Flyback transformer device and process for preparing same

Details Flyback transformer device and process for preparing same Flyback transformer device and process for preparing same

1994-12-23

2001-04-03

Heinrich, Samuel M. (Department: 1725)

Metal fusion bonding

Process

Plural diverse bonding

C228S179100, C228S259000

Reexamination Certificate

active

06209776

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a flyback transformer device for use in television receivers and various display devices, and more particularly to the structure of a flyback transformer device wherein leads of electronic components are fixedly connected by electric welding to terminal pieces provided upright on a coil bobbin and a process for preparing the device.
BACKGROUND OF THE INVENTION
Flyback transformer devices
70
having coils provided in layers generally comprise, as shown in
FIG. 23
, a plurality of divided coils
74
wound around a coil bobbin
71
, and pairs of terminal pieces
73
provided upright at opposite ends of the bobbin
71
. A diode, resistor or like electronic component
6
is connected between each pair of opposed terminal pieces
73
,
73
.
Each of leads
63
,
63
extending from opposite sides of the electronic component
6
is electrically fixedly connected to the terminal piece
73
conventionally by shaping the terminal piece
73
in a Y-form as illustrated, placing the outer end of the lead
63
on the Y-shaped portion of the terminal piece
73
, crimping the Y-shaped portion to fix the lead
63
in this state and thereafter soldering the crimped portion by dipping (see, for example, Unexamined Japanese Utility Model Publication HEI 1-105383).
Another method of mounting electronic components on a coil bobbin has been proposed as shown in
FIG. 24. A
lead
63
is connected to a terminal piece
73
a
with a solder
66
as shown in
FIG. 25
by bending the outer end
63
a
of the lead
63
to an L-shape, fitting the lead end
63
a
in a cavity
65
in a post
71
a
of the coil bobbin at one side of the terminal piece
73
a
to preliminarily fix the lead
63
as held in contact with the terminal piece
73
a
and thereafter dipping the fixed portion in solder (Unexamined Japanese Patent Publication SHO 63-15668 and Examined Japanese Utility Model Publication hei 2-1171).
However, the conventional method of mounting electronic components with use of Y-shaped terminal pieces requires the work of fixing the lead by crimping the terminal piece and therefore has the problem of being complex and necessitating cumbersome work.
On the other hand, the method wherein cavities are formed in the coil bobbin not only requires a device for bending leads and a device for inserting the lead into the cavity but also makes the die for producing bobbins complex in configuration to result in an increased cost. Another problem is also encountered in that the coil bobbin becomes larger.
Further when solder dipping is resorted to for connection, the solder dipping device requires labor for maintenance. This leads to an increase in manufacturing cost.
SUMMARY OF THE INVENTION
An object of the present invention is to provide the structure of a flyback transformer device wherein the leads of electronic components are fixedly connected to terminal pieces of a coil bobbin by electric welding although this has not been practiced, and a process for preparing the device so as to overcome all the problems described above.
The leads of electronic components can be connected to the terminal pieces of the coil bobbin by electric welding firmly with great ease. This simplifies the production process and leads to an automated connecting procedure.
Another object of the invention is to provide a process for preparing a flyback transformer device which includes the steps of producing a coil bobbin having upright terminal pieces, winding a coil conductor around the coil bobbin, twining an end portion of the wound coil conductor around one of the terminal pieces, fixing a lead of an electronic component to another one of the terminal pieces by spot welding, and soldering the twined portion of the coil conductor around the terminal piece by dipping.
After the coil conductor end portion has been preliminarily fixed to the terminal piece by the conductor twining step of the process, the solder dipping step ensures a mechanical and electrical connection between the coil conductor and the terminal piece.
Another object of the invention is to provide an apparatus for preparing flyback transformer devices which apparatus comprises an electronic component feeder, a lead cutter, a bobbin feed position determining mechanism, an electronic component transfer mechanism and an electric welder. The electronic component feeder feeds a component supply tape having a plurality of electronic components arranged at a specified pitch by paying off the tape longitudinally thereof by the specified pitch to send the components one after another to a lead cutting position. The lead cutter cuts off the electronic component in the lead cutting position at outer ends of leads to separate the component from the supply tape. The bobbin feed position determining mechanism feeds a coil bobbin toward a predetermined welding position to position a terminal piece of the coil bobbin in the welding position.
The electronic component transfer mechanism transfers the electronic component as cut off from the supply tape by the cutter toward the welding position and positions the lead of the component alongside the terminal piece of the bobbin in the welding position. The electric welder comprises a welding head movable toward or away from the welding position, and a pair of electrode pieces projecting from the welding head for holding therebetween the terminal piece of the coil bobbin and the lead of the component in the welding position.
With the apparatus described, the electronic component feeder, lead cutter, bobbin feed position determining mechanism, electronic component transfer mechanism and electric welder are related to one another and operate concurrently to produce the flyback transfer device within a short cycle time.
More specifically, the component supply tape is paid off by the feeder at the specified pitch in the longitudinal direction to feed electronic components one after another to the lead cutting position. When one electronic component is set in the lead cutting position, the lead cutter operates at the same time to cut off the component at the outer ends of leads and separate the component from the supply tape. The electronic component separated from the supply tape is transported by the component transfer mechanism from the lead cutting position toward the predetermined welding position. At this time, the coil bobbin is set in the predetermined welding position by the bobbin feed position determining mechanism.
Accordingly, when the component is set in the welding position by the transfer mechanism, the component has its lead positioned on the terminal piece of the coil bobbin in the welding position while being held by the transfer mechanism.
In this state, the electric welder operates, the welding head moves toward the welding position, and the pair of electrode pieces are positioned at opposite sides of the terminal piece and the lead. The terminal piece and the lead are thereafter held from opposite sides between the pair of electrode pieces. Simultaneously with this, current is passed across the electrode pieces, whereby the lead is joined to the terminal piece by spot welding.
With the production apparatus described, the welder operates with the component lead positioned alongside the bobbin terminal piece by the transfer mechanism to electrically weld the lead to the terminal piece. This eliminates the need to preliminarily fix the lead to the terminal piece. Accordingly, the terminal piece can be shaped merely in the form of a rod, and there is no need to form lead inserting cavities in the bobbin which are conventionally necessary, nor is it necessary to bend the leads of electronic components. As a result, it is possible to compact the flyback transformer device and to reduce the manufacturing cost of the device.
Moreover, the step of electrically welding the lead to the terminal piece is executed almost simultaneously with the step of positioning the lead alongside the bobbin terminal piece by causing the component transfer mechanism to hold the component. This resul

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