JP2001210512A - Coil assembly and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil assembly and its manufacturing method where the conductor density is high and the number of required coils can be readily incorporated. SOLUTION: The coil assembly and its manufacturing method comprising a pedestal, a cylindrical support having an outer periphery shape adapted to the shape of an air-core part of an air-core coil formed by a plurality of insulating partitions, where one end is fixed to the pedestal and which are erect on the end and are separated independently, the air-core coil formed by a self-fused wires where the support is inserted into the air core part and one end part is put on the pedestal, and so that a core is attached by inserting into an air space of the support, and configured so as to pinch the support by the core and the air core coil.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil assembly for forming a coil used for an electromagnet or the like, and a method for manufacturing the coil assembly.

[0002]

2. Description of the Related Art Conventionally, coils are widely used for electromagnetic force and the like. In order to improve the efficiency of a coil in which an insulated wire is wound around a bobbin, it is necessary to increase the conductor density of the coil. Therefore, measures such as winding coils in a line or reducing the thickness of bobbins are taken. The portion occupied by the bobbin in the volume occupied by the coil is an electrically useless volume. Therefore, air-core coils are advantageous for designing high-efficiency coils. However, some support is required to mount the coil on the electric device. Therefore, the thickness of the bobbin has been reduced as much as possible. However, this cannot be made too thin due to physical limitations in molding and deformation of bobbin dimensions due to coil winding pressure. An air-core coil using a self-fusing wire is widely used in flat motors and the like.

[0003]

SUMMARY OF THE INVENTION The present invention relates to a coil assembly for forming a coil having an increased conductor density by reducing the volume of a structure that is not related to the conductor density in the coil volume and increasing the conductivity density. A manufacturing method is provided.

[0004]

According to the present invention, there is provided a method for forming an air-core portion of an air-core coil formed by a pedestal and a plurality of insulating partitions which are fixed at one end to the pedestal and are independently separated from each other. A cylindrical support having a suitable outer peripheral shape, an air-core coil formed by a self-fusing wire with the support inserted into the air core and one end placed on a pedestal, and a void in the center of the support 1. A coil assembly comprising a core inserted into a core and having a support sandwiched between the core and an air-core coil 2. The pedestal is a pedestal having a core insertion hole, and the support is set around the core hole. 2. The coil assembly according to item 1, wherein the core inserted into the support is inserted and fixed in the insertion hole of the pedestal 3. The pedestal is a pedestal having no core insertion hole, and is inserted from above the support. The lower end of the attached core is placed on the base, 1
A coil assembly according to the item. 4. Item 4. The coil assembly according to any one of Items 1 to 3, wherein the air-core coil is a coil formed by a self-bonding wire. 5. The support is 周 of the length of the periphery of the air core of the coil.
5. The coil assembly according to any one of items 1 to 4, wherein the support is formed by arranging insulating partitions having a width of 1/12 in an arc shape corresponding to the shape of the air core of the coil. 6. Item 6. The coil assembly according to any one of Items 1 to 5, further comprising a coil retaining protrusion that protrudes outward at an upper end of the insulating partition wall. 7. The insulating partition is a flexible, curvilinear thin partition, 1
Item 7. A coil assembly according to any one of Items 6 to 6. 8. 9. The method according to any one of items 1 to 7, wherein the inner diameter of the air core portion of the air core coil, the outer diameter of the support, the inner diameter of the support, and the outer diameter of the core are sizes that can be fitted without any gap. Coil assembly. 9. The air core portion of the air core coil is mounted on a cylindrical support having an outer peripheral shape adapted to the shape of the air core portion of the air core coil formed by a plurality of independently separated insulating partitions fixed at one end to the pedestal. Coil assembly characterized by inserting and mounting one end of a coil on a pedestal, then inserting a core into a cylindrical support, and fixing an insulating partition by sandwiching the insulating partition between the inner surface of the air-core coil and the outer surface of the core. Product manufacturing method. About.

[0005]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention uses an air-core coil formed by winding a self-fusing wire. An air-core coil formed by winding a self-fusing wire has a good winding property and has a property of maintaining the shape of the coil itself. An air-core coil wound in a line is more preferable because it has a high conductor density. An upright support with one end fixed to the pedestal is placed, this support is inserted into the air core of the air-core coil, a core is inserted into a void at the center of the support, and the coil and the core support the support. The coil is assembled by integrating the coil. The air-core coil is formed, for example, by heat-sealing a self-fusing insulated wire having a fusion layer mainly composed of copolymer amide.

The support has a cylindrical shape formed by a plurality of insulating partitions which are independently separated from each other. The cylindrical shape may be any shape suitable for the shape of the air core of the air core coil. For example, the shape is, for example, cylindrical or rectangular. The insulating partition wall forming the support is composed of a plurality of separated and independent walls, and if it is a flexible and curved thin wall, it is deformed according to the shape of the air core portion of the coil, and the adhesion is good. Is preferred. When the air-core portion of the air-core coil is square, the wall of the insulating partition forming the support is provided at the apex of the two sides sandwiching each corner to improve the stability of the coil. If a coil removal prevention claw that protrudes outward is provided at the top of the insulating partition wall, the inserted coil can be prevented from coming off. As described above, even when the retaining claws of the coil protruding outward are arranged, the insulating partition is separated into a plurality of parts when the coil is inserted, and there is no problem because the insulating partition wall is flexible and has a curved property.

The core functions as a wedge when the air-core coil and the support are integrated, and the material may be metal, ceramic, plastic, or the like as long as it has appropriate strength, and must be insulated from the coil. However, the coil assembly of the present invention is isolated without the core being in contact with the coil by the insulating partition wall forming the support.

On the pedestal, one end of an air-core coil is mounted. On the pedestal provided with a core insertion hole, the core is inserted into the insertion hole from below the pedestal, and the insulating partition is connected to the coil. The coil is assembled by being sandwiched between cores. When the core is inserted from above the support, the insertion hole of the pedestal becomes unnecessary. Insert the support into the air core of the air core coil,
One end of the coil is placed on the pedestal, and then the core is inserted into the hollow part of the support.

In this manner, the support inserted into the air-core portion of the air-core coil is sandwiched between the core inserted into the hollow portion at the center of the support and the air-core coil. The support and the core are integrated, and the coil is assembled. Therefore, it is preferable that the inner diameter of the air core portion of the air core coil, the outer diameter of the support, and the inner diameter of the support and the outer diameter of the core have dimensions that can be fitted without any gap. Since the insulating partition wall forming the support is flexible and bendable, it can be inserted even if the outer diameter is larger than the air core portion of the air core coil. However, if the dimensions are too different, it is not preferable because the assembly work is hindered. The coil assembly of the present application uses a pedestal of a plate-like body, a plurality of coil assemblies are formed on the pedestal of the plate-like body, and the plurality of coil assemblies can be formed into one plate-like body.

An embodiment will be described with reference to the drawings. FIG.
Denotes a support body 3 composed of a plurality of insulating partitions 2 which are fixed and fixed at one end to a pedestal 1 and stand independently. Reference numeral 6 denotes a core insertion hole, in which a core is inserted from below. FIG. 2 shows the air-core coil 4. FIG. 3 shows a state where the air core coil 4 is inserted into the support 3. FIG.
Is shown. FIG. 5 shows that the coil is inserted into the hollow portion of the support after inserting the air-core coil 4 into the support 3 shown in FIG.

FIG. 6 shows a cross section of the coil assembly of the present invention shown in FIG. 5 cut along a plane parallel to the pedestal. The insulating partition wall 2 forming a support on the inner surface of the air core portion of the air core coil 4 includes: Coil 4
A gap 7 is formed between the insulating partition walls which are sandwiched by the core 5 and the separated insulating partition walls. In this example, since the air-core coil is quadrangular, an insulating partition is formed at a corner portion of the support, and the support is formed as a columnar partition 8 extending over two sides.
In addition, there is a partition 9 extending over three sides.

FIG. 7 is a cross-sectional view of the coil assembly of FIG. 5 taken along a plane perpendicular to the pedestal. One end of the coil 4 is placed on the front of the pedestal. An insulating partition wall 2 forming a support rises from the pedestal and is sandwiched between the coil 4 and the core 5. In this example, the core is inserted into the hollow portion of the support from the core insertion hole 6 of the pedestal.

[0013]

Next, the present invention will be described specifically with reference to examples. Example 1 As shown in FIG. 8, a plastic pedestal 1 having two 2 m × 3 m core insertion holes is used, and a pair of plastic insulation partition walls 2 are opposed to each other around the core insertion hole 6. The support 3 is formed by arranging, and an air-core coil 4 wound using a self-fusing wire having a wire diameter of 0.1 mm is inserted into the assembly shown in FIG. 9 to obtain the iron core shown in FIG. 5 was inserted from the core insertion hole 6 of the pedestal to obtain a coil assembly.

[0014]

The present invention uses an air-core coil in which the coil itself is fixedly formed, so that there is no need for a winding frame, an air-core coil having good winding properties is used, and no winding frame is used. The core and coil are securely separated by a gap between the core and the coil, and the coil can be fixed to the pedestal without using an adhesive etc. To play.

[Brief description of the drawings]

FIG. 1 is an explanatory view of a pedestal and a support forming a coil assembly of the present invention.

FIG. 2 is an explanatory view of an air-core coil forming a coil assembly of the present invention.

FIG. 3 is an explanatory view showing a state where an air-core coil is inserted into a support.

FIG. 4 is an explanatory diagram of a core.

FIG. 5 is an explanatory view of a coil assembly of the present invention.

FIG. 6 is a cross-sectional view of the coil of the present invention cut along a plane parallel to the base.

FIG. 7 is a sectional view taken along line AA of FIG.

FIG. 8 is an explanatory view in which three supports are installed on a base.

9 is an explanatory diagram in which air-core coils are inserted into the support of FIG. 8, respectively.

FIG. 10 is an explanatory diagram of a core inserted into a support.

[Explanation of symbols]

 Reference Signs List 1 pedestal 2 insulating partition 3 support 4 air core coil 5 core 6 core insertion hole 7 core and coil gap 8 columnar insulating partition 9 insulating partition spanning three sides 10 coil assembly

Claims (9)

[Claims] A cylindrical support having an outer peripheral shape adapted to the shape of the air core portion of an air core coil formed by a pedestal and a plurality of insulating partitions which are fixed at one end to the pedestal and are standing and separated independently. And an air-core coil formed by a self-fusing wire with a support inserted into the air core and one end placed on a pedestal, and a core inserted into a void in the center of the support, A coil assembly in which a support is sandwiched between air-core coils. 2. The pedestal having a core insertion hole,
2. The coil assembly according to claim 1, wherein the support is provided so as to surround the core hole, and the core inserted into the support is inserted and fixed in the insertion hole of the pedestal. 3. The coil assembly according to claim 1, wherein the pedestal is a pedestal having no core insertion hole, and the lower end of the core inserted from above the support is placed on the pedestal. 4. The coil assembly according to claim 1, wherein the air-core coil is a coil formed by a self-bonding wire. 5. The support body is formed by arranging insulating partition walls having a width of 1/2 to 1/12 the length of the periphery of the air core of the coil in an arc shape according to the shape of the air core of the coil. The coil assembly according to any one of claims 1 to 4, which is a support. 6. The coil assembly according to claim 1, further comprising a coil retaining protrusion that protrudes outward at an upper end of the insulating partition wall. 7. The coil assembly according to claim 1, wherein the insulating partition is a flexible, thin, curved partition. 8. The inner diameter of the air core portion of the air core coil, the outer diameter of the support, and the inner diameter of the support and the outer diameter of the core are each sized to fit without any gap. Item 2. The coil assembly according to item 1. 9. An air-core coil mounted on a cylindrical support having an outer peripheral shape conforming to the shape of the air-core portion of an air-core coil formed by a plurality of independently separated insulating partitions fixed at one end to a pedestal and standing upright. Of the coil, one end of the coil is placed on the pedestal,
A method of manufacturing a coil assembly, comprising: inserting a core into a cylindrical support; and fixing the insulating partition by sandwiching the insulating partition between the inner surface of the air-core coil and the outer surface of the core.