JP2005197388A - Coil and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil made of a conductive material and its manufacturing method. <P>SOLUTION: A cylindrical pipe that is made of a conductive material and has a specified thickness is cut spirally at a specified width while it is continuously connected between one end of the pipe and the other end thereof so as to make a pipe coil. Then, the pipe coil is covered with an insulating layer, and an adhesive agent is applied and the pipe coil is pressed from both ends to stuck and adhere the cut parts with each other. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a coil and a manufacturing method thereof.

  Most of the conventional coil wires are made of a conductive wire having a circular cross section (hereinafter referred to as “round wire”). Of course, in the coil using the round wire, since the cross-sectional shape of the round wire is circular, when the coil is manufactured, a gap is generated between the round wire and the round wire, and the space factor is reduced. Has drawbacks. It is also well known that a wire rod having a cross-sectional shape of a rectangle or a square is manufactured in order to eliminate the drawback.

  In any case, the conventional coil manufacturing method and coil structure uses a wire having a predetermined cross-sectional shape such as a circle or a rectangle or a square, and an insulating material made of resin or the like is provided on the surface of the wire. A uniformly coated (covered) insulating layer is provided, and as shown in FIGS. 31 and 32, the wire 26 is wound around a predetermined core (bobbin) 27 or a core with a desired width and number of layers. It will be. Therefore, in order for the wound wire to maintain the coil shape (hereinafter referred to as “winding shape”) along the shape of the object, an adhesive layer is inevitably required outside the insulating layer provided on the wire.

  That is, the coil wire is basically linear, and when the wire is wound around the object, so-called bending deformation occurs in which the wire deforms along the shape of the object up to a certain range. If the winding end is left open while being wound, the wire from the end of the wire tries to return to the original straight state by the springback force, and the desired coil shape cannot be maintained. It is a well-known place to be in a loose state as called.

Accordingly, in order to wind a linear wire around a desired bobbin or the like and maintain the desired winding shape, that is, the desired coil shape, it is necessary to take measures to prevent a broken state when the wire is wound around an object. It is. The measure is a method in which the wire rods are firmly bonded to each other while maintaining the winding shape, and the desired winding shape is maintained. For this purpose, an adhesive is applied to the outside of the insulating layer of the wire rod as described above. An adhesive layer applied at a constant thickness is required.

  As the adhesive, a thermoplastic material and a thermosetting material are frequently used. A thermoplastic material is wound while being heated to a desired temperature by applying hot air to the surface of the wire during winding. In other words, the adhesive layer of the wire is wound in a molten state necessary for adhesion, the adhesive is thermally fused between the wound wires, and the temperature naturally decreases immediately after the winding is finished, so the adhesive is the initial The wire rods exhibiting performance are bonded together in a desired winding shape, and the desired coil is completed while maintaining a solid state.

  When the adhesive layer is thermosetting, the winding is performed while immersing the adhesive layer in a solvent and reactivating the solvent during winding. However, the adhesive strength in the solvent reactivated state is a so-called temporary fixing state that is changed only by applying a small amount of force to the winding end, and does not reach the predetermined strength inherent in the adhesive. . Therefore, the heat treatment is performed from the solvent reactivation state, and the heat treatment can be easily performed by leaving the coil in an oven or the like in a predetermined temperature atmosphere for a predetermined time.

  In general, thermoplastic materials have good production efficiency, but the operating temperature range is low, and thermosetting materials have the opposite characteristics.

  It is well known that the demands on the performance of coils these days are increasing further, and it is also well known that improvement of the conductor space factor in the coils is essential as a measure for improving the performance. As one of the improvement of the space factor, the thickness of the insulating layer and the adhesive layer is required to be reduced, and both layers are reduced to the limit depending on the purpose of use.

  However, although the insulating layer is indispensable for the nature of the coil, it is not a matter of course that it is ideal that the adhesive layer is as thin as possible or absent. It is well known that a coil wire must be wound while applying a predetermined tension (tension) in order to wind the coil wire in a predetermined winding shape accurately, and can withstand the repulsion (spring back) force of the tension and the wire. It is natural that the adhesive strength is required for the adhesive layer.

  However, as the wire becomes thicker, the repulsive force increases and the tension naturally increases, and it is necessary to increase the adhesive force in the adhesive layer corresponding to the repulsive force and the like. In other words, assuming an adhesive with a constant material, the amount of adhesive that is set to the lower limit amount is increased, that is, it must be handled by increasing the thickness, and naturally the conductor space factor decreases. It will be. Therefore, while seeking a high-performance coil, there is a drawback that results in performance degradation.

  An object of the present invention is to provide a wound coil manufacturing method using the above-described conventional coil wire material and a higher performance coil and manufacturing method that can fundamentally solve the drawbacks of the coil structure.

  According to the first aspect of the present invention, a pipe made of a conductive material and having a predetermined thickness is formed in a coil shape in a continuous and connected state from one pipe end to the other end with a predetermined width. Cut and coated with an insulating layer on the pipe thus cut, and then adhesive is applied and then the pipe is pressed from both ends so that the cut parts are brought into close contact with each other and fixed. It is.

  The invention according to claim 2 is a state in which a cylindrical pipe made of a conductive material and having a predetermined thickness is continuously and connected from one pipe end to the other end with a predetermined width. Cut into a spiral shape, cover the pipe cut in this way with an insulating layer, then place an adhesive and then press the pipe from both ends to adhere and fix the cut parts together It is what has.

  The invention described in claim 3 is characterized in that a plurality of the coils are arranged in a multilayer to form a multilayer coil.

  The invention according to claim 4 is characterized in that, when the multilayer coil is configured, the coils of each layer are expanded by heating or contracted by cooling, and then the coils are fitted to each other.

  According to the fifth aspect of the present invention, a pipe made of a conductive material and having a predetermined thickness is coiled in a state of being connected and connected from one pipe end to the other end with a predetermined width. The pipe cut in this way is covered with an insulating layer, and the cut parts are in close contact with each other and fixed with an adhesive.

  The invention according to claim 6 is a state in which a cylindrical pipe made of a conductive material and having a predetermined thickness is continuous and connected from one pipe end to the other end with a predetermined width. The pipe cut in a spiral shape is covered with an insulating layer, and the cut parts are in close contact with each other and fixed by an adhesive.

  The invention according to claim 7 is characterized in that the plurality of coils are multilayer coils arranged in multiple layers.

  The coil of the present invention cuts a pipe in a spiral shape in the case of a cylindrical pipe by cutting the pipe into a coil shape in a continuous and connected state from one end to the other end with a predetermined width. By doing so, the cut pipe itself maintains the coil form, and there is no need to apply a predetermined tension (tension) to the wire as in the case of a coil with a conventional winding, and it is inherent in the coil as in the past. There is no repulsion (springback) force of the wire.

  In the multilayer coil of the present invention, the coil coated with the insulating layer is expanded or compressed by heating or cooling, and is assembled by utilizing the difference in thermal expansion, so that the inner diameter portion and the outer portion of the coil constituting each layer of the multilayer coil are assembled. Since the diameter portion has the size of a close-fitting, it is easy to assemble, and since each layer is constituted by a very strong frictional force, a sufficient strength can be obtained. Further, the conductor space factor in the coil can be improved, and a higher performance coil can be obtained.

  In the present invention, there is no repulsive force inherent in the coil and the coil strength is large, so that the amount of adhesive used is much smaller than that of the conventional coil.

  In a method using a conductive wire and a winding core as in a conventional coil, the smaller the inner diameter of the coil, the more difficult it is to manufacture even one layer. On the other hand, according to the present invention, since it is not necessary to wind a conductive wire around a coil by using a pipe, it can be reliably and easily manufactured even with a small-diameter coil, and a coil application product, for example, small and powerful. This has a great effect that it can be applied to solenoid devices.

  As shown in FIGS. 31 and 32, in a coil manufacturing method by winding a conductive wire around a winding core like a conventional coil, the width of the conductive wire 26 to be wound in the same direction as the axis 28 of the rotation axis of the winding core 27 Where t is w and the width in the direction perpendicular to the axis 28 is w, so-called winding of the conductive wire 26 having a cross section of t <w, which has been very difficult until now, is performed. Vertically wound coils can also be formed with freely t and w dimensions.

  Next, embodiments of the present invention will be described with reference to the drawings.

  1 to 30 are drawings according to an embodiment of the present invention, FIG. 1 is a perspective view showing a coil (one layer) of the present invention, FIG. 2 is a sectional view of a single layer coil, and FIG. 2 is a partially enlarged view of FIG. 2, FIG. 4 is a cross-sectional view of a multilayer coil, FIG. 5 is a perspective view of a pipe used in the present invention, FIG. 6 is an explanatory view showing cutting of the pipe, and FIG. 8 to 12 are cross-sectional views showing a pipe machining coil having an inner diameter of 20 to 28φ, and FIGS. 13 to 17 are an insulating layer coil having an inner diameter of 20 to 28φ and an outer jig for inserting the insulating layer coil. 18 to 22 are sectional views showing a state in which an insulating layer coil having an inner diameter of 20 to 28φ is inserted into an outer jig and a heating state in an oven, and FIG. 23 is an inner diameter of the first layer. FIG. 24 is a perspective view showing the removal of the outer jig from the insulating layer coil of 20φ, FIG. 25 is a perspective view showing the removal of the multilayer coil from the inner jig, FIGS. 26 to 28 are explanatory views showing the attachment of the multilayer coil and the substrate, FIG. 29, FIG. 30 is a perspective view showing a coil on which a substrate is mounted. 2 to 4, only the cross-sectional portion is shown and the other portions are omitted.

  1-3, the one-layer coil 1b of the present invention has a predetermined shape from the end of one pipe to the other end of the aluminum cylindrical pipe 1 shown in FIG. A pipe machining coil (hereinafter referred to as “pipe coil”) 1a (FIG. 8) is cut in a spiral shape in a continuous and connected state with a dimensional width, and an insulating layer is formed on the pipe coil 1a as shown in FIG. 8 (FIGS. 2 and 3), and the adhesive layer 9 (FIG. 2) is applied to the pipe coil 1b (hereinafter referred to as “insulating layer coil”) in which the insulating layer 8 is formed in this way. 2 and FIG. 3), the coil is pressed from the outside to the inside to bring the cut parts of the coil into close contact with each other (hereinafter, the cut part of the pipe is referred to as “conductive wire part”) and the adhesive layer (adhesion) Agent) 9 to fix the conductive wire part. There. 2 and 3, the thicknesses of the insulating layer 8 and the adhesive layer 9 do not indicate actual thicknesses.

  The pipe used in the present invention is not limited to a cylindrical shape having a circular cross section as shown in FIG. 5, and a square pipe having a triangular or other polygonal cross section may be used. For example, a square pipe having a triangular cross-sectional shape can be cut in a continuous and connected state from one pipe end to the other end to form a triangular cross-sectional coil.

  The coil of the present invention can freely change the thickness (cross-sectional area) of the conductive wire portion by changing the thickness of the pipe or changing the cutting width of the pipe.

Further, by using a cutting means such as a CO ₂ laser for cutting the pipe, the cutting width of the coil can be freely changed at a desired position in the axial direction of the pipe. For example, it is possible to easily form a coil shape in which the conductive wire portions at both ends of the coil are thicker than the center portion.

  As shown in FIGS. 4 and 25, the multilayer coil according to the present invention includes the above-mentioned one-layer insulating layer coil 1b (FIGS. 1 to 3) and an insulating layer coil whose inner diameter is larger by a predetermined dimension than the insulating layer coil 1b. 2b to 5b (FIGS. 13 to 17), and the multilayer coil 6 (insulating layer coils 1b to 5b) is formed by overlapping the insulating layer coils 1b to 5b.

  In the present embodiment, the multilayer coil 6 has five layers (FIGS. 4 and 25), but the number of layers can be freely increased or decreased. Furthermore, it is possible to change the thickness of the conductive wire of each multilayer coil by changing the thickness and cutting width of the pipe, and to change the cutting width of the coil at a desired position in the axial direction of the pipe. A desired multilayer coil can be freely manufactured according to the purpose by combining the above.

  Next, the manufacturing method of the coil of this invention is demonstrated. In addition, the dimension of the member shown in this Embodiment is an example, and it cannot be overemphasized that this invention is not restricted to this dimension.

  First, the production of a single layer coil will be described.

  As shown in FIG. 5, a cylindrical aluminum pipe 1 having an inner diameter of 20 mm, a thickness (wall thickness) of 1 mm, and a total length of 51.2 mm is manufactured.

Next, as shown in FIG. 6, a CO ₂ laser 29 is used, the CO ₂ laser 29 is fixed, and the pipe 1 is rotated at a predetermined speed and moved in one direction while one end of the pipe 1 is moved. From the first part to the other end part, it is continuously cut in a spiral shape (helical shape) with a width of 1 mm and a cutting margin of 0.2 mm, an inner diameter of 20 mm, and a coil conductor (conductive wire part) thickness of 1 mm square A pipe coil (referred to as “20 coils”) 1 a having a square cross-sectional shape of 1 mm on one side is manufactured.

For cutting the pipe, a method of cutting an aluminum pipe using a CO ₂ laser is used, but other methods, for example, cutting with a water jet may be used. Moreover, it is not awaited that a method with a small cutting allowance is preferable, and if a smaller method is proposed, the method can be used. In short, there is no need to stick to the cutting method as long as it is a more efficient and highly accurate cutting method.

  Next, as shown in FIG. 7, the pipe coil 1 a is immersed in an electrodeposition liquid (resin) 31 in the electrodeposition tank 30, and the conductor surface of the pipe coil 1 a is formed on the conductor surface of the pipe coil 1 a to a thickness of about An insulating layer coil 1b is manufactured by covering a 10 μm insulating film. In FIG. 7, description of other equipment for electrodeposition is omitted. Further, when the conductor is aluminum, alumite may be used as the insulating layer.

  Next, although not shown in the drawing, the insulating layer coil 1b is immersed in an adhesive tank containing an adhesive to cover the adhesive layer, and then the coil is pressed from the outside to the inside to adhere the conductive wire portion (conductor portion). It sticks in the state of being let. Thus, an insulating layer coil is obtained. The method for forming the adhesive layer is not limited to the above method.

  Next, production of the multilayer coil will be described.

  As shown in FIG. 5, a cylindrical aluminum pipe 1 having an inner diameter of 20 mm, a thickness (wall thickness) of 1 mm, and an overall length of 51.2 mm is manufactured, and the inner diameters are 22 mm, 24 mm, 26 mm, and 28 mm, respectively. A cylindrical aluminum pipe having the same thickness and the same length as the pipe 1 (thickness is 1 mm and the total length is 51.2 mm) is manufactured.

  Next, as shown in FIG. 6, each pipe is continuously cut in a spiral shape (helical shape) from one end to the other end with a width of 1 mm and a cutting margin of 0.2 mm. The inner diameter is 20 mm (hereinafter referred to as “20 coils”), the inner diameter is 22 mm (hereinafter referred to as “22 coils”), the inner diameter is 24 mm (hereinafter referred to as “24 coils”), and the inner diameter is 26 mm (hereinafter referred to as “26 coils”). The pipe machining coils 1a to 5a having an inner diameter of 28 mm (hereinafter referred to as “28 coils”) are manufactured.

  Next, each of the pipe coils 1a to 5a (20 to 28 coils) is coated with an insulating film having a thickness of about 10 μm on the conductor surface of each pipe coil by the cationic electrodeposition method shown in FIG. (Insulating layer coils) 1b to 5b are manufactured.

  Subsequently, the insulating layer coils 1b to 5b are overlapped to form a five-layer multilayer coil 6 having an inner diameter (diameter) of 20 mm, a total length of 50 mm, and a coil conductor (conductive wire portion) having a thickness of 1 mm square. Below, the process of assembling the multilayer coil 6 of 5 layers from the insulating layer coils 1b-5b is demonstrated.

  As shown in FIGS. 13 to 22, first, each of the insulating layer coils 1b to 5b is inserted into each of the outer jigs 10 to 14 for assembly (hereinafter, the insulating layer coils inserted into the outer jig are referred to as “outer jig”. Insulated layer coil with). After the insertion, each of the insulating layer coils with the outer jig is put into an oven (not shown) set to a predetermined temperature and held as it is for a predetermined time. The outer jigs 10 to 14 are made of iron, and the inner diameters (diameters) of the respective outer jigs 10 to 14 are sliding fit dimensions (F6 to G6) with respect to the outer diameters (diameters) of the respective insulating layer coils 1b to 5b. ) Is processed.

  Therefore, if the coils 1b to 5b with the outer jigs 10 to 14 are held in the oven as described above, due to the difference in thermal expansion between the outer jigs 10 to 14 made of iron and the insulating layer coils 1b to 5b made of aluminum. The outer peripheral portions of the respective insulating layer coils 1b to 5b are in close contact with the inner peripheral portions of the respective outer jigs 10 to 14. At the time of close contact, first, the insulating layer coil 1b with the outer jig 10 having the smallest inner diameter is taken out of the oven and immediately inserted into the inner jig 15 as shown in FIG. The inner jig 15 is cooled to a room temperature or lower. The inner jig 15 is also made of iron, and the outer diameter (diameter) of the inner jig 15 is a sliding fit dimension (F6 to G6) with respect to the inner diameter (diameter) of the insulating layer coil 1b (inner diameter φ20) at room temperature (about 20 ° C.). ) Is processed.

  As described above, the inner diameter dimension of the insulating layer coil 1b with the outer jig 10 which is heated and expanded by the oven is larger than that at room temperature, and the inner jig 15 is cooled to below room temperature. The outer diameter of the inner jig 15 is smaller than that at room temperature, and the clearance is much larger than the inner diameter of the mutual insulating layer coil 1b and the sliding fit dimensions (F6 to G6) set to the outer diameter of the inner jig 15. A dimension is generated, and the outer diameter portion of the inner jig 15 is easily inserted into the inner diameter of the insulating layer coil 1b with the outer jig 10.

  Further, immediately after the insertion into the inner jig 15, the inner diameter portion of the insulating layer coil 1b with the outer jig 10 is rapidly cooled from the outer diameter portion of the inner jig 15, so that the insulating layer coil 1b naturally contracts. The inner diameter portion of the insulating layer coil 1 b is in close contact with the outer diameter portion of the inner jig 15. Since the material of the insulating layer coil 1b is aluminum as described above, the thermal conductivity is very good and the reaction is fast. Accordingly, a sufficient clearance is generated between the outer diameter portion of the insulating layer coil 1b and the inner diameter portion of the outer jig 10, so that the outer jig 10 can be easily detached from the insulating layer coil 1b as shown in FIG. Can be extracted.

  Further, the insulating layer coil 2b (inner diameter φ22) with the outer jig 11 held in the oven for a predetermined time is taken out, and the inner diameter portion of the insulating layer coil 2b is inserted into the outer diameter portion of the insulating layer coil 1b. As a matter of course, since the insulating layer coil 1b is cooled, and further, the insulating layer coil 2b is heated, a clearance with a margin for insertion is generated as described above, and the insulating layer coil 1b can be easily formed. The inner diameter portion of the insulating layer coil 2b can be inserted into the outer diameter. Similarly to the above, after insertion, the insulating layer coil 2b is cooled more than the outer diameter portion of the insulating layer coil 1b.

  The inner diameter (diameter) dimension of the insulating layer coil 2b is set to the same dimension as the outer diameter (diameter) dimension of the insulating layer coil 1b. Therefore, when the insulating layer coil 2b is cooled and reaches the same temperature as the insulating layer coil 1b, the inner diameter portion of the insulating layer coil 2b and the outer diameter portion of the insulating layer coil 1b are brought into close contact with each other, and the clearance is zero, so-called A close-fit state is generated, and a sufficient clearance is generated between the outer diameter portion of the insulating layer coil 2b and the inner diameter portion of the outer jig 11 so as to be detachable.

  Of course, the insulation layer coil 2b has a slip fit clearance even at room temperature, but immediately after insertion into the insulation layer coil 1b (the insulation layer coil 1b inserted in the inner jig 15), the outer jig 11 Since it is made of iron, the thermal conductivity of the outer jig 11 is naturally lower than that of the insulating layer coil 2b made of aluminum. Therefore, the contraction speed due to cooling is slower than that of the insulating layer coil 2b, and a sufficient clearance is generated to make it detachable as described above. Therefore, the outer jig 11 can be easily extracted from the insulating layer coil 2b.

  Further, when the insulating layer coils 3b to 5b (inner diameters φ24, φ26, and φ28) with the outer jigs 12 to 14 are sequentially taken out from the oven and the same process is repeated, the multilayer coil 6 (insulating layer) is obtained as shown in FIG. The outer jig 14 is extracted from the coils 1b to 5b), and the insulating layer coils 1b to 5b are attached to the inner jig 15 as shown in FIG. Furthermore, when the inner jig 15 is installed in a room temperature environment, a predetermined clearance (sliding fit dimension) is generated between the inner diameter portion of the insulating layer coil 1b and the outer diameter portion of the inner jig 15, so that it is shown in FIG. As described above, the five-layered insulating layer coils 1b to 5b are extracted from the inner jig 15, and thus the five-layered multilayer coil 6 is obtained.

  The multilayer coil 6 obtained as described above is incomplete as a coil, and the process of completing the coil of the present invention as a coil will be described below.

  About 0.1 mm of grinding | polishing process is given with respect to the both ends of the multilayer coil 6 (insulating layer coil 1b-5b) (FIG. 4) manufactured by the above. By this polishing process, conductive portions (background, that is, aluminum) and insulating layers appear concentrically at intervals of 1 mm. In the present embodiment, a rust inhibitor is applied to the exposed portion to temporarily prevent surface oxidation of the exposed aluminum portion that is a conductive material. Further, the exposed portion of the aluminum may be subjected to oxidation treatment such as plating.

  When the exposed portion is connected and wired, the coil is completed. In the present embodiment, the print pattern wiring that we have already proposed is used as the connection wiring method. Hereinafter, the process will be described.

  First, using what is commonly called a glass-epoxy substrate, which is commonly used by the general public and is laminated with a copper foil of a predetermined thickness on a 1.6 mm thick glass fiber epoxy substrate, as shown in FIGS. A printed pattern having a proper shape was produced. As a matter of course, two types of printed boards (A board and B board) are prepared for the printed board for wiring.

  As shown in FIGS. 26 to 28 showing the conductive patterns of the A substrate and the B substrate, the A substrate 16 is provided with a copper foil 18 having a predetermined thickness as a conductive material on both surfaces of the substrate due to the coil input part. As shown in FIG. 26B, the insulating layer coil 1b (φ20) is formed so that the side (the “inside” of the A substrate) that contacts the exposed aluminum portion at one end of the multilayer coil 6 is concentrically formed. ) 18a, insulating layer coils 2b and 3b (φ22, φ24) 18b, and insulating layer coils 4b and 5b (φ26, φ28) 18c. Furthermore, the inner wall portion of the inner diameter of the circular hole 17 provided in the center of the substrate is attached with copper of a predetermined thickness by copper plating, and the opposite side (“outside of the substrate A” shown in FIG. ]), Which is connected to the copper foil 18 and is generally called a through hole. In addition, a hole 19 for mounting the input lead wire 20 of the insulating layer coil 1b is provided at a predetermined position on the lower side of the A substrate 16 shown in FIGS. 26 (a) and 26 (b).

  On the other hand, the B substrate 21 having the circular hole 22 in the center of the substrate is one in which a copper foil 23 having a predetermined thickness as a conductive material is provided on one surface of the substrate, as shown in FIG. The concentric circles 23a for the insulating layer coil 5b (φ28), the insulating layer coils 4b, 3b (φ26), which are substantially similar to the A substrate 16 so as to connect and wire from the innermost outermost layer of the B substrate 21 to the inner layer sequentially , Φ24) 23b and insulating layer coils 2b, 1b (φ22, φ20) 23c. In addition, a hole 24 for mounting the input lead wire 25 of the insulating layer coil 5b (φ28) is provided at a predetermined position on the B substrate 21 shown in FIGS. 28 (a) and 28 (b).

  The A substrate 16 and the B substrate 21 are attached to both ends of the multilayer coil 6. In this embodiment, cream solder is applied to the inner concentric patterns of the A substrate 16 and the B substrate 21 by a silk screen method. The rust preventive agent applied to the exposed portion of the copper wire is wiped off with a cloth containing a solvent, and as shown in FIGS. 29 and 30, the exposed portion of the copper wire at the end of the multilayer coil 6 (insulating layer coils 1b to 5b). And the inside of the A board | substrate 16 and the B board | substrate 21 was contacted, and it was made to press. Although not shown in the drawings, in the substrate mounting process, positioning is performed using an assembly jig so that the pattern of each substrate and the exposed portion of the copper wire at the coil end are appropriately arranged. ing.

  If it is kept in a pressed state, that is, with the assembly jig mounted, for a predetermined time in an oven at a predetermined temperature, the cream solder is melted, and the respective substrate pattern and aluminum exposed portion are connected and wired. When the assembly jig is removed after taking out from the oven and cooling, the solder is cured and the printed circuit board is fixed to the coil.

  Next, the leading ends of the input lead wires 20 and 25 are inserted into the input holes 19 and 24 provided in the A board 16 and the B board 21 and soldered to complete the coil 7. In the case of the present embodiment, the example in which the input lead wire is connected to the board by soldering is shown. However, even if the input terminal is mounted on the board, it is possible to design it freely according to the purpose. be able to.

  In the case of the present embodiment, an example in which an epoxy substrate containing glass fiber is used for the connection wiring of the copper wire exposed portion at the coil end as described above, but depending on the purpose, a copper pattern is applied to the polyimide film or the like. A commonly called film substrate may be used, or direct connection wiring may be performed directly using a jumper wire or the like.

  Furthermore, in the case of the present embodiment, aluminum is used as the material of the conductor (pipe). However, as a matter of course, copper (Cu) or other conductive materials can be used for any purpose. It is possible to use them properly. In particular, when copper is used as the conductor, it can be easily implemented by using an Fe alloy containing a small coefficient of thermal expansion, for example, W (tungsten), for the outer jig and the inner jig.

  Further, in the present embodiment, an example in which a pipe made of a conductor is cut to a required length and then a spiral cut, an insulating layer coating, etc. is performed is shown. Even if it uses the method of cut | disconnecting the insulation layer coil to required length after that, it carries out spiral cutting, insulation layer coating | covering, etc. to the pipe which has first to make an insulation layer coil, and it can implement similarly. .

It is a perspective view which shows the coil of 1 layer which concerns on embodiment of this invention. It is sectional drawing of the coil which concerns on embodiment of this invention. FIG. 3 is a partially enlarged view of FIG. 2 according to the embodiment of the present invention. It is sectional drawing which shows the multilayer coil which concerns on embodiment of this invention. It is a perspective view which shows the pipe used for this invention which concerns on embodiment of this invention. It is explanatory drawing which shows the cutting | disconnection of the pipe which concerns on embodiment of this invention. It is explanatory drawing which shows the coating | cover of the insulating layer which concerns on embodiment of this invention. It is sectional drawing which shows the pipe coil whose internal-diameter dimension 20phi cut | disconnected continuously helically which concerns on embodiment of this invention. It is sectional drawing which shows the pipe coil whose internal-diameter dimension which cut | disconnected helically and which concerns on embodiment of this invention is 22 (phi). It is sectional drawing which shows the pipe coil whose internal-diameter dimension which cut | disconnected continuously helically which concerns on embodiment of this invention is 24 (phi). It is sectional drawing which shows the pipe coil whose internal-diameter dimension which cut | disconnected spirally and which concerns on embodiment of this invention is 26 (phi). It is sectional drawing which shows the pipe coil whose internal-diameter dimension which cut | disconnected helically and which concerns on embodiment of this invention is 28 (phi). It is a perspective view which shows the outer jig | tool which inserts the insulation layer coil which has an internal diameter dimension of 20 (phi) based on embodiment of this invention, and an insulation layer coil. It is a perspective view which shows the outer jig | tool which inserts the insulation layer coil which has an internal diameter dimension of 22 (phi) based on embodiment of this invention, and an insulation layer coil. It is a perspective view which shows the outer jig | tool which inserts the insulating layer coil which has an internal diameter dimension of 24 (phi) based on embodiment of this invention, and an insulating layer coil. It is a perspective view which shows the outer jig | tool which inserts the insulation layer coil which has an internal diameter dimension of 26 (phi) based on embodiment of this invention, and an insulation layer coil. It is a perspective view which shows the outer jig | tool which inserts the insulating layer coil which has an internal-diameter dimension of 28 (phi) concerning embodiment of this invention, and an insulating layer coil. It is sectional drawing which shows the state which inserted the insulation layer coil whose internal-diameter dimension which concerns on embodiment of this invention to 20 (phi) in the outer jig, and the heating state in oven. It is sectional drawing which shows the state which inserted the insulation layer coil whose internal-diameter dimension which concerns on embodiment of this invention to 22 (phi) in the outer jig, and the heating state in oven. It is sectional drawing which shows the state which inserted the insulation layer coil whose internal-diameter dimension which concerns on embodiment of this invention to 24 (phi) in the outer jig, and the heating state in oven. It is sectional drawing which shows the state which inserted the insulating layer coil whose internal-diameter dimension which concerns on embodiment of this invention is 26 (phi) in the outer jig, and the heating state in oven. It is sectional drawing which shows the state which inserted the insulating-layer coil whose internal-diameter dimension which concerns on embodiment of this invention is 28 (phi) in the outer jig, and the heating state in oven. It is a perspective view which shows the removal of the outer jig | tool from the insulating layer coil whose inner-diameter dimension of the 1st layer which concerns on embodiment of this invention is 20phi. It is a perspective view which shows the removal of the outer jig from the multilayer coil which concerns on embodiment of this invention. It is a perspective view which shows taking out of the multilayer coil from the internal jig which concerns on embodiment of this invention. (A) of the A board | substrate of the printed pattern board | substrate which concerns on embodiment of this invention is a front view which shows an outer side, (b) is a rear view which shows an inner side. It is sectional drawing which shows the multilayer coil which concerns on embodiment of this invention, A board | substrate, and B board | substrate. (A) of the B board | substrate of the printed pattern board | substrate which concerns on embodiment of this invention is a front view which shows an inner side, (b) is a rear view which shows the outer side. It is a disassembled perspective view which shows the coil which mounted | wore the board | substrate which concerns on embodiment of this invention. It is a perspective view which shows the coil which mounted | wore the board | substrate which concerns on embodiment of this invention. It is a perspective view which shows the manufacturing method of the coil by the winding of a conventional system. It is a perspective view which shows the manufacturing method of the coil by the winding of a conventional system.

Explanation of symbols

1 Pipe 1a-5a Pipe coil (pipe processing coil)
1b-5b Insulation layer coil (pipe coil with insulation layer)
6 Multi-layer coil (insulating layer coils 1b to 5b)
7 Board mounting coil 8 Insulating layer 9 Adhesive layer 10-14 Outer jig 15 Inner jig 16 A board 17 Hole 18, 18a-c Copper foil 19 Input lead wire mounting hole 20 Input lead wire 21 B board 22 Holes 23, 23a ~c foil 24 input hole 25 input lead 26 conductive wire 27 wound core 28 axis 29 CO ₂ laser 30 for lead wire attached electrodeposition tank 31 electrodepositing solution

Claims (7)

  A pipe made of a conductive material and having a predetermined thickness was cut into a coil shape in a continuous and connected state from one pipe end to the other end at a predetermined dimension width, and thus cut. A method of manufacturing a coil, wherein an insulating layer is coated on the pipe, and then an adhesive is provided, and then the pipe is pressed from both ends so that the cut portions are brought into close contact with each other and fixed.   A cylindrical pipe made of a conductive material and having a predetermined thickness is cut into a spiral shape in a continuous and connected state from one pipe end to the other end with a predetermined width. A method of manufacturing a coil, comprising: coating an insulating layer on the pipe cut into pieces, then placing an adhesive and then pressing the pipe from both ends to bring the cut portions into close contact with each other.   The coil manufacturing method according to claim 1, wherein a plurality of the coils are arranged in a multilayer to form a multilayer coil.   The coil manufacturing method according to claim 3, wherein, in forming the multilayer coil, the coils of each layer are expanded by heating or contracted by cooling, and then the coils are fitted together.   A pipe made of a conductive material and having a predetermined thickness is cut into a coil shape in a continuous and connected state from one pipe end to the other end with a predetermined width. The coil is characterized in that the pipe is covered with an insulating layer, and the cut parts are in close contact with each other and fixed with an adhesive.   A cylindrical pipe made of a conductive material and having a predetermined thickness is cut in a spiral shape in a continuous and connected state from one pipe end to the other end with a predetermined width. An insulating layer is coated on the pipe cut into pieces, and the cut parts are in close contact with each other and fixed with an adhesive.   The coil according to claim 5 or 6, wherein the plurality of coils are multilayer coils arranged in multiple layers.

Images