WO2005069317A1

WO2005069317A1 - Method for assembling and fabricating balun transformer

Info

Publication number: WO2005069317A1
Application number: PCT/KR2005/000107
Authority: WO
Inventors: Young-Suk Park; Chang-Pyo Hong
Original assignee: Young-Suk Park; Chang-Pyo Hong
Priority date: 2004-01-19
Filing date: 2005-01-13
Publication date: 2005-07-28
Also published as: KR20040028829A

Abstract

The present invention relates to a method for assembling and fabricating a Balun transformer in which a consumption of materials is decreased, an assembling time is significantly decreased, and a soldering property on a PCB substrate is excellent. In the present invention, a consumption of material is decreased, and an assembling time is significantly decreased. The soldering property of a PCB substrate is excellent.

Description

Title: METHOD FOR ASSEMBLING AND FABRICATING

BALUN TRANSFORMER

Technical Field

The present invention relates to a method for assembling and

fabricating a Balun transformer.

Background Art

The Balun transformer is a kind of a high frequency transformer as an

electronic part that has been generally used as a circuit element in various

electronic products such as a television tuner.

As shown in Figure 6, a Balun transformer 30 includes a core body 33

having two wire insertion holes 31 and 32, and a primary wire 35 and a

secondary wire 36 inserted through the wire insertion holes 31 and 32 and

welded to a PCB substrate 34. When a voltage is applied to the primary wire 35, the converted voltage

is outputted to the secondary wire 36.

However, since the core body 33 has a small size, and the diameters of

the wire insertion holes 31 a nd 32 are very small, so that it is impossible to

assemble the wires 35 and 36 by a manual work. In addition, the primary and

secondary wires 35 and 36 are coated by an insulation coating material, and the

ends 35a and 36a of the wires 35 and 36 are twisted and connected with each other, resulting in the following problems.

As shown in Figure 7, the assembling process of the conventional

Balun transformer will be described.

Wires 35 and 35 are cut with a certain length using rod wires 37 and 38

coated with insulation materials (Step 1), and the wires 35 an 36 are bent in a

U-shape and are inserted into the wire insertion holes 31 and 32 of the core

body 33 (Step 2).

Next, the ends 35a and 36a that are support legs of each wire 35 and

36 are gathered and twisted and connected with each other (Step 3). The connected wires are cut with a certain length using a cutter 39

wherein the ends of the same are uniformly aligned (Step 4).

The thusly fabricated Balun transformer 30 is moved to a PCB substrate

assembling process and are mounted on the PCB substrate 34 at a certain

position of the circuit using a soldering method (Figure 7). However, according to the above conventional assembling and

fabricating method of the Balun transformer 30, when the wires 35 and 36 are

inserted into the core body 33 for thereby finishing the assembling process, the

lengths of four support legs 35a, 35b, 36a and 36b exposed through the wire

insertion holes 31 and 32 are similarly same. Therefore, in this case, it is

impossible to instantly confirm two support legs 35a and 36a because they are

gathered and twisted with each other. Therefore, a work time is extended due to

the long confirmation time. The productivity is decreased. T he lengths of the exposed legs are generally long for an easier twisting work. It is needed to cut

away the exposed legs for a good alignment, so that a lot amount of waste rod

wires is produced.

In the support legs 35a, 35b, 36a and 36b of the Balun transformer 30,

since the ends of the wires 35 and 36 are coated when soldering the PCB

substrate 34, it is needed to melt the materials coated on the ends. Therefore,

the soldering temperature is set high, and the soldering time is extended.

Disclosure of Invention Accordingly, it is an object of the present invention to provide a method

for assembling and fabricating a Balun transformer by which a consumption of

material is decreased, and an assembling time is significantly decreased. The

soldering property of a PCB substrate is excellent.

To achieve the above objects, in a method for assembling and

fabricating a Balun transformer in which a primary wire and a secondary wire

are assembled to a core body, there is provided a method for assembling and

fabricating a Balun transformer, comprising a rod wire supply step in which a

rod wire coated with an insulation coating material and wound on a bobbin is

continuously supplied; a coated material removing step in which a coated

insulation material is peeled from the continuously supplied rod wire at a certain

section and interval, so that a coated portion and a spiral portion are repeatedly

formed; a cutting step in which an intermediate portion of the spiral portion is cut so that the spiral portion of one side has a certain length longer than the spiral

portion of the opposite side with respect to the coated portion for thereby

forming a primary wire and a second wire, respectively; a bending step in which

the wire is bent in a J-shape with respect to the coated portion so that the leg of

one side of the wire is exposed longer than the leg of the other side; a wire

insertion step in which the J-shaped bent primary and secondary wires are

inserted i nto w ire i nsertion h oles o f t he c ore b ody h aving t wo h oles, a nd t he

longer support legs are inserted into different insertion holes and are protruded;

a wire winding step in which two opposite longer support legs are gathered and

twisted; and a length alignment cutting step in which the support legs are cut

with constant lengths.

A soldering coating step is performed with respect to the peeled spiral

stare support legs after the alignment cutting step is performed.

According to the above fabrication method, the support legs that are

gathered and twisted are protruded longer than the support legs of the other

side that are not twisted, so that it is possible to easily recognize the twisted

legs. Therefore, two support legs can be easily caught for thereby achieving an

easier twisting work. In addition, the amount of the support legs to be cut away

during the alignment work is decreased, so that it is possible to save the rod

wire. In addition, since the coated portions of the support legs are easily peeled,

it does not need to melt the coated materials in the present invention. Therefore,

even when the products according to the present invention are stored for a long time period, it is possible to the products from rust. Since the material and

solder can be easily melted and hardened due to the solder coated on the

support legs during the soldering work of the PCB substrate, it is possible to

significantly decrease the work time.

Brief Description of Drawings

The present invention will become better understood with reference to

the accompanying drawings which are given only by way of illustration and thus

are not limitative of the present invention, wherein; Figure 1 is a schematic view illustrating a process of assembling and

fabricating a Balun transformer according to the present invention;

Figure 2 is a detailed view illustrating a method of assembling and

fabricating a Balun transformer by process according to the present invention;

Figure 3 is a cross sectional view illustrating an insulation coating state of

a rod wire and a wire according to the present invention;

Figure 4 is a perspective view illustrating a core body according to the

present invention;

Figure 5 is a view illustrating a state that a Balun transformer is installed

at a PCB substrate according to the present invention; Figure 6 is a view illustrating the construction of a conventional art; and

Figure 7 is a view illustrating an assembling process of a conventional

Balun transformer. Best Mode for Carrying Out the Invention

The construction of the present invention will be described with

reference to the accompanying drawings. Figure 1 is a schematic view illustrating a process of assembling and

fabricating a Balun transformer according to the present invention, and Figure 2

is a detailed view illustrating a method of assembling and fabricating a Balun

transformer by process according to the present invention.

Rod wires 3 and 4 rolled on bobbins 1 and 2 are unrolled in series and

are extended in a forward direction like a straight line (Step 1 ).

As shown in Figure 3, the rod wires 3 and 4 are coated with coating

materials 8 and 9 that are insulation materials due to the following reasons.

After the wire insertion process of Figures 1 and 2 are p erformed, when the

coated portions of two wires 6 and 7 contact with each other (reference

numerals 8 and 9 of step 5), it is needed to keep an insulated state. In addition,

the colors of the insulation coating materials 8 and 9 of two rod wires 3 and 4

are different from each other, for example, the color of the coating material 8 of

the rod wire 3 is red, and the color of the coating material 9 of the rod wire 4 of

the other side is black. Therefore, it is easy to perform the wire winding process

that will be described later.

The coating material peeling process for peeling the coated material from

the rod wires 3 and 4 at regular sections and intervals is performed (Step 2). When peeling the coated materials, the tool 20 is needed to rotate with respect

to the outer surface of the rod wire in a state that a tool tip 19 is contacted with

an outer surface of the rod wires 3 and 4. The tool 20 is fed (or rod wire is fed)

along the rod wires 3 and 4 by a certain length L, so that it is possible to remove

the coated material of the rod wires 3 and 4 by a certain length L.

The support legs 6a, 6b, 7a and 7b of both ends that will be described

later become a spiral shape after the coated material removing process.

The intermediate portions of the rod wires 3 and 4 from which the coated

material is removed at a regular length L are cut away (L1 : shorter support leg,

and L2: longer shorter for twisting) using the cutters 5 and 5a for thereby

forming the support legs 6a, 7a and 6b, 7b having shorter and longer spiral

ends, so that it is possible to form primary and secondary wires 6 and 7 cut and

separated from the rod wires 3 and 4 (whole length of cut wires is L1+L2+L3)

(Step 3). Next, a bending p rocess i s performed, i n which t he w ires 6 a nd 7 a re

bent in a J-shape with respect to the coated portions 8 and 9 (or bent in a stick

shape), so that the support legs 6a and 7a are bent longer than the support legs

6b and 7b of the other side (Step 4).

The core body 10 is fed into a lower side of the J-shaped wires 6 and 7

through a media alignment conveyor based on a separate supply line except for

the rod wire supply line (Steps A and B), and the support legs 6a, 6b, 7a and 7b

of the bent wires 6 and 7 are inserted into the wires insertion holes 11 and 12 of the c ore b ody 1 0. The I onger s upport I egs 6 a a nd 7 a a re i nserted i nto o ther

insertion holes for thereby performing a wire insertion process (Step 5).

In the above state, the longer support legs 6a and 7a are downwardly

protruded longer than the shorter support legs 6b and 7b. After the wire insertion process is performed, two longer support legs 6a

and 7a are gathered and twisted in the wire winding process (S6). At this time,

the two longer support legs 6a and 7a are gathered using pliers, and the tool is

rotated in the manual work. In the present invention, the two longer support legs

6a and 7a are gathered using an automatic winding apparatus invented by the

same inventor of the present invention and then are twisted for thereby finishing

a twisting work. It is easy to recognize the longer support legs 6a and 7a that

are protruded longer than the shorter support legs 6b and 7b for an easier

twisting work. In addition, it is easy to catch and twist the longer support legs 6b

and 7b, so that the productivity is significantly enhanced. After the wire winding process is finished, an aligning cutting process is

performed, in which all support legs 6a, 6b, 7a and 7b are cut with a set length

(I) using a cutter 13 (Step 7).

Next, the support legs 6sa, 6b, 7a and 7b are flooded in a rinsing liquid

14 for thereby performing a rinsing process (Step 8). A Flux liquid is coated on

the support legs 6a, 6b, 7a, and 7b for an easier soldering on the PCB substrate

and a re flooded i n t he s oldering I iquid 1 5 for t hereby c oating a s older i n t he

soldering coating process (Step 9), so that the fabrication of the Balun transformer 16 is finished.

While the rod wires 3 and 4 are beiηg supplied in the processes, the wire

cutting process may be performed first, and then the coated material removing

process may be performed thereafter. At this time, during the automation of the

above processes, it is preferred to perform the coated material removing

process first, and then to perform the wire cutting process just b efore t he J-

shape bending process is performed.

As shown in Figure 5, the finished Balun transformer 16 is fed to the

fabrication factory of the electronic products. The support legs 6a, 7a, 6b and 7b

are mounted on the PCB substrate by a soldering 18 for thereby achieving a

function of designed transformer.

Industrial Applicability

As described above, in the present invention, the primary and secondary

wires are bent in a J-shape (stick shape), so that the support legs of one side

are protruded longer than the support legs of the other side. The support legs

are inserted into the wire insertion holes of the core body for thereby finishing

an assembling process. Therefore, it is easy to recognize the protruded two

longer support legs and to gather and twist the same. The winding work time is

significantly decreased, and it is needed to cut only the longer support legs

protruded rather than the shorter support legs during the current process for

thereby preventing the rod wires from being waster, resulting a saving of the wires. The spiral support legs soldered on the PCB substrate are coated with a

solder and are stored and sold. Therefore, even when the products according to

the present invention are stored for a long time period, it is possible to prevent

the oxidation of the support legs. The soldering can be easily performed for a

shorter time period even at a lower temperature, so that the work time for

mounting on the PCB substrate can be significantly decreased.

As the present invention may be embodied in several forms without

departing from t he s pirit o r e ssential c haracteristics t hereof, i t s hould also be

understood that the above-described examples are not limited by any of the

details of the foregoing description, unless otherwise specified, but rather

should be construed broadly within its spirit and scope as defined in the

appended c laims, a nd t herefore a II c hanges a nd m odifications t hat fall w ithin

the meets and bounds of the claims, or equivalences of such meets and bounds

are therefore intended to be embraced by the appended claims.

Claims

Claims:

1. In a method for assembling and fabricating a Balun transformer in which

a primary wire and a secondary wire are assembled to a core body, a method

for assembling and fabricating a Balun transformer, comprising: a rod wire supply step in which a rod wire coated with an insulation

coating material and wound on a bobbin is continuously supplied; a coated material removing step in which a coated insulation material is

peeled from the continuously supplied rod wire at a certain section and interval,

so that a coated portion and a spiral portion are repeatedly formed; a cutting step in which an intermediate portion of the spiral portion is cut

so that the spiral portion of one side has a certain length longer than the spiral

portion of the opposite side with respect to the coated portion for thereby

forming a primary wire and a second wire, respectively; a bending step in which the wire is bent in a J-shape with respect to the

coated portion so that the leg of one side of the wire is exposed longer than the

leg of the other side; a wire insertion step in which the J-shaped bent primary and secondary

wires are inserted into wire insertion holes of the core body having two holes,

and the longer support legs are inserted into different insertion holes and are

protruded; a wire winding step in which two opposite longer support legs are

gathered and twisted; and a length alignment cutting step in which the support legs are cut with

constant lengths.

2. The method of claim 1 , wherein after the length alignment cutting step

is performed, a soldering coating step is performed with respect to the peeled

spiral support legs for thereby soldering the support legs.

3. The method of claim 2, wherein a rinsing and Flux coating step is

performed with respect to the support legs before the soldering coating step is

performed.

4. The method of one of claims 1 through 3, wherein said primary and

secondary wire cutting steps are performed before a coated material removing

step is performed, and in said coated material removing step, the coated

material is removed from both ends of the wires at different intervals,

respectively.