JP2003086438A - Air-core coil and coil device, and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an air-core coil with a lower interlayer voltage than the prior art and superior in the frequency characteristics. SOLUTION: An air-core coil 21 is made by spirally winding a conducting wire to continuously form a plurality of unit-winding sections 25, 26, and 27, having inside periphery lengths different each other in a direction of winding axis, and repeatedly forming unit coil sections, comprising the plurality of the unit-winding sections 25, 26, and 27 in a direction of winding axis, to form a intermediate coil products 20. After manufacturing the intermediate coil products 20, compressing the intermediate products 20 in a direction of the winding axis to push in the unit-winding of the length of the inside periphery smaller into the unit-winding section with the longer length of the inside periphery out of a plurality of unit-winding sections composing each unit coil, makes each unit coil section multilayered.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an air-core coil, a coil device and a method for manufacturing the same, which are installed in a rectifier circuit, a noise prevention circuit, a resonance circuit, etc. in various AC devices.

[0002]

2. Description of the Related Art As a method for manufacturing a coil device in which a coil is wound around a core, the applicant has shown in FIG.
A manufacturing method as shown in (b) has been proposed (JP 2000
No. 277337). In the method for manufacturing the coil device, as shown in FIG. 13 (a), the air-core coil (8) is transferred from the gap portion (71) of the C-shaped core (7) to the central hole (70) of the core (7). The air core coil (8) is attached to the periphery of the core (1) by passing it through one side portion of the core (1) to obtain a coil device as shown in FIG. 13 (b). According to the manufacturing method, the core
Since the air-core coil (8) is manufactured separately from (7), and the air-core coil (8) is attached to the core (7) to form a coil device, winding for the core (7) is performed. No work is required, and the manufacturing process is simplified by automating the manufacture of the air-core coil (8).

Further, as shown in FIG. 25, there is known a toroidal type coil device in which an air core coil (81) is wound around a bobbin (10). The air-core coil (81) is produced, for example, by winding a conductor wire around the outer peripheral surface of a winding jig (not shown) in the order shown by the numbers 1 to 29 in the drawing. First, a conductor wire is wound around the outer peripheral surface of the winding jig in the order of numbers 1 to 10 in the figure to form a first layer (82), and then the first layer (8
A conductive wire is wound around the outer peripheral surface of 2) in the order of numbers 11 to 19 in the figure to form a second layer portion (83), and finally, the second layer portion (8
A wire is wound around the outer peripheral surface of 3) in the order of numbers 20 to 29 in the drawing to form the third layer portion (84), thereby manufacturing the air-core coil (81) having a three-layer structure.

[0004]

By the way, FIG. 14 (a)
In the manufacture of the conventional coil device shown in (b), the core
In order to increase the ratio of the cross-sectional area of the conductor (9) that passes through the central hole (70) of (7) multiple times to the central hole (70), that is, the space factor of the conductor (9), A method of using a rectangular conductor wire or a trapezoidal conductor wire as the conductor wire of the core coil can be adopted. Since the rectangular conductor wire and the trapezoidal conductor wire have the same cross-sectional area as the round wire and a short side shorter than the diameter of the round wire, the central hole (70) of the core (7)
It is possible to accommodate a large number of conductors, which increases the space factor of the conductors. However, the flat conductor wire and the trapezoidal conductor wire have a problem that they are more expensive than the round wire.

Another coil device manufacturing method for increasing the space factor is to wind the conductive wire (9) around the core (7) in the order represented by the numbers 1 to 13 in FIG. 14 (a). After
In the order represented by the numbers 14 to 23 in FIG.
A method is known in which (9) is wound around the core (7) to form one coil layer on the outer peripheral side of the core and two coil layers on the inner peripheral side of the core. This allows the central hole (70) of the core (7)
Since many conductors can be accommodated in the wire, the space factor of the conductor is high. However, the process of winding the conductive wire (9) around the core (7) is difficult to automate and has to be performed manually, which causes a problem of low production efficiency.

In the air-core coil (81) shown in FIG. 25, the first layer portion (82), the second layer portion (83) and the third layer portion (84) are laminated in series. Therefore, as shown in FIG. 26, stray capacitance exists between the windings that are adjacent to each other in the winding axis direction, and also exists between the windings that overlap in the direction orthogonal to the winding axis. Here, the winding number 1 of the first layer portion (82) and the winding number 19 of the second layer portion (83) overlap each other, and the winding number 11 and the winding number of the second layer portion (83) Since the winding number 29 of the three-layer portion (84) overlaps each other, the potential difference (interlayer voltage) V1 between the overlapping windings becomes high as shown in FIG. As a result, the pressure resistance of the air-core coil (81) becomes a problem. Also, since the stray capacitance is large, the air core coil (81)
There was a problem that the frequency characteristic of the was deteriorated.

Therefore, an object of the present invention is to provide a coil device capable of realizing a high space factor without using an air-core coil, a rectangular conductor wire or a trapezoidal conductor wire in which an interlayer voltage is lower and frequency characteristics are improved as compared with the prior art. And a method for manufacturing a coil device capable of automating the process.

[0008]

In the air-core coil according to the present invention, unit coil portions formed by spirally winding at least one conductor wire are repeatedly arranged in the winding axis direction. The part is formed of a plurality of unit winding parts having different inner circumferences, and at least a part of the unit winding part having a small inner circumference is pushed inside the unit winding part having a large inner circumference.

In a specific configuration, the plurality of unit winding portions forming each unit coil portion are sequentially wound from the inner peripheral side to the outer peripheral side or from the outer peripheral side to the inner peripheral side,
The outermost or innermost unit winding portion is connected to the outermost or innermost unit winding portion of an adjacent unit coil portion.

In the above air core coil of the present invention, the plurality of unit winding portions constituting each unit coil portion are overlapped with each other in the direction intersecting with the winding axis, but these unit winding portions are continuous. Since the conductors are wound and formed sequentially and the winding numbers are continuous, the stray capacitance between the windings is small. or,
Even in the unit coil portions adjacent to each other, the plurality of unit winding portions are overlapped in the winding axis direction, but since the unit coil portions adjacent to each other are sequentially formed from one continuous conductor wire, Has a relatively small stray capacitance.

Further, in the method for manufacturing an air-core coil according to the present invention, a plurality of unit winding parts having mutually different inner peripheral lengths are continuous in the winding axis direction by winding at least one conductor wire in a spiral shape. And the unit coil portion composed of the plurality of unit winding portions is repeatedly formed in the winding axis direction to produce an intermediate product of the air-core coil, and then the intermediate product is compressed in the winding axis direction, At least a part of the unit winding part having a small inner circumference length is pushed into the inside of the unit winding part having a large inner circumference length among the plurality of unit winding parts constituting each unit coil, and at least a part of each unit coil part is formed. Make multiple layers. In the manufacturing method, the intermediate product of the air-core coil is one in which a plurality of unit winding parts having different inner peripheral lengths are arranged in the winding axis direction, and a conductor wire forming the unit winding part is orthogonal to the winding axis. direction
Since they do not overlap each other (in the winding diameter direction), they can be easily manufactured by spirally winding one conductor wire while changing the inner circumference length. The air-core coil of the present invention can be obtained by simply compressing the thus obtained intermediate product of the air-core coil in the winding axis direction.

In a specific configuration, the intermediate product is produced by winding a conductor wire on the outer peripheral surface of the winding jig, and the winding jig is composed of a plurality of winding core portions arranged in the axial direction,
Adjacent winding core portions have mutually different outer peripheral lengths, by forming a unit winding portion having a small inner peripheral length by winding a conductive wire around the winding core portion having a small outer peripheral length of the winding jig,
A unit winding part having a large inner circumference is formed by winding a conductive wire around a winding core part having a large outer circumference of the winding jig.
According to the specific configuration, by winding the conductive wire around the winding jig, it is possible to easily manufacture an intermediate product including a plurality of winding portions with varying inner circumferential lengths, and to automate the process. It will be possible.

A method of manufacturing a coil device according to the present invention is a method of manufacturing a coil device in which a coil is wound around a core, and is composed of a plurality of unit winding portions arranged in the winding axis direction. Each unit winding portion has one or a plurality of winding numbers, and the unit winding portions that are adjacent to each other in the winding axis direction have different inner circumference lengths. Compressing in the axial direction, pushing at least a part of the unit winding part having a small inner circumference length inside the unit winding part having a large inner circumference length, and mounting the air core coil around the core. There is.

In the method for manufacturing a coil device according to the present invention, the inner layer is obtained by compressing the single-layer air-core coil obtained in the air-core coil manufacturing step in the winding axis direction in the air-core coil mounting step. At least a part of the unit winding portion having a small inner circumferential length is pushed into the inside of the unit winding portion having a large length to cause an overlap, and the single-layer air-core coil is wound around the core as a coil having a plurality of layers. As a result, more conductors can be accommodated in a certain area than the conventional coil device,
This increases the space factor. Also, since the process of winding the air-core coil around the core is adopted, the process of winding the conductive wire around the core is unnecessary, and the air-core coil manufacturing process and the air-core coil mounting process can be automated. is there.

[0015]

According to the air-core coil of the present invention, the stray capacitance between the windings becomes smaller than that of the conventional one, so that the inter-layer voltage becomes lower, and excellent withstand voltage is obtained, and the frequency The characteristics are improved. Further, according to the coil device of the present invention, a high space factor can be realized regardless of the type of conductor wire. Furthermore, according to the coil device manufacturing method of the present invention, the process can be automated.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION The embodiments of the present invention will be described below.
A detailed description will be given with reference to the drawings.Example of coil device FIG. 1 is manufactured by the coil device manufacturing method according to the present invention.
It shows a manufactured choke coil device. The chokeco
The ill device has a C-shaped core (1) having a gap (14).
The coil (2) is wound around the coil. Coil (2)
The wire to be formed is wound in one layer on the outer peripheral side of the core (1).
And is wound in two layers on the inner peripheral side of the core (1).
Both ends of the coil (2) extend in the same direction and form a pair of leads.
The parts (17) and (18) are formed.

The core (1) is composed of a C-shaped core piece (11) having a gap serving as the gap portion (14) and a core piece (11) excluding a pair of core end faces sandwiching the gap portion (14). Insulation layer covering the surface
It consists of (12) and. In FIG. 1, the width of the core (1) in the radial direction is represented by W and the height is represented by L. The gap part (14) of the core (1) is displaced from the central axis of the core (1) by the penetration direction in a cross section orthogonal to the central axis of the core (1) being inclined with respect to the radial direction of the core (1). ing. The core (1) has a convex portion projecting toward the inner side of the core (1) at a position near one of the pair of core end faces sandwiching the gap (14) and having a short distance from the center of the core. (15) is formed. The distance between the pair of core end faces, that is, the width of the gap (14), is
It is slightly larger than the diameter of the conductor wire that constitutes (2).

In the manufacturing process of the coil device according to the present invention, first, an air-core coil is manufactured by using the winding jig (3) as shown in FIG. The winding jig (3) is constructed by projecting a winding core (30) on the surface of a support plate (33), and the winding core (30) has a rectangular cross section of one of the prismatic parts (34). Sides with multiple ridges (36)
And a side surface (37) opposite to the convex portion (36) is formed into a flat surface. Square column of winding jig (3)
The cross-sectional shape of the (34) is defined so that the width X and the height Y in the cross section perpendicular to the longitudinal direction thereof are slightly larger than the width W and the height L of the core (1). The convex streak portion (36) of the winding jig (3) is formed in a U shape along the outer peripheral surface of the prismatic portion (34) so as to cover a substantially half circumference thereof, and the height from the surface of the prismatic portion (34). H is slightly larger than the diameter of the conductor wire, and the width B along the longitudinal direction of the prismatic portion (34) is formed to a size capable of winding one conductor wire.

The plurality of ridges (36) of the winding jig (3) are arranged at intervals such that three continuous ridges (36) (36) (36) can wind one conductor wire. A plurality of groups (35) are arranged at intervals so that two continuous wires (36), (36), and (36) can be wound around one conductor group (35). The winding jig (3)
On the surface of, a region where two conducting wires can be wound is formed at a constant cycle by interposing a plurality of regions where one conducting wire can be wound. The winding core (30) of the winding jig (3) is composed of a plurality of members,
Although disassembling and assembling are possible, in FIG. 2, for the sake of convenience, the drawing is shown in the state of being made of a single member.
Thus, in the winding jig (3), the first winding core portion (31) is formed by the region where the ridge portion (36) is formed, and
The second winding core portion (32) is formed by the region between the two adjacent ridge portions (36) (36).

In the air-core coil manufacturing process, as shown in FIG. 3, the wire (3) is placed in order from the support plate (33) side of the winding jig (3).
9) is wound around the winding core (30) along the surface of each winding core (31) (32). In this process, each core (31) (32)
The number of times the conductor wire (39) is wound around is 1 or 2 times, depending on the width of the winding core. In this way, the conductive wire (39) is wound up to the winding core portion at the end of the winding jig (3), and then the winding core (30) is disassembled and removed. As a result, the air-core coil (4) shown in FIGS. 4 and 5 is obtained.

In the air-core coil (4), a first unit winding portion (41) having a large inner peripheral length formed by being wound around the first winding core portion (31) of the winding jig (3). ) And a second unit winding part (42) having a small inner circumference length formed by being wound around the second winding core part (32) of the winding jig (3) are alternately arranged. .

As shown in FIG. 5, one side portion (44) of the air-core coil (4), which is formed along the side surface (37) of the winding jig (3), which is a flat surface, is While the outer peripheral surfaces of the first unit winding portion (41) and the second unit winding portion (42) are aligned, the other is formed along the convex portion (36) of the winding jig (3). Sides of (45)
The outer peripheral surface of the first unit winding portion (41) is the second unit winding portion.
An uneven shape is formed by projecting outward from the outer peripheral surface of (42). Hereinafter, the one side portion (44) will be referred to as a planar side portion (44), and the other side portion (45) will be referred to as an uneven side portion (45).

FIG. 6 shows the first unit winding portion (4) of the air-core coil (4).
The concrete shapes of 1) and the second unit winding portion (42) are shown.
The first unit winding part (41) is a first to fourth drawing a trapezoidal loop.
The second unit winding part (42) is composed of the conducting wire parts (41a) (41b) (41c) (41d), and the first to fourth conducting wire parts (42a) (42b) (42b) 42c) and (42d). And
Of the first unit winding part (41), the fourth conducting wire part (41d) corresponding to the short side of the trapezoid overlaps with the fourth conducting wire part (42d) of the second unit winding part (42), and both the fourth conducting wires. By the parts (41d) (42d), the planar side part (4
4) is formed. Further, in the first unit winding portion (41), the first conducting wire portion (41a) corresponding to the long side of the trapezoid is the second unit winding portion (42).
The first conductor portion (42a) of the
The uneven side portions (45) are formed by (41a) and (42a). Further, in the first unit winding part (41), the second conductor part (41b) and the third conductor part (41c) corresponding to the two sides of the trapezoid are located at both ends of the fourth conductor part (41d). From the first conductive wire portion (41a) toward both end positions, and the distance between them extends.

Here, the holes (4) formed inside the first to fourth conducting wire portions (42a) (42b) (42c) (42d) of the second unit winding portion (42).
8) has a rectangular shape slightly larger than the cross-sectional shape along the radial direction of the core (1), and the first to fourth conducting wire portions (41a) (41b) (41c) (of the first unit winding portion (41) ( 41d) inside the holes (4
7) includes the holes (48) of the second unit winding portion (42),
The size of the second unit winding portion (42) includes the entire first conductor portion (42a) and a part of the second and third conductor portions (42b) and (42d). That is, the first winding portion (41) of the first unit winding portion (41)
Between (a) and the second winding part (42a) of the second unit winding part (42), a slight gap penetrating in the winding axis direction is formed over the entire area and the first unit winding part (42a) is formed. The second and third winding parts of the part (41)
(41b) (41c) and the second and third winding parts (4) of the second unit winding part (42)
Between 2b) and (42c), a slight gap penetrating in the winding axis direction is formed in a part of the region on the first winding part (41a) side.
The gap is not always necessary, and the first winding portions (41a) (42a) may be slightly overlapped with each other.

Thereafter, in the air core coil mounting step,
As shown in FIGS. 7 and 8, the air-core coil (4) is attached to the core (1) which is separately manufactured. First, as shown in FIG.
Of the pair of core end faces (1a) (1b) sandwiching the gap part (14) of (1), the core end (1c) having one core end face (1b) far from the core center is the air-core coil (4). So that it penetrates into the central hole of the core, the uneven side part (45) of the air-core coil (4) is inserted into the gap part of the core (1).
Push it into (14). At this time, the uneven side portion of the air core coil (4)
(45) is squeezed by using the insertion assisting tool (5), and the uneven shape is corrected into a flat shape and pushed into the gap portion (14) of the core (1). As a result, the side portion of the air core coil (4) is
(45) passes through the gap portion (14) having a width slightly larger than the diameter of the conducting wire (39).

When the air core coil (4) is pushed further into the inner part of the core (1), the side portion (4) of the air core coil (4) is moved as shown in FIG.
5) sequentially moves from the unit winding part (41) at the front end to the central hole (13) from the gap part (14) of the core (1), and with this movement, the side part (45) presses the pinch force. The core is released from the
In the central hole (13) of (1), the outer peripheral surface of the first unit winding portion (41) protrudes toward the center of the core more than the outer peripheral surface of the second unit winding portion (42) and returns to the original uneven shape. It will be. In this way, the air core coil (4) is pushed forward to push the side portion (45) into the central hole (13) along its entire length.

In this process, the front end of the air-core coil (4) is shown in FIG.
By contacting the convex portion (15) of the core (1) and further pressing the air-core coil (4) as shown in (1), the air-core coil (4) receives a compressive force in the winding axis direction, and the core (1) ), The second unit winding portion (42) of the air-core coil (4) is pushed into the inside of the first unit winding portion (41). At this time, as shown in FIG. 6, the air-core coil
In the uneven side portion (45) of (4), between the first conducting wire portion (41a) of the first unit winding portion (41) and the first conducting wire portion (42a) of the second unit winding portion (42). Since a slight gap is formed, the second unit winding portion (42) is located inside the first unit winding portion (41) without the first conductor portions (41a) (42a) interfering with each other. It will be pushed in smoothly. In addition, in the state before compressing the air-core coil (4), when the gap between the first conductor portions (41a) and (42a) is zero,
Even if there is a slight overlap between the conductor portions (41a) and (42a), the second and third conductor portions are compressed by the air core coil (4).
Since (42b) and (42c) are bent, the second unit winding portion (42) can be pushed into the inside of the first unit winding portion (41).

As a result, the air-core coil (4) is formed in two layers within the central hole (13) of the core (1) as shown in the sectional view of FIG. FIG. 11 shows a winding sequence of 1 to 3 when the conductor wire (39) is wound around the winding jig (3) to form a plurality of unit winding portions (41) (42) in the above-described air core coil manufacturing process.
The position of each unit winding part when the air-core coil (4) produced by this is attached to the core (1) is represented by the number indicating the winding order.

As shown in the drawing, the first unit winding portion (41) and the second unit winding portion in which the winding sequence is, for example, 3 and 4 or 23 and 24 when wound on the winding jig (3). Division (4
2) is attached to the core (1),
The layers are stacked on each other at (13) to form a two-layer structure including a first layer including the second unit winding portion (42) and a second layer including the first unit winding portion (41).

By the way, in this embodiment, as shown in FIG. 11, the lead wire 1 is provided with a constant interval between the convex portions 36 of the winding jig 3.
The size is changed from the size of one wire to the size of two conducting wires. However, assuming that the array pitch of the convex portions (36) is constant, the unit winding parts of the air core coil (4) are all formed with the same number of turns. If you do, the following problems will occur. That is, since the air-core coil bends in a C shape as it is attached to the C-shaped core, the first layer and the first unit winding formed by the second unit winding portion (42) in the central hole of the core. There is a difference in the radial distance from the core center of the second layer formed by the portion (41), and the first unit winding portion (41) and the second unit winding portion having the same number of turns are arranged along the circumferential lines of different radii. (42)
Since the first unit winding portion (41) and the second unit winding portion (42) in the continuous winding order are gradually displaced and separated from each other, both unit winding portions (41) (42) are arranged. It is not possible to obtain an orderly winding state in which the wires are in contact with each other.

On the other hand, in the present embodiment, as described above, the interval between the convex portions (36) of the winding jig (3) is set at a constant period from the size of one conductor wire to the size of two conductor wires. Since the second unit winding part (42) having the number of turns of 2 is intervened in the array of the second unit winding part (42) of the number of turns of 1 at a constant cycle, the number of turns is 2 The first unit winding part (41) and the second unit winding part to be arranged along the circumferential lines of different radii by the second unit winding part (42) of
There will be a difference in the number of (42). As a result, the first unit winding part (41) and the second unit winding part (42) in the continuous winding order
By absorbing the gap between them, as shown in FIG. 11, the first unit winding part (41) and the second unit winding part (42) can be laminated by contacting each other, and an orderly winding state can be obtained. You can do it.

As described above, according to the method for manufacturing the coil device of the present invention, the conductor wire accommodated in the central hole (13) of the core (1) is laminated in a plurality of layers. Since it is possible to increase the number of conducting wires that can be accommodated in the central hole (13) of the core (1), a coil device having a high space factor can be obtained. Further, even if the diameter of the core is reduced, the same number of conductors can be accommodated in the reduced central hole, so that the coil device can be downsized without deteriorating the characteristics. . In addition, it is possible to automate the process of manufacturing the air-core coil (4) using the winding jig (3) and also the process of mounting the air-core coil (4) on the core (1). Therefore, the automation of the whole process will bring about a significant improvement in production efficiency.

Furthermore, the frequency characteristic of the coil device can be improved. That is, in the coil device of FIG. 14 in which the coil is manually wound, the leading wire end portion (96) in the winding order and the leading wire end portion (98) in the final winding order are mutually adjacent. They will overlap and the ends of these two wires (96)
Since the voltage of the entire coil is applied during (98), there is a problem that the withstand voltage between the conductors becomes insufficient. Also, the central hole of the core (7)
Since the conductor part of the first coil layer and the conductor part of the second coil layer arranged in (70) overlap each other in the conductor parts whose winding order is greatly different, a large stray capacitance is generated and the frequency characteristic of the coil device is increased. There was a problem of decline.

On the other hand, in the coil device according to the present invention, as shown in FIG. 11, the air core coil (4) is attached to the core (1).
With the installed, the leading wire end (61) in the winding order and the last wire end (62) in the winding order are sufficiently separated,
However, since the unit winding portions (41) and (42) in which the winding order is continuous are arranged in contact with each other, the voltage difference between the conductors is small, which improves the insulation performance between the conductors. High frequency characteristics can be obtained by reducing the stray capacitance between lines.

[0035]Example of air core coil 15 and 16 show the structure of the air-core coil (21) according to the present invention.
Represents a structure. The air core coil (21) is of the bobbin (10).
It is constructed by winding a conducting wire (91) around the outer peripheral surface, as shown in the figure.
In the example, the first layer (21a), the second layer (21b) and the third layer (21c)
It has a laminated structure consisting of

The air-core coil (21) is numbered 1 to 1 in FIG.
It is formed by winding one conductor wire in the winding order shown by 29, and has a plurality of consecutive numbers (1 to 3), (4 to 6), ...
., (25 to 27), and (28 to 29) windings respectively form unit coil portions, and these unit coil portions are arranged in 10 rows in the winding axis direction. Each unit coil portion is formed of a unit winding portion having a maximum inner circumference length of 1, and an intermediate inner circumference length and a unit winding portion having a minimum inner circumference length, each having a number of turns of 1. The unit coil portion having the intermediate inner circumferential length is pushed inward, and the unit coil portion having the minimum inner circumferential length is pushed inside the unit coil portion having the intermediate inner circumferential length. For example,
In the unit coil portion formed by the windings with winding numbers 1 to 3, the winding number 2 is provided inside the unit winding portion with winding number 3.
The unit winding portion of No. 1 is pushed in, and the unit winding portion of winding number 1 is pushed inside the unit winding portion of winding number 2.

Therefore, in the case of the air-core coil (21) shown in FIG. 16, each unit coil portion is formed by three unit winding portions which are wound in order from the inner peripheral side to the outer peripheral side. And a unit coil portion formed of three unit winding portions that are sequentially wound from the outer peripheral side toward the inner peripheral side are alternately arranged in the winding axis direction, and the outermost periphery or the outermost portion of each unit coil portion is arranged. The inner peripheral unit winding portion is connected to the outermost peripheral or innermost unit winding portion of the adjacent unit coil portions.

The air-core coil (21) of the present invention comprises a conductive wire (91).
Has a structure in which the unit coil portion is repeatedly formed in the direction perpendicular to the winding axis while forming a unit coil portion by winding the unit coil portion in the direction orthogonal to the winding axis. The line numbers will be close. For example, the unit winding part of winding number 4 and the unit winding part of winding number 9 are adjacent to each other, but the difference between the winding numbers of both unit winding parts is only 5.
Therefore, as shown in FIG. 17, almost no stray capacitance exists between the windings adjacent to each other in the direction orthogonal to the winding axis, and the stray capacitance between the windings adjacent to each other in the winding axis direction is also extremely small. Become. As a result, the potential difference (interlayer voltage) V2 between the windings adjacent to each other becomes sufficiently low, and the pressure resistance of the air-core coil (21) is improved. Further, since the stray capacitance is small, the frequency characteristic of the air core coil (21) is improved.

For example, if the voltage between the terminals of the coil is 200V and the number of turns is 29 turns, the voltage per turn is about 6.9V. The conventional air-core coil (8
In 1), the interlayer voltage V1 of the unit winding part of the winding number 1 and the unit winding part of the winding number 19 is 6.9 V × 18 = 124.2.
In contrast to V, the air core coil (2
In 1), the interlayer voltage V2 of the unit winding part of the winding number 1 and the unit winding part of the winding number 6 is 6.9V × 5 = 34.5V, which is about one-third that of the conventional case. Since the pressure resistance of the coil becomes a problem especially when an abnormal voltage is applied, the air-core coil (21) of the present invention has high reliability.

FIG. 18 shows a winding jig (51) used for manufacturing the air-core coil (81) of the present invention. The winding jig (5
1) is a stepped member on each end of both sides of the flat plate member (52).
(53) is detachably fixed. Stepped member (5
3) is the lower step portion as shown in FIGS. 19 and 20 (a) (b).
(55), the middle step portion (56), the high step portion (57), the middle step portion (56) and the low step portion (55) as one cycle, these steps are formed repeatedly. is there. 20 (a) shows the stepped member.
FIG. 20 (b) is a plan view of (53), and FIG. 20 (b) is a side view of the stepped member (53). Each step of the stepped member (53) has a number indicating the order in which the conductor wire is wound. Numbered 1 to 29.

21 (a) (b) and 22 (a) (b) show a coil intermediate product (20) formed by winding a conducting wire (91) around the winding jig (51). 21 and 22 are views of the coil intermediate product (20) viewed from different directions by 180 degrees.
The conducting wire (91) begins to be wound from the lower step (55) located at the end of the winding jig (51) shown in FIG.
The winding is advanced to (56), the high step (57), the middle step (56) and the low step (55). The lower step portion (55) and the middle step portion (56) each have a width for winding the conducting wire (91) only once, while the higher step portion (57) has a conducting wire (91). 91) has a width for winding only 2 times.

By winding the conducting wire (91) around the lower step portion (55), the first unit winding portion (25) having the minimum inner circumferential length is formed, and the conducting wire (91) is wound around the middle step portion (56). The second unit winding part (26) having an intermediate inner circumference is formed by winding the wire around the circumference,
The third unit winding part (27) having the maximum inner circumferential length is formed by winding the (91) around the high step part (57). In this process, when the winding is advanced from one step of the winding jig (51) to the adjacent end as shown in FIGS.
(51) Transition between steps while extending diagonally on one side surface. On the other side surface of the winding jig (51), as shown in FIGS. 22 (a) and 22 (b), the conductive wire (91) extends straight between the steps having the same height.

Around the winding jig (51) the required number of turns (9
After winding 1) and then disassembling the winding jig (51), the coil intermediate product (2) shown in FIGS. 21 (a) and 22 (a) is obtained.
0) is obtained. Then, by compressing the coil intermediate product (20) in the winding axis direction as shown in FIGS. 23 (a) and 24 (a), the third unit winding as shown in FIG. 23 (b) and FIG. 24 (b). The second unit winding portion (26) is pushed inside the portion (27), and the first unit winding portion (25) is pushed inside the second unit winding portion (26). As a result, a three-layer air core coil (21) is obtained.

In the three-layer air-core coil (21) shown in FIGS. 23 (b) and 24 (b), an elastic repulsive force that stretches in the winding axis direction is generated. With the air core coil (21) attached to the bobbin (10), the bobbin (10)
By this, the elastic repulsive force of the air-core coil (21) is received and the three-layer coil structure is maintained. Alternatively,
A three-layer air-core coil (21) shown in FIGS. 23 (b) and 24 (b).
It is also possible to maintain the three-layer coil structure by taping the.

According to the method for manufacturing the air-core coil (21),
FIG. 23 (a) using the winding jig (51) shown in FIGS.
And after manufacturing the coil intermediate product (20) shown in FIG. 24 (a), the coil intermediate product (20) is manufactured as shown in FIGS. 23 (b) and 24 (b).
The air-core coil (21) of the present invention can be produced only by compressing in the winding axis direction as shown in, so that the process can be easily automated and the winding arrangement does not have a collapsed winding. The air core coil (21) can be obtained.

The configuration of each part of the present invention is not limited to the above-mentioned embodiment, and various modifications can be made within the technical scope described in the claims. For example, the unit winding portion forming the air-core coil (21) shown in FIG. 1 is not limited to two types, that is, a unit winding portion having a small inner circumference length and a unit winding portion having a large inner circumference length. Air core coil (21) from three or more types of unit windings with different lengths
Can also be configured. Further, the air-core coil (21) shown in FIG. 15 is not limited to the three-layer structure and may have a two-layer structure or a multi-layer structure of four or more layers. Moreover, FIG. 2 and FIG.
The shape of the winding jigs (3) and (51) shown in is not limited to the above-mentioned configuration, and it is possible to manufacture air core coils having different inner circumference lengths between adjacent unit winding parts. If so, various shapes can be adopted. Further, the shape of the core constituting the coil device shown in FIG. 1 is not limited to the C-shaped core described above, and, for example, after a rod-shaped core or an air-core coil is attached to a C-shaped core piece. A ring-shaped core in which the gap portion of the core piece is filled with a magnetic material or a non-magnetic material may be used.

Furthermore, the air-core coil (4) shown in FIG. 4 and FIG.
The conducting wires (39) and (91) forming the air-core coil (21) shown in (1) are not limited to the single wire as in the above embodiment, but may be the double wire. For example, as shown in FIG. 12, two or more conducting wires (39a) (39b)
As a conductor wire bundle (39c), the conductor wire bundle (39) is wound around the winding jig (3) in the same manner as in the case of a single wire, and one or a plurality of conductor wire bundles (39c) forms a unit having a large inner circumference. It is also possible to form the winding portion and form a unit winding portion having a small inner circumferential length by one or a plurality of conducting wire bundles (39c). In this case as well, in the air core coil mounting step, at least a part of the unit winding part having a small inner peripheral length is pushed inside the unit winding part having a large inner peripheral length, and the two layers are formed in the central hole of the core. Will be formed. Furthermore, air core coil
(4) The conducting wires (39) and (91) forming (21) are not limited to round wires having a circular cross section, and may be rectangular wires having a rectangular cross section.

[Brief description of drawings]

FIG. 1 is a perspective view of a choke coil device obtained by a method for manufacturing a coil device according to the present invention.

FIG. 2 is a partially cutaway perspective view of a winding jig used in the manufacturing method.

FIG. 3 is a diagram showing a state in which a conductive wire is wound around the winding jig.

FIG. 4 is a front view of an air-core coil obtained by the air-core coil production process of the present invention.

FIG. 5 is a back view of the air-core coil.

FIG. 6 is a partially cutaway side view of the air-core coil.

FIG. 7 is a diagram showing how the air-core coil is inserted into the gap portion of the core in the air-core coil mounting step of the present invention.

FIG. 8 is a diagram showing a state of elastic recovery when the tip of the air-core coil passes through the gap portion of the core in the step.

FIG. 9 is an enlarged plan view showing a part of the choke coil device obtained by the process.

FIG. 10 is a sectional view of the choke coil device.

FIG. 11 is an explanatory view showing the relationship between the order of winding the conductive wire around the jig and the position of each unit winding portion of the air-core coil in the manufacturing process of the coil device according to the present invention.

FIG. 12 is an explanatory view of the above in the manufacturing process of the coil device using the conductor wire bundle composed of two conductor wires.

FIG. 13 is a process diagram showing a method of manufacturing a conventional choke coil device.

FIG. 14 is a process drawing showing another manufacturing method of the conventional choke coil device.

FIG. 15 is a perspective view of an air-core coil according to the present invention.

FIG. 16 is a sectional view of the air-core coil.

FIG. 17 is an equivalent circuit diagram of the air-core coil.

FIG. 18 is a perspective view of a winding jig.

FIG. 19 is a perspective view of a stepped member.

FIG. 20 is a plan view and a side view of a stepped member.

FIG. 21 is a perspective view and a sectional view of a coil intermediate product.

22 is a perspective view and a cross-sectional view of the coil intermediate product viewed from a direction different from that of FIG. 21 by 180 degrees.

FIG. 23 is a cross-sectional view illustrating a compression process of a coil intermediate product.

24 is a cross-sectional view illustrating a compression process of the coil intermediate product viewed from a direction different from that of FIG. 23 by 180 degrees.

FIG. 25 is a cross-sectional view of a conventional air core coil.

FIG. 26 is an equivalent circuit diagram of the air-core coil.

[Explanation of symbols]

(1) Core (13) Central hole (14) Gap part (3) Winding jig (30) Core (31) First winding core (32) Second winding core (39) Conductor (4) Air core coil (41) First unit winding section (42) Second unit winding part (44) Flat side (45) Uneven side (5) Insertion aid (7) Core (70) Central hole (71) Gap part (8) Air core coil (39c) Conductor bundle

Claims (13)

[Claims] 1. A unit coil portion formed by winding at least one conductive wire in a spiral shape is repeatedly arranged in the winding axis direction, and each unit coil portion has a plurality of unit windings having different inner circumferential lengths. An air-core coil in which at least a part of a unit winding part having a small inner circumference is pressed inside a unit winding part having a large inner circumference. 2. A plurality of unit winding portions forming each unit coil portion are sequentially wound from the inner peripheral side toward the outer peripheral side or from the outer peripheral side toward the inner peripheral side, and the outermost periphery or the innermost periphery is formed. 2. The air-core coil according to claim 1, wherein the unit winding part is connected to the outermost or innermost unit winding part of the adjacent unit coil parts. 3. A plurality of unit winding parts having mutually different inner peripheral lengths are continuously formed in the winding axis direction by winding at least one conducting wire in a spiral shape, and the plurality of unit winding parts are formed. The unit coil part consisting of is repeatedly formed in the winding axis direction to produce an intermediate product of the air-core coil, and then the intermediate product is compressed in the winding axis direction to form a plurality of unit winding parts constituting each unit coil. An air-core coil characterized in that at least a part of a unit winding part having a small inner circumference is pushed into the inside of a unit winding part having a large inner circumference, and each unit coil part is multilayered at least in part. 4. A plurality of unit winding parts having different inner circumference lengths are continuously formed in the winding axis direction by winding at least one conducting wire in a spiral shape, and the plurality of unit winding parts are formed. The unit coil part consisting of is repeatedly formed in the winding axis direction to produce an intermediate product of the air-core coil, and then the intermediate product is compressed in the winding axis direction to form a plurality of unit winding parts constituting each unit coil. Of the air-core coil, wherein at least a part of the unit winding part having a small inner circumference is pushed into the inside of the unit winding part having a large inner circumference, and each unit coil part is multilayered at least in part. Production method. 5. The intermediate product is produced by winding a conductive wire around an outer peripheral surface of a winding jig, and the winding jig comprises:
The winding core is composed of a plurality of winding cores arranged in the axial direction, and adjacent winding cores have different outer peripheral lengths from each other. The air core according to claim 4, wherein a unit winding portion having a small circumference is formed, and a conducting wire is wound around a winding core portion having a large outer circumference of the winding jig to form the unit winding portion having a large inner circumference. Coil manufacturing method. 6. A method of manufacturing a coil device in which a coil is wound around a core, comprising a plurality of unit winding parts arranged in a winding axis direction, each unit winding part having one or a plurality of winding numbers. The unit winding portions that are adjacent to each other in the winding axis direction have different inner peripheral lengths,
The process of manufacturing the air-core coil and compressing the air-core coil in the axial direction of the core to push at least a part of the unit winding part with a small inner circumference into the inside of the unit winding part with a large inner circumference, And a step of mounting an air-core coil around the periphery of the coil device. 7. The air-core coil producing step is carried out by winding a conductive wire around the outer peripheral surface of the winding jig, and the winding jig is composed of a plurality of winding core portions arranged in the axial direction, and adjacent winding cores. The parts have different outer peripheral lengths, and a conductor wire is wound around a winding core part having a small outer peripheral length to form a unit winding part having a small inner peripheral length. The method for manufacturing a coil device according to claim 6, wherein the unit winding portion having a large inner circumferential length is formed by winding a conductive wire around a winding core portion having a large length. 8. In the air-core coil mounting step, the air-core coil is mounted around the core by passing a side portion of the air-core coil from a gap part formed by cutting off a part of the core to a central hole of the core. A method for manufacturing a coil device according to claim 6 or 7. 9. The air core coil mounting step, wherein the core is formed in a C shape, and the gap portion has a penetration direction in a cross section orthogonal to the central axis of the core inclined with respect to the radial direction of the core. Then, of the pair of core end faces that sandwich the gap part,
The method for manufacturing a coil device according to claim 8, wherein a core end portion having one core end surface far from the central axis of the core is caused to enter the central hole of the air-core coil. 10. In the air-core coil manufacturing step, at one side of the air-core coil to be arranged on the outer peripheral side of the core,
The outer peripheral surface of the unit winding part having a large inner circumference of the air core coil and the outer peripheral surface of the unit winding part having a small inner circumference are aligned, and at the other side of the air core coil to be arranged on the inner circumference side of the core. A plurality of unit winding portions are formed such that an outer peripheral surface of a unit winding portion having a large inner peripheral length of the air-core coil protrudes toward a core center more than an outer peripheral surface of a unit winding portion having a small inner peripheral length. 8. The method for manufacturing the coil device according to claim 8 or 9. 11. In the air-core coil mounting step, a plurality of unit winding portions on the other side portion of the air-core coil to be passed through the gap portion of the core are aligned with the outer peripheral surfaces thereof, and the air-core coil side is arranged. The method for manufacturing a coil device according to claim 10, wherein the portion is fed into the gap portion. 12. The unit winding part having a small inner peripheral length is pushed inside the unit winding part having a large inner peripheral length of the air core coil on the inner peripheral side of the core in the air core coil mounting step. Item 12. A method for manufacturing a coil device according to any one of items 11. 13. In the air-core coil manufacturing process, unit winding portions having a large inner circumference length and unit winding portions having a small inner circumference length are alternately formed, and in forming the unit winding portion having a small inner circumference length, The method for manufacturing a coil device according to claim 8, wherein a unit winding portion having a larger number of turns than a unit winding portion having a large circumference is formed at one or a plurality of locations.