (74) of said first post (68), and placing the other end (82) of the coil wire (80) into and along said first groove (72), across the tip (84) and into and along said second groove (74) of said second post (70) prior to passing said posts (68, 70) through the corresponding aper- tures (40, 42) in said printed circuit board (34). O PI ™

Inventors: REECE JOHN W, WEEKS DAVID E, WIRTH ROBERT L, REECE, JOHN, W., WEEKS, DAVID, E., WIRTH, ROBERT, L.
Applicants: NCR CO, NCR CORPORATION
Application year: 1984
Main classification: B41J3
IPC codes: B41J2, H01F7, H01F27, H05K1, H05K3