Patent Description:
A resin molded type electromagnetic coil has been used in a solenoid valve, the resin molded type electromagnetic coil being formed by covering a magnet wire (hereinafter, often refer simply to as "wire") wound to a bobbin or a connection terminal with a resin, and integrally molding a connector mating portion mated to a connector of an external device with the resin.

Further, in the electromagnetic coil mentioned above, in order to protect the other circuit elements such as a switching element from a surge voltage which is generated when switching energization of the electromagnetic coil, a flywheel diode (free-wheeling diode or hereinafter often refer simply to as "diode") may be provided.

Further, the following patent literatures are provided for disclosing the resin molded type electromagnetic coil provided with the diode as mentioned above.

<CIT> discloses an improved solenoid operated fluid control valve particularly adapted for use as a vacuum control switch in a motor vehicle. According to one aspect, a coil assembly is adapted to be wound and terminated using completely automated processes. This is provided through the use of a bobbin structure having protruding coil winding posts which position the start and finish ends of the coil wire. Terminal members are installed onto the bobbin and have terminal contact portions which can be folded onto the wire.

<CIT> discloses a solenoid in which a coiling part whereupon a solenoid coil is to be wound and a guide for inserting an external connector are integrally formed. The external connector insertion guide for inserting an external connector is provided with terminal inserting parts which allow the outer side connecting parts of coil terminals to be inserted into the guide in a previously fixed direction. The solenoid is provided with a bobbin whereupon the guide for external connector insertion is formed.

<CIT> discloses a control valve of a variable displacement compressor which is equipped with a control valve part to control the displacement of the variable displacement compressor, a valve to drive the control valve part, and a connector part wherewith a power supply for driving of the valve drive part is connected, wherein the connector part and the solenoid to constitute the valve drive part are formed in a single piece through molding process.

<CIT> discloses a field coil assembly of an electromagnetic clutch for a compressor, in which a coil wire of an electromagnetic coil body exposed to a protrusion of a bobbin is electrically connected with a compressing portion of a coil wire formed at one side portion of terminals mounted inside a sleeve, and the terminals and the electromagnetic coil body are molded with the resin.

<CIT> discloses a sleeve connector for an electromagnetic clutch having a first holder carrying a diode and a resistor for absorbing surge voltage and removing an induced magnetic field generated by an electromagnetic clutch field coil assembly. First and second terminals respectively connected with the diode and the resistor are held by a second holder so the terminals are insulated from each other. A molded plastic middle assembly encapsulates the diode, resistor, both holders and both terminals and joins the holders to each other.

In the meantime, an insulating coated layer is thin in a winding wire of a coil in comparison with a normal electrical wire, and a mechanical strength of the winding wire itself before being molded with resin into a product is not enough strong. Therefore, there is a risk that the coated layer may be injured and damaged during manufacturing such as the wire winding time and the molding time.

Therefore, it is necessary to inspect in the final step for manufacturing whether or not the winding wire is short-circuited in the middle, or whether or not the coated layer is in a state in which the coated layer is injured to cause a future short-circuit. This inspection is carried out by a Layer Short test which applies a high-voltage pulse to the coil and analyzes an obtained resonance waveform. However, in order to more securely find a defective product, it is desirable to carry out the inspection in a state in which the product is as close to the finished product as possible.

In the electromagnetic coil provided with the flywheel diode for the purpose of protecting from the high-voltage surge voltage, the diode gets in the way of the test, and it is hard to carry out the high-precision inspection in a state in which the product is close to the finished product.

On the contrary, the inventions described in the patent literatures mentioned above neither point out the problem mentioned above nor show any coping process.

Therefore, an object of the present invention is to make it possible to carry out a high-precision product inspection of an electromagnetic coil provided with a flywheel diode, in particular, of a winding wire.

In order to solve the problem and achieve the object, a resin molded electromagnetic coil according to the present invention is a resin molded electromagnetic coil according to present claim <NUM>, including a magnet wire which is wound to a bobbin, and a pair of connection terminals for electrically connecting the magnet wire to an external circuit, the resin molded electromagnetic coil being constructed by covering the magnet wire, and the pair of connection terminals with a mold resin, and including a flywheel diode which is connected between the pair of connection terminals. In the present application, the resin molded electromagnetic coil may be often referred simply to as "electromagnetic coil", "molded coil" or "coil", and the magnet wire may be often referred simply to as "wire".

The bobbin has a tubular portion to which the magnet wire is wound, a first flange which is disposed in one end portion of the tubular portion and protrudes outward from an outer peripheral surface of the tubular portion, and a second flange which is disposed in the other end portion of the tubular portion and protrudes outward from the outer peripheral surface of the tubular portion. In this case, "outward" means a direction which gets away from a center axis of the tubular portion.

The pair of connection terminals include a first terminal and a second terminal which are disposed so as to extend in parallel to each other and outward from an edge portion of the first flange. Further, the first terminal is provided with a diode connecting portion to which a starting point of the magnet wire is connected, and to which the flywheel diode is connectable. Further, the second terminal is provided with a diode connecting portion to which an ending point of the magnet wire is connected, and to which the flywheel diode is connectable.

Further, the flywheel diode is connected between the diode connecting portion of the first terminal and the diode connecting portion of the second terminal, and a covering layer made of the mold resin has a diode attaching hole which is communicated with the diode connecting portion of the first terminal and the diode connecting portion of the second terminal exposing the diode connecting portions at a surface of the diode attaching hole in such a manner that the flywheel diode is attachable after forming the covering layer, and is capable of receiving the flywheel diode. Further, the diode attaching hole is closed by a sealing material which is provided separately from the mold resin.

The term "mold resin" mentioned above is a resin which is used for forming with a mold such as an injection forming and a cast molding forming. Further, the term "provided separately" about the sealing material means being provided in a separate step from the mold resin, that is, not being provided together with (or simultaneously with) the mold resin. Further, it goes without saying that the sealing material is a material which has an electrical insulation property (non-conductive property) and can prevent the moisture and the foreign matter from entering, for the purpose of covering a connection portion between the diode and the connection terminal (the diode connecting portion). As the sealing material, an insulating resin, for example, an epoxy resin can be preferably used. The sealing material may be a different material from the mold resin or may be the same material as the mold resin.

In the electromagnetic coil according to the present invention, the diode can be attached by utilizing the diode attaching hole after covering the coil main body obtained by winding the magnet wire to the bobbin with the mold resin. Therefore, it is possible to apply a inspect such as the Layer Short test to the winding wire (the magnet wire) which is molded (covered with the mold resin) to the same state as the final product and to which the flywheel diode is not connected. Thus, it is possible to carry out the higher-precision inspect which is not affected by the diode, and it is possible to more securely find a defective item of the electromagnetic coil with the flywheel diode.

According to one aspect of the present invention, both of the first terminal and the second terminal have an external connection portion for connecting to an external circuit in a leading end portion thereof, have a support portion for supporting the terminal to the first flange in a base end portion thereof, and are provided with the diode connecting portion between the leading end portion and the base end portion.

The flywheel diode is typically a surface mount diode. The present invention does not exclude use of an axial lead diode.

Further, the electromagnetic coil according to the present invention may be further provided with a connector mating portion which the leading end portion of the first terminal and the leading end portion of the second terminal are arranged inside and which is mated to a connector of the external circuit for connecting the magnet wire to the external circuit.

Further, a solenoid valve according to the present invention is provided with the resin molded electromagnetic coil according to any one of the aspects of the present invention mentioned above.

Further, a method of manufacturing an electromagnetic coil according to the present invention is defined in claim <NUM>.

Further, the manufacturing method may include an inspection process of an inspection for whether or not an insulating coated layer of the magnet wire is damaged, after the molding step and before the diode attaching step, and the testing step may be conducted by a Layer Short test.

According to the present invention, it is possible to conduct a higher-precision product inspection of the electromagnetic coil provided with the flywheel diode, in particular the winding wire, and it is possible to more securely find a defective item.

The other objects, features and advantages of the present invention can be apparent from the following description of embodiments according the present invention which will be given on the basis of the accompanying drawings. It is apparent for a person skilled in the art that the present invention is not limited to the following embodiments, but can be variously modified within the scope of the claims. Further, in the drawings, same reference numerals denote same or corresponding portions.

As shown in <FIG>, a resin molded electromagnetic coil <NUM> according to an embodiment of the present invention is constructed by covering a coil main body, and a pair of connection terminals <NUM> (31a and 31b) with a molded resin <NUM>. The coil main body is constructed by winding a magnet wire <NUM> to a bobbin <NUM>. A pair of connection terminals <NUM> connect the coil main body to an external circuit (an external device) for feeding an electric power to the magnet wire <NUM>. Further, the resin molded electromagnetic coil <NUM> is provided with a flywheel diode <NUM> which is connected in parallel between both the connection terminals <NUM>. Further, it goes without saying that the resin molded electromagnetic coil <NUM> according to the present invention can be preferably employed as an electromagnetic coil of a solenoid valve.

The diode <NUM> is connected between the connection terminals 31a and 31b through a diode attaching hole 51c after molding, as mentioned in detail later. Further, each of the drawings shows a mutually orthogonal two-dimensional or three-dimensional coordinates which represents a longitudinal direction, a lateral direction and a vertical direction, and the following description will be given on the basis of these directions. Further, the vertical direction may be referred to as a perpendicular direction, and a direction including the longitudinal direction and the lateral direction and being orthogonal to the perpendicular direction may be referred to as a horizontal direction, respectively.

The bobbin <NUM> is constructed by a tubular portion <NUM> having a cylindrical shape, and a pair of flanges <NUM> disposed in both ends of the tubular portion <NUM>. Further, a pair of flanges <NUM> are constructed by a first flange 14a which horizontally protrudes circumferentially from an upper end portion of the tubular portion <NUM>, and a second flange 14b which horizontally protrudes circumferentially from a lower end portion of the tubular portion <NUM>. Further, a terminal attaching portion <NUM> for installing a connection terminal <NUM> is formed in a front edge portion of an upper surface of the first flange 14a.

A pair of connection terminals <NUM> installed in the terminal attaching portion <NUM>, that is, a first terminal 31a and a second terminal 31b are both made of an electrically conductive material, and are installed so as to extend in parallel to each other at a fixed distance laterally and horizontally forward. The first terminal 31a corresponds to one connection terminal among the connection terminals <NUM> and the second terminal 31b corresponds to the other connection terminal.

Further, leading end portions (front end portions) of the respective connection terminals 31a and 31b are provided with external connection portions 32a and 32b which electrically connect to an external circuit (not shown). Further, base end portions (rear end portions) of the respective connection terminals 31a and 31b form support portions 36a and 36b for fixing the connection terminals 31a and 31b to the terminal attaching portion <NUM>. Further, intermediate portions of the respective terminals 31a and 31b positioned between the leading end portions (the external connection portions 32a and 32b) and the base end portions (the support portions 36a and 36b) are set to wire connection portions 33a and 33b for connecting the magnet wire <NUM>, and lower surfaces of the intermediate portions are set to diode connecting portions 37a and 37b connecting the diode.

The external connection portions 32a and 32b at the leading ends of the connection terminals protrude horizontally into an internal space 51b of a connector mating portion 51a mentioned later to enable an electrical connection to the external circuit.

A constriction portion <NUM> is formed at the wire connection portions 33a and 33b in the middle of the connection terminals, the constriction portion <NUM> being narrowed so as to allow the magnet wire <NUM> to be tied up (wound up). Further, the wire connection portions 33a and 33b at the middle of the connection terminals are provided with a protruding piece <NUM> which can pinch an end portion (a starting point portion 15a or an ending point portion 15b) of the magnet wire <NUM>. The protruding piece <NUM> can pinch the end portion of the wire <NUM> between the protruding piece <NUM> and the upper surfaces of the wire connection portions 33a and 33b by bending downward.

In the meantime, the lower surfaces of the intermediate portions of the connection terminals are formed as flat surfaces (horizontal surfaces) expanding horizontally, and terminal electrodes 41a and 41b of a surface mount flywheel diode <NUM> can be connected by utilizing the horizontal surfaces (the diode connecting portions 37a and 37b).

The support portions 36a and 36b at the base ends of the connection terminals are formed into a tabular shape which expands horizontally in connection to the wire connection portions 33a and 33b and the diode connecting portions 37a and 37b. These support portions 36a and 36b can be press fitted (inserted) into terminal support holes 22a and 22b mentioned later, thereby allowing each of the connection terminals 31a and 31b to be supported to the terminal attaching portion <NUM>.

In the meantime, the terminal attaching portion <NUM> formed in an upper surface front edge portion of the first flange 14a has in a front face thereof a terminal support hole (a first terminal support hole) 22a which can press fit the support portion 36a of the first terminal 31a, and a terminal support hole (a second terminal support hole) 22b which can press fit the support portion 36b of the second terminal 31b.

The coil main body (the bobbin <NUM> and the wire <NUM>) and the connection terminals 31a and 31b (except the external connection portions 32a and 32b) are covered with the mold resin, and the connector mating portion 51a is integrally formed concurrently with the molding time. The connector mating portion 51a is configured to have an outer shape which adapts to the specification of the external device to be connected, for enabling the connection to the external device in a tubular portion extending horizontally forward from the terminal attaching portion <NUM> of the first flange 14a.

Further, a rear end portion of the connector mating portion 51a is formed as a solid structure (a structure filled with the resin) for covering and sealing the connection portion between the connection terminals 31a and 31b and the wire <NUM>. On the contrary, a front end portion of the connector mating portion 51a is formed as a hollow structure (a structure having an internal space 51b) for exposing the external connection portions 32a and 32b of the connection terminals 31a and 31b and enabling the electrical connection to the external device.

In a lower surface portion at a rear end portion of the connector mating portion 51a, the diode attaching hole 51c is formed for allowing the diode <NUM> to be attached between the connection terminals 31a and 31b after molding (refer to <FIG>, <FIG>, <FIG>). The diode attaching hole 51c is a hole which is communicated with the diode connecting portions 37a and 37b in a lower surface of the intermediate portions of both the connection terminals 31a and 31b from the lower surface at the rear end portion of the connector mating portion 51a, and the terminal electrodes 41a and 41b of the diode <NUM> can be connected to the diode connecting portions 37a and 37b through the diode attaching hole 51c (refer to <FIG>).

The diode attaching hole 51c is closed by being filled with a sealing resin 51d, for example, an epoxy resin, after connecting the diode <NUM> (refer to <FIG>).

The diode attaching hole 51c is not limited its shape as long as the diode attaching hole 51c is communicated with the diode connecting portions 37a and 37b and can connect the diode <NUM> between the connection terminals 31a and 31b after molding. For example, a periphery of an internal space receiving the diode <NUM> is not necessarily enclosed completely, but may be formed into a groove shape in which both ends are opened as shown in <FIG>.

A process of manufacturing the electromagnetic coil according to the present embodiment will be mentioned as follows.

The first terminal 31a and the second terminal 31b are fixed to the first flange 14a of the bobbin <NUM> by press fitting the support portions 36a and 36b of the respective connection terminals 31a and 31b to the respective terminal support holes 22a and 22b of the terminal attaching portion <NUM> in the upper surface of the first flange 14a.

The starting point portion 15a of the magnet wire <NUM> drawn from a wire feeding reel of a coil winding machine (not shown) is locked by being wounded to the constriction portion <NUM> of the first terminal 31a. The bobbin <NUM> is rotated in this state, and the wire <NUM> is wound to an outer peripheral surface of the tubular portion <NUM> in multiple layers.

In this case, the connection terminals 31a and 31b do not prevent a winding work of the wire <NUM> and it is possible to efficiently perform the work. This is because the terminal attaching portion <NUM> exists in the upper surface of the first flange 14a, the connection terminals 31a and 31b extend horizontally in parallel to the upper surface of the first flange 14a, the connection terminals 31a and 31b are arranged while avoiding a path of the wire <NUM> wound to the bobbin <NUM> from the automatic coil winding machine, and the diode <NUM> is not attached to the connection terminals 31a and 31b.

After the winding work of the wire <NUM> to the tubular portion <NUM> is finished, the ending point portion 15b of the wire <NUM> is locked by being wound to the constriction portion <NUM> of the second terminal 31b.

Further, the protruding piece <NUM> of the first terminal 31a is bent, the starting point portion 15a of the wire <NUM> is sandwiched between the protruding piece <NUM> and the terminal intermediate portion (the wire connection portion 33a), the protruding piece <NUM> and the starting point portion 15a are pinched and pressurized by an electrode (not shown) of a fusing welding machine from above and below so as to be closely attached, and an insulating coated layer of the wire <NUM> is melted by energizing them, thereby welding and electrically connecting the starting point portion 15a of the wire <NUM> and the first terminal 31a. In the same manner, the protruding piece <NUM> of the second terminal 31b is bent, the ending point portion 15b of the wire <NUM> is sandwiched between the protruding piece <NUM> and the terminal intermediate portion, the protruding piece <NUM> and the ending point portion 15b of the wire are pinched and pressurized by the electrode (not shown) of the fusing welding machine from above and below so as to be closely attached, and the insulating coated layer of the wire <NUM> is melted by energizing them, thereby welding and electrically connecting the ending point portion 15b of the wire <NUM> and the second terminal 31b.

A whole of the coil is installed within the metal mold and the mold resin is injected and filled around the coil main body. At the same time, the connector mating portion 51a is integrally formed. Further, the diode attaching hole 51c at the lower surface of the rear end portion of the connector mating portion 51a is formed at the same time. The internal space 51b of the leading end portion of the connector mating portion 51a and the diode attaching hole 51c at the rear end portion of the connector mating portion may be formed by arranging an insert for mold. For example, polyphenylene sulfide (PPS) can be preferably used for the mold resin.

A test is conducted whether or not the insulating coated layer of the wire <NUM> wound to the bobbin <NUM> is damaged. The test is conducted by the Layer Short test, and the subsequent steps are applied only to good products in which any problem is not found by this test to obtain the finished product. When conducting the test, the wire <NUM> and the connection portion between the wire <NUM> and the connection terminals 31a and 31b are covered with the mold resin, the diode <NUM> is not connected yet. Therefore, the high-precision test can be conducted without being affected by the diode <NUM>, and the defective item can be more securely found.

The diode <NUM> is attached between the diode connecting portions 37a and 37b of both the connection terminals 31a and 31b which are exposed to the upper surface of the diode attaching hole 51c (refer to an arrow C in each of the drawings). More specifically, each of the terminal electrodes 41a and 41b of the diode <NUM> are connected to each of the diode attaching portions 37a and 37b by soldering. At this time, according to the present embodiment, the terminal electrodes are soldered to the diode attaching portions 37a and 37b which correspond to comparatively wide flat surfaces in the bottom surface of the intermediate portion of the connection terminal. Therefore, it is possible to enhance a reliability of electrical connection of the diode <NUM>.

Claim 1:
A resin molded electromagnetic coil comprising:
a magnet wire (<NUM>) which is wound to a bobbin (<NUM>);
a pair of connection terminals (<NUM>) for electrically connecting the magnet wire (<NUM>) to an external circuit;
the resin molded electromagnetic coil being constructed by covering the magnet wire (<NUM>) and the pair of connection terminals (<NUM>) with a mold resin; and
a flywheel diode (<NUM>) which is connected between the pair of connection terminals (<NUM>),
wherein the bobbin (<NUM>) comprises:
a tubular portion (<NUM>) to which the magnet wire (<NUM>) is wound;
a first flange (14a) which is disposed in one end portion of the tubular portion (<NUM>) and protrudes outward from an outer peripheral surface of the tubular portion (<NUM>); and
a second flange (14b) which is disposed in the other end portion of the tubular portion (<NUM>) and protrudes outward from the outer peripheral surface of the tubular portion (<NUM>),
wherein the pair of connection terminals (<NUM>) include a first terminal (31a) and a second terminal (31b) which are disposed so as to extend in parallel to each other and outward from an edge portion of the first flange (14a),
wherein the first terminal (31a) comprises a diode connecting portion (37a) to which a starting point of the magnet wire (<NUM>) is connected, and to which the flywheel diode (<NUM>) is connectable,
wherein the second terminal (31b) comprises a diode connecting portion (37b) to which an ending point of the magnet wire (<NUM>) is connected, and to which the flywheel diode (<NUM>) is connectable,
wherein the flywheel diode (<NUM>) is connected between the diode connecting portion (37a) of the first terminal (31a) and the diode connecting portion (37b) of the second terminal (31b),
characterised in that a covering layer made of the mold resin has a diode attaching hole (51c) which is communicated with the diode connecting portion (37a) of the first terminal (31a) and the diode connecting portion (37b) of the second terminal (31b) exposing the diode connecting portions (37a, 37b) at a surface of the diode attaching hole (51c) in such a manner that the flywheel diode (<NUM>) is attachable after forming the covering layer, and is capable of receiving the flywheel diode (<NUM>), and wherein the diode attaching hole (51c) is closed by a sealing material which is provided separately from the mold resin.