JP2003274619A - Method of forming coil for motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of forming a cylindrical motor coil by fixing planar coils on an inner wall surface of the inside of a motor housing, which is capable of precisely fixing the planar coil on the inner wall surface of the inside of the housing. <P>SOLUTION: The planar coil 11 which is rounded into a cylinder form is inserted into the housing 15 of a motor. Then, a diameter expanding device 16 having a diameter expanding function is inserted into the inside of the coil 11 which is rounded in cylindrical form. Then, by operating the device 16 in this state, the cylindrically rounded coil 11 is pressed onto the inner surface of the inside of the housing and is fixed by an adhesive 17. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a cylindrical motor coil by fixing a planar coil to an inner wall surface inside a motor housing, and more particularly to a stator coil inside a small motor such as a micromotor. The present invention relates to a forming method of a stator coil, which can fix a planar coil to an inner wall surface inside a housing with high positional accuracy.

[0002]

2. Description of the Related Art A stator coil (stator coil) in a small motor such as a micromotor is formed by rolling a thin flat coil into a cylindrical shape, inserting the coil into the housing of the motor, and fixing it to the inner wall surface of the housing. can do.

As a method for producing a thin planar coil,
There are methods of printing conductive paste and etching of conductive film, but as a planar coil that forms the stator coil inside a small motor, it is fixed by pressing a wire material such as a conductor onto an adhesive surface such as an adhesive tape. The wire-laid planar coil that forms the coil is excellent in terms of durability, insulation between wires, and high density of the coil.

A method for manufacturing a wiring type planar coil is disclosed in
The method disclosed in Japanese Patent Application Laid-Open No. 001-126942 is a technique capable of forming a highly accurate wiring pattern by intermittently laying a conductive wire while making point contact with the adhesive sheet surface. In this technique, the thickness of the plane coil can be made approximately the same as the thickness of the conductor to be laid, so that it is possible to form a plane coil having a thickness of several tens of μm, and a diameter of 0.1 to It is possible to form a very small plane coil or antenna of about 2 mm. As the industrial application of the flat coil, it is particularly suitable for a stator coil for a micromotor having an outer diameter of about several mm.

[0005]

As described above, the stator coil inside the small motor is formed by rolling the flat coil into a cylindrical shape, inserting the flat coil into the housing, and fixing the flat coil to the inner wall surface of the housing. You can

However, as described above, when the size of the motor becomes extremely small, for example, about several mm in outer diameter, the cross section of the stator coil is formed in an accurate circular shape, and the shaft is accurately positioned at the center of the stator coil. Especially, due to technical difficulties, it becomes difficult to keep the gap between the stator coil and the magnet rotor arranged inside the stator coil uniformly over the entire circumference of the stator coil. Was in decline.

The present invention has been made in view of the above circumstances, and is a method of forming a motor coil such as a stator coil of a micromotor, in which a planar coil is fixed to the inner wall surface inside the housing with high positional accuracy. The purpose is to provide a possible method.

[0008]

In order to achieve the above-mentioned object, the present invention is a method for fixing a plane coil to an inner wall surface inside a housing of a motor and forming a cylindrical motor coil by the plane coil. The cylindrical coil rolled into the housing of the motor, and a diameter expansion device having a diameter expansion function to expand the outer diameter is inserted inside the cylindrical coil rolled into the cylindrical state. By activating the diameter expanding function of the diameter expanding device, the cylindrical coil rolled flat coil is pressed against and fixed to the inner wall surface inside the housing to provide a motor coil forming method.

According to the present invention, by operating the diameter expanding function of the diameter expanding device, it is possible to apply a uniform pressure to the entire inner surface of the tubular coil rolled into a cylindrical shape and press the planar coil against the inner wall surface of the housing. Since the flat coil can be fixed to the inner wall surface of the housing in this state, the flat coil can be fixed to the inner wall surface of the housing with high positional accuracy.

In the present invention, as the plane coil, those manufactured by various methods can be used. For example, a method of fixing a wire material such as a conductor to an adhesive surface such as an adhesive tape (wiring method), a conductive paste Although it is possible to use the one manufactured by a method of printing a sheet, a method of etching a conductive film, or the like, a plane coil by a wiring method is particularly suitable for forming a stator coil inside a small motor.

The diameter-expanding device used in the present invention may be of any type as long as it has a diameter-expanding function for expanding the outer diameter. For example, a tube-shaped or balloon-shaped material made of an elastic material can be used. It is a hollow shape that expands by injecting a fluid such as air or water into it. A diameter expansion device that expands by heating and a rod-shaped expander that expands when heated. A device, a rod-shaped device having rubber elasticity, and a diameter expanding device that expands by applying a compressive load in the axial direction are conceivable.

Further, since it is preferable that the outer diameter of the diameter expanding device is as uniform as possible in the longitudinal direction, the shape is preferably a tube shape or a rod shape.

Furthermore, since it is necessary to remove the diameter expanding device after fixing the cylindrical flat coil to the inner wall surface of the housing, the outside diameter of the diameter expanding device can be immediately returned to the original reduced state. preferable. That is, the diameter expansion function should be a reversible function with good response.

From the above viewpoint, the diameter expanding device is a tube body made of a material having rubber elasticity and having one end sealed, or a rod-shaped body made of a material having rubber elasticity, and has a function of expanding the outer diameter. It is preferable to have a function of quickly returning to the original shape.

In the present invention, the means for fixing the planar coil to the inner wall surface inside the housing is not limited, and, for example, a mechanical fixing method, an adhesive fixing method, or the like can be used. The method of fixing is simple and suitable. The adhesive may be applied to either the inner wall surface of the housing, the outer surface of the planar coil, or both. Furthermore, a method of giving an adhesive function to the adhesive layer for laying the planar coil is also conceivable.

In the present invention, the cylindrical coil may be inserted into the motor housing and then the diametrical expansion device may be inserted inside the cylindrical coil. After inserting the diameter-expanding device inside the flat coil, the cylindrical flat coil may be inserted inside the motor housing.

Further, in the present invention, the shape and structure of the motor housing for fixing the planar coil to the inner wall surface of the inside are not limited, and the present invention can be applied to any housing such as a cylindrical housing and a block-shaped housing. Can be applied.

Furthermore, the present invention can be applied to any case in which a cylindrical motor coil is formed by a planar coil inside a motor housing, and can be applied to various cases other than a stator coil of a micromotor. It is also applicable to the formation of motor coils.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described specifically and in detail with reference to the accompanying drawings by way of example embodiments.

(Embodiment 1) This embodiment is an example of an embodiment relating to a method for forming a motor coil according to the present invention, and FIGS. 1 to 5 show a stator coil forming method according to this embodiment. FIG.

Step 1 In this embodiment, as the plane coil, as shown in FIG. 1, the plane coil 11 in which three coils 14 are formed on the adhesive layer 12 is used. In the figure, 14A is a coil portion,
B indicates a lead portion.

Here, a method of forming the above planar coil 11 will be described. First, the thickness is 50μ after the release process.
m polyethylene terephthalate (PET) film substrate (not shown) and a 40 μm thick thermosetting modified epoxy resin adhesive coated on the substrate 1
A pressure-sensitive adhesive sheet composed of 2 is formed. Next, the conductor 13 having a diameter of 30 μm is laid on the adhesive layer 12 of the above-mentioned adhesive sheet. Under the conditions of a temperature of 150 ° C. and a pressure of 1.96 × 10 ⁵ Pa, the lined adhesive sheet is pressed for about 1 hour to completely cure the adhesive, and then the above-mentioned substrate is removed to obtain a flat surface. The coil 11 is completed.

In addition to the above method, after the conductor 13 is laid, a substrate film or the like may be attached to the surface on which the conductor 13 is laid. The adhesive sheet may be other than the above as long as the conductor 13 can be wired. For example, a rubber-based pressure-sensitive adhesive layer, a silicon-based pressure-sensitive adhesive layer, an acrylic pressure-sensitive adhesive layer, a UV-curable acrylic pressure-sensitive adhesive layer, etc. are provided on a substrate made of polyester, polyimide, polypropylene, or the like.
It may have flexibility.

Step 2 Next, as shown in FIG.
The planar coil 11 is rolled into a tubular shape and inserted into the housing 15 so that the individual coils overlap. At this time, the length of the outer circumference of the planar coil 11 rolled into a tubular shape is determined by the housing 1
It is preferable that the length is equal to or slightly shorter than the length of the inner circumference of No. 5. That is, when the outer circumference of the planar coil 11 is longer than the inner circumference of the housing 15, both ends of the coil 14 or the adhesive layer 12 overlap each other after the stator coil is formed, and the positional accuracy of the stator coil deteriorates. . The housing used in this embodiment has an inner diameter of 1.8 mm and an inner circumference of 5.65 mm, and the cylindrical coil has a maximum outer diameter of about 1.5 mm and an outer circumference of 5.4 mm.

Step 3 Subsequently, as shown in FIG. 3, the flattening coil 11 which is rolled into a tubular shape can be pushed out from the inside of the flattening coil 11 inserted into the housing 15. 1
Insert 6.

Here, the structure and mechanism of the diameter expanding device 16 will be described. As shown in FIG. 6A, the diameter expansion device 16 is
It is composed of a tube holding device 16A having a circular cross section and a tube portion 16B having a circular cross section. The tube portion 16B is a tube made of a material having rubber elasticity and having an outer diameter of 1.0 mm, and has one end A opened and one end B sealed. The tube holding device 16A is a pipe-shaped member made of a material that is more rigid than the tube portion 16B.
The A end side of B is held inside. The B end side of the tube portion 16B is not held by the holding device 16A, and this portion is inserted inside the planar coil 11 that is rolled into a tubular shape. The length of the portion of the tube portion 16B that is not held by the holding device 16A depends on the dimensions of the planar coil 11 and the housing 15.
Adjust according to the dimensions of.

The diametrical expansion device 16 has a tube portion 1 from the A side.
By injecting a medium such as air or water into the inside of 6B and applying an internal pressure, the tube portion 16B on the B side expands and the diameter thereof is expanded. The tube holding device 16A is mounted so that the tube portion on the B side does not expand when the internal pressure is applied to the tube portion 16B and the tube portion on the B side does not expand. ,
It is not absolutely necessary.

Step 4 Subsequently, the diameter expanding function is activated by applying an internal pressure to the tube portion 16B, and as shown in the cross section in FIG. 4, the planar coil 11 rolled into a tubular shape is expanded and the inner wall surface of the housing 15 is expanded. Press on. While maintaining this state, the planar coil 11 is fixed to the inner wall surface of the housing 15.

As a method of fixing the planar coil 11 to the inner wall surface of the housing 15, in the case of a small motor such as a micromotor, it is appropriate to use the adhesive 17 because of its small size loss and easy operation. Is. For the selection of the adhesive, it is preferable to use a material that has an adhesive ability between the housing 15 and the planar coil 11 and has heat resistance as much as possible in consideration of heat generation when the motor is used. For example, a thermosetting epoxy adhesive is suitable.

The adhesive may be applied to either the inner wall surface of the housing 15 or the outer surface of the planar coil 11,
You may apply to both. Further, when the motor is particularly small, the thickness of the adhesive agent also affects the dimensions, so it is preferable to apply the adhesive as thinly and uniformly as possible.

When the planar coil 11 is fixed with the adhesive, it is necessary to activate the diameter expanding function of the diameter expanding device 16 until the adhesive is cured to some extent. This is because if the diameter-expanding function is terminated in a state where the adhesive is uncured, the positional accuracy of the planar coil 11 with respect to the housing 15 is deteriorated due to the curing shrinkage of the adhesive.

Further, since the thermosetting epoxy adhesive is used in the present embodiment, the diameter expanding device 16 is operated and the flat coil 11 is heated while being pressed against the inner wall surface of the housing 15 to cure the adhesive. Let However, the processing method in this step differs depending on the type of adhesive used.

Step 5 After the planar coil 11 is fixed to the inner wall surface of the housing 15, the internal medium of the tube 16B under internal pressure is leaked to the outside, thereby reducing the outer diameter of the tube 16B and expanding the diameter. 16 is pulled out from the inside of the housing 15. As a result, as shown in FIG.
A cylindrical stator coil made up of the planar coil 11 is formed inside.

(Embodiment 2) This embodiment is another embodiment of the method for forming a motor coil according to the present invention. The method for forming the stator coil of the present embodiment is
The method is the same as that of the first embodiment except that the diameter expanding device is different. That is, in the present embodiment example, the diameter expanding device 18 as shown in FIG. 7 is used as the diameter expanding device.

The diameter expanding device 18 includes an inner diameter of the housing 15,
And has a rod shape having an outer diameter smaller than the inner diameter of the planar coil 11 rolled into a tubular shape, and is made of a material having rubber elasticity. Various materials can be applied to the material of the diameter expanding device 18, and examples thereof include silicone rubber, acrylic rubber, and chloroprene rubber.

When a compressive load is applied in the axial direction, the diameter expanding device 18 shortens in the axial direction, and the outer diameter of the body portion expands. Therefore, it has a function of expanding the outer diameter. Although the length of the diameter expansion device 18 depends on the diameter expansion ratio, it is preferably 1.1 to 1.3 times the length of the inner wall surface of the housing 15. If the diameter-expanding device 18 is too long, the force escapes in a direction other than the axial direction when a compressive load is applied, and if it is too short, the diameter-expanding device 18 is shorter than the length of the inner wall surface of the housing 15 when the compressive load is applied. This makes it difficult to apply a compression load, or it becomes difficult to obtain a predetermined expansion ratio.

The diameter expanding device 18 expands the diameter of the cylindrical flat coil 11 and fixes it to the inner wall surface of the housing 15, and then restores the original thin shape by removing the compressive load. Can be removed from

In the first and second embodiments described above, the diameter expanding device may be other than the above, as long as it has a mechanism for expanding the diameter by some method.

When the cylindrical flat coil 11 is inserted into the housing 15, the flat coil 11 is wound around a rod-shaped body having a diameter smaller than the inner diameter of the housing 15 and inserted into the housing 15 together with the rod-shaped body. Then it is easy to work. Further, if the rod-shaped body has a diameter expanding function, it is easier to work, and in this case, the rod-shaped body functions as the diameter expanding device in the present invention.

[0040]

According to the method for forming a coil for a motor of the present invention, when a cylindrical flat coil is fixed to the inner wall surface of the motor housing, a uniform inner pressure is applied to the entire inner surface of the flat coil. Since it can be pressed against the inner wall surface of the housing and the flat coil can be fixed in that state, the flat coil can be fixed to the inner wall surface of the housing with high positional accuracy. Therefore, according to the present invention, the gap between the stator coil of the small motor and the magnet rotor arranged inside can be kept uniform over the entire circumference of the stator coil, and various performances of the small motor can be improved. It was

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of a plane coil used for forming a motor coil.

FIG. 2 is a perspective view showing a state in which a cylindrical flat coil is inserted into the motor housing.

FIG. 3 is a cross-sectional view showing one step of forming a motor coil.

FIG. 4 is a cross-sectional view showing one step of forming a motor coil.

FIG. 5 is a cross-sectional view showing one step of forming a motor coil.

FIG. 6A is a perspective view showing the diameter expanding device used in the first embodiment, and FIG. 6B is a perspective view showing a state where the diameter expanding function of the diameter expanding device is activated.

FIG. 7 is a perspective view showing a diameter expanding device used in a second embodiment.

[Explanation of symbols]

11 plane coil 12 Adhesive layer 13 conductors 14 coils 14A coil part 14B lead part 15 housing 16 Expanding device 16A tube holding device 16B tube 17 Adhesive 18 Expander

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Junichi Ishizuka             2-6-1, Marunouchi, Chiyoda-ku, Tokyo             Kawa Electric Industry Co., Ltd. (72) Inventor Masaaki Arahori             2-6-1, Marunouchi, Chiyoda-ku, Tokyo             Kawa Electric Industry Co., Ltd. F-term (reference) 5H604 AA08 BB01 BB14 CC01 CC04                       CC12 DB16 QA03                 5H615 AA01 BB01 BB14 PP01 PP17                       RR01 SS18 TT27 TT33

Claims (3)

[Claims] 1. A method for fixing a plane coil to an inner wall surface inside a housing of a motor to form a tubular motor coil by the plane coil, wherein the plane coil rolled into a tubular shape is provided inside the motor housing. While inserting, insert a diameter expansion device having a diameter expansion function to expand the outer diameter into the inside of the planar coil rolled into the tubular shape, by operating the diameter expansion function of the diameter expansion device in this state, A method for forming a coil for a motor, comprising pressing the planar coil rolled into a tubular shape against an inner wall surface inside a housing to fix the coil. 2. The method for forming a motor coil according to claim 1, wherein the diameter expanding device is a tube body having one end sealed of a material having rubber elasticity. 3. The method for forming a motor coil according to claim 1, wherein the diameter expanding device is a rod-shaped body made of a material having rubber elasticity.