JPH07201575A - Flat winding and its manufacture - Google Patents

Abstract

PURPOSE:To provide a thin, flat winding capable of allowing a comparatively large current to flow. CONSTITUTION:The winding is formed by laminating a plurality of winding substances 31 obtained by forming conductive parts 33 having rectangular transverse sections into spiral shapes on the same planes, joining the adjoining inner circumferential ends 39 or peripheral ends of these conductive parts 33 mutually, and forming insulating layers in the peripheries of the conductive parts 33. Besides, its manufacturing method is composed of processes of forming a spiral slit 35 in a conductive metal plate and manufacturing a winding substance having a conductive part 33 of a rectangular transverse section, of laminating winding substances 31 and joining the adjoining inner circumferential ends 39 or peripheral ends of these conductive parts 33 mutually, and of forming insulating layers on the peripheries of the conductive parts 33.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plate winding used for inductors, transformers and the like and a method for manufacturing the same.

[0002]

2. Description of the Related Art Generally, windings having a plurality of turns are used in inductors, transformers and the like.

Conventionally, as a method for forming such a winding having a plurality of turns, a method using a printed wiring or a method using an enamel wire has been used.

FIG. 7 shows a winding using printed wiring. In this winding, a pattern 1 and a pattern 2 are formed on both surfaces of a base material (not shown), and a hole 3 of the pattern 1 is formed. , And the hole 4 of the pattern 2 are connected, the pattern 1 and the pattern 2 become a series of patterns, and as a result, between the wiring port 5 and the wiring port 6, 2
A turn winding 7 is formed.

On the other hand, as the winding using the enamel wire, as shown in FIG. 8, a winding wire 13 obtained by spirally winding an enamel wire 11 having a circular cross section, and a circular cross section as shown in FIG. 15, which is a spiral winding of the enamel wire 11 on the same plane, and a winding 19 which is a spiral winding of the enamel wire 17 having a rectangular cross section, as shown in FIG.
It has been known.

[0006]

However, in the winding wire 7 using the printed wiring shown in FIG. 7, there is a limit to the thickness of the copper foil for forming the patterns 1 and 2. Patterns 1 and 2 with 100 μm and 5 mm width,
If the current density is 10 [A / mm ² ], only about 5 A can be loaded, which is not suitable for a large current.

Further, in order to obtain a printed wiring, there is a problem that a special design is required, which requires a lot of time and cost. Further, in order to assemble an inductor as shown in FIG. 11 using such a winding 7, for example, an insulating plate 23 for insulating the core 21 from the patterns 1 and 2 and patterns 1 and 2 are used. Wiring port 5,
There is a problem that the pin member 25 or the like for electrically connecting 6 is required, the number of parts is increased, and the assembly is complicated.

On the other hand, in the winding using the enameled wire,
For example, in order to load a large current of 50 A and reduce the current density at this time to about 10 [A / mm ² ], in the case of the circular enameled wires 13 and 15 shown in FIGS. 8 and 9, Requires thick enameled wires 13 and 15 having a cross-sectional area of 5 mm ² and a diameter of about 2.5 mm. In the winding 13 shown in FIG. 8, the H ₁ dimension is 15 mm, and the inductor,
There is a problem that it is difficult to reduce the thickness of the transformer or the like.

In the winding 15 shown in FIG. 9, W ₁
Since the size is 15 mm, there is a problem that it is difficult to miniaturize the inductor, the transformer and the like. And
When the enameled wire 19 having a rectangular cross section shown in FIG. 10 is used, the cross sectional shape of 1.8 mm × 2.8 mm is 5 mm ²
Can be obtained, and in this case, the H ₁ dimension is 11 mm, and it is possible to reduce the thickness to some extent, but this is insufficient.

Further, in the enameled wire 17 having a rectangular cross section,
As shown in FIG. 12, when the enamel wire 17 is wound, the inner side I is contracted and the outer side O is extended, so that there is a dimensional limit in processing, and further, there is a problem that the insulating coating is cracked during processing. It was

In general, the windings 13, 15, 19 made of enameled wire are arranged in a window portion 29 formed between a pair of cores 27, as shown in FIGS. 13, 14, and 15. Although they are used, as is apparent from these figures, there is a problem that the winding wire 13, 15, 19 occupies a small area with respect to the area of the window portion 29 and the mounting efficiency is very poor.

The present invention has been made to solve the above-mentioned conventional problems, and an object thereof is to provide a thin plate-shaped winding capable of loading a relatively large current and a manufacturing method thereof. And

[0013]

A plate-shaped winding according to claim 1 has a plurality of winding bodies formed by forming a conductive portion having a rectangular cross section in a spiral shape in the same plane. The inner peripheral edge portion or the outer peripheral edge portion adjacent to each other is joined to each other, and an insulating layer is formed on the outer periphery of the conductive portion.

According to a second aspect of the present invention, there is provided a method for producing a plate winding, wherein a spiral slit is formed in a conductive metal plate to produce a winding body having a conductive portion having a rectangular cross section, and the winding. The method includes the steps of stacking linear bodies and joining adjacent inner peripheral ends or outer peripheral ends of the conductive parts to each other, and forming an insulating layer on the outer periphery of the conductive parts.

[0015]

According to the plate-shaped winding of the present invention, since the plurality of winding bodies formed by forming the conductive portion having a rectangular cross section in a spiral shape in the same plane are stacked, the plate-shaped winding is thin. Moreover, since the cross-sectional area of the conductive portion can be made larger than that of the winding formed by the printed wiring or the like, a large current can be loaded.

In the method of manufacturing the plate-shaped winding of claim 2, the plate-shaped winding of claim 1 can be manufactured easily and reliably by processing the conductive metal plate.

[0017]

Embodiments of the present invention will be described below in detail with reference to the drawings. 1 to 3 show one embodiment of the plate-shaped winding of the present invention, in which the reference numeral 31 is used.
Shows a set of windings.

These winding bodies 31 are formed by forming a conductive portion 33 having a rectangular cross section in a rectangular spiral shape in the same plane. Then, the adjacent conductive portion 33
A slit 35 is formed between them, and a rectangular hole 37 is formed in the center.

The pair of winding bodies 31 are superposed, and the inner peripheral end portions 39 of the conductive portions 33 adjacent to each other are joined to each other. The insulating layer 41 is formed on the outer periphery of the conductive portion 33.

An L-shaped lead-out portion 43 is formed on the outer peripheral end of the conductive portion 33. The plate-shaped winding described above is manufactured as described below.

First, for example, a slit 35 is formed in a spiral shape on a conductive metal plate made of copper, and a winding body 31 having a conductive portion 33 having a rectangular cross section is manufactured. The slits 35 are formed by etching, laser cutting, press working, etc., but these are selected in consideration of the plate thickness of the metal plate, the gap size L of the slits 35, mass productivity and the like. Be seen.

At the same time, the hole 37 and the lead-out portion 43 are formed. After this, a set of windings 3
1 are overlapped, and the adjacent inner peripheral end portions 39 of the conductive portions 33 are joined to each other.

The joining is performed by spot welding, soldering 45, brazing, or screws, rivets or the like. After that, the insulating layer 41 is formed on the outer periphery of the conductive portion 33 excluding the lead portion 43.

The insulating layer 41 is formed by coating the conductive portion 33 with an epoxy resin, a fluororesin, an acrylic resin, or a composite material thereof.
Although various methods are known as coating methods, for example, by using the electrodeposition method, it is possible to easily form the insulating layer 41 having a uniform thickness over the entire surface.

At the time of coating, a pair of winding bodies 31 are pulled in directions away from each other to form slits 35.
By increasing the gap between the insulating layer 4 and the
1 can be formed.

FIGS. 4 and 5 show an inductor using the above-mentioned plate-shaped winding, and cores 49 are arranged on both sides of the plate-shaped winding 47 described above. Recesses 51 having a rectangular cross section are formed at predetermined intervals in the core 49, and plate windings 47 are accommodated in these recesses 51.

Further, the convex portion 53 formed between the concave portions 51.
Are inserted into the holes 37 of the plate winding 47. In the plate-shaped winding 47 described above, a pair of winding bodies 31 formed by spirally forming the conductive portion 33 having a rectangular cross section in the same plane are stacked, and thus the plate-shaped winding 47 is formed. Four
7 can be easily made thin, and as a result, it is possible to make the inductor, the transformer and the like using the plate winding 47 thin.

Further, in the above-mentioned plate winding 47, as shown in FIG.
As shown in FIG. 7, it is possible to make the exclusive cross-sectional area of the plate winding 47 with respect to the area of the window 55 formed between the pair of cores 49 very large, and it is possible to improve the mounting efficiency. .

Further, in the above-described plate-shaped winding 47, it is possible to easily increase the cross-sectional area of the conductive portion 33 as compared with a winding by printed wiring, etc. As a result, a large current is loaded. Will be possible.

Further, in the above-mentioned plate winding 47, since the insulating layer 41 is formed on the outer periphery of the conductive portion 33, the insulating plate and the like required for the inductor using the printed wiring are not required, and the number of assembling steps is reduced. can do.

In the above-described method for manufacturing the plate-shaped winding, the conductive metal plate is processed to form the winding body 31.
Thus, the plate winding 47 can be manufactured easily and reliably.

For example, when the wound body 31 is formed by winding an enameled wire having a rectangular cross section, the winding becomes very difficult. It is possible to reliably manufacture with high accuracy.

In the embodiment described above, the number of turns is 3
An example in which a pair of winding bodies 31 are joined to form the plate-shaped winding 47 having 6 turns has been described, but the present invention is not limited to this embodiment, and the winding body 31 is formed. Needless to say, the number of turns to be made may be plural, and the number of the winding bodies 31 to be joined may be plural.

That is, for example, as shown in FIG. 6, by joining four winding bodies 31 having three turns,
It is possible to easily form a plate winding having 12 turns.

In the plate winding shown in FIG. 6, the second and third windings are
The winding bodies 31 of the tier are joined by joining the outer peripheral ends 57 of these winding bodies 31 to each other. Further, in the above-described embodiment, an example in which the winding body 31 is formed in a rectangular shape has been described, but the present invention is not limited to this embodiment, and may be formed in a circular shape or the like. Of course.

Further, in the above-mentioned embodiment, the example in which the insulating layer 41 is formed after the winding body 31 is joined has been described, but the present invention is not limited to this embodiment, and the winding body is not limited thereto. It goes without saying that the insulating layer 41 may be formed in a state where the bonding portion is masked before the bonding of 31.

[0037]

As described above, in the plate-shaped winding of claim 1, a plurality of winding bodies formed by spirally forming the conductive portion having a rectangular cross section in the same plane are stacked. Therefore, it is possible to easily make the plate winding thin.

Further, it is possible to easily increase the cross-sectional area of the conductive portion as compared with a winding by printed wiring, etc. As a result, a large current can be loaded. In the method for manufacturing a plate-shaped winding according to claim 2, since the winding body is obtained by processing a conductive metal plate,
There is an advantage that the plate-shaped winding of claim 1 can be manufactured easily and reliably.

[Brief description of drawings]

FIG. 1 is an exploded perspective view showing an embodiment of a plate winding of the present invention.

FIG. 2 is a perspective view showing the plate-shaped winding of FIG.

3 is a cross-sectional view of FIG.

4 is an exploded perspective view showing an inductor using the plate winding of FIG. 1. FIG.

5 is a cross-sectional view of the inductor of FIG.

FIG. 6 is an exploded perspective view showing another embodiment of the plate winding of the present invention.

FIG. 7 is a perspective view showing a winding formed by conventional printed wiring.

FIG. 8 is a cross-sectional view showing a conventional winding of an enameled wire having a circular cross section.

FIG. 9 is a cross-sectional view showing a conventional winding with an enameled wire having a circular cross section.

FIG. 10 is a perspective view showing a conventional winding of an enameled wire having a rectangular cross section.

FIG. 11 is an exploded perspective view showing an inductor using a winding made of the printed wiring shown in FIG. 7.

12 is an explanatory diagram for explaining elongation and contraction that occur when the enameled wire having a rectangular cross section in FIG. 10 is wound.

13 is a cross-sectional view showing a part of an inductor using the winding wire of FIG.

14 is a cross-sectional view showing a part of an inductor using the winding wire of FIG.

15 is a cross-sectional view showing a part of an inductor using the winding wire of FIG.

[Explanation of symbols]

 31 winding body 33 conductive portion 35 slit 39 inner peripheral end portion 41 insulating layer 47 plate winding 57 outer peripheral end portion

Claims (2)

[Claims] 1. A plurality of winding bodies formed by spirally forming conductive parts having a rectangular cross section in the same plane, and adjacent inner peripheral ends or outer peripheral ends of the conductive parts are mutually overlapped. A plate-shaped winding, which is formed by forming an insulating layer on the outer periphery of the conductive portion while being joined to the. 2. A step of forming a spiral slit on a conductive metal plate to produce a winding body having a conductive portion having a rectangular cross section, and stacking the winding bodies to form a conductive portion. And a step of joining adjacent inner peripheral ends or outer peripheral ends to each other, and a step of forming an insulating layer on the outer periphery of the conductive portion.