JP2008072801A - Coil device, stator, and motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil device which can be enhanced in the space factor of a coil. <P>SOLUTION: In the coil device 10 having a core 11 formed by laminating a large number of thin core materials 12, an insulator 20 formed of an insulating material into a coil bobbin shape for covering the core 11 and the wiring materials 30 of a quadrangle cross section wound around the bobbin part 21 of the insulator 20, escape grooves 25, 25 are annually formed at the opposite end sides of the bobbin part 21 of the insulator 20. The escape groove 25 formed in the barrel part 22 of the bobbin part 21 prevents the corner of the coil wiring material 30 of a quadrangle cross section from running on the rounded part of the barrel part, securing a proper aligning property to enhance the space factor of the coil, even when the coil wiring material 30 of a quadrangle cross section is wound around the bobbin part 21. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a coil device, and more particularly to improvement of an insulator (coil bobbin), for example, to an effective one used for a stator (stator) used in a brushless motor or the like.

  A brushless motor having a stator in which a plurality of coil devices are combined may be used for an automobile electric motor, a servo motor, or the like.

As a coil device used for the stator of such a brushless motor, there is provided a core (iron core) formed in a rod shape and an insulator (coil bobbin) around which the coil wire is wound. There is.
The insulator is formed in a bobbin (pincushion) shape using an insulating resin.

In such a coil device, it can be proposed to increase the coil space factor by using a coil wire having a square cross section.
However, since the corner of the bobbin portion of the insulator is rounded (so-called R chamfering) determined by the mold, when the coil wire having a square cross section is wound on the insulator, the corner of the square quadrilateral runs over the roundness. There is a problem that the alignment of the windings of the coil wire is deteriorated and the space factor cannot be increased.

  An object of the present invention is to provide a coil device, a stator, and a motor that can increase the coil space factor.

Typical means for solving the above-described problems are as follows.
(1) A core formed of a magnetic material and an insulator covered with the core and wound with a coil wire around the bobbin portion, and a relief portion is formed at a corner of the bobbin portion of the insulator. A coil device characterized by comprising:
(2) A stator in which a plurality of the coil devices of (1) are arranged in a circular ring shape.
(3) A motor in which a rotor (armature) is arranged on the center line of the stator of (2).

  According to said (1), even if it is a case where a coil wire with a square cross section is wound on a bobbin part, the alignment of the coil wire of a coil wire is maintained by escaping the corner | angular part of a cross-sectional square with a relief part. Can increase the space factor.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

In the present embodiment, as shown in FIG. 1, the coil device 10 according to the present invention is wound on the core 11 formed of a magnetic material, the insulator 20 covered on the core 11, and the insulator 20. The coil wire rod 30 is provided.
The coil wire rod 30 is made of a conductor such as copper and is formed in a square shape with a square cross section. Although not shown, the surface of the coil wire 30 is covered with an insulating film such as enamel.

As shown in FIG. 2, the core 11 is formed by laminating a large number of core materials 12. The core material 12 is made of a magnetic material and is formed into a generally H-shaped thin plate. Therefore, the core 11 is formed in a substantially H-shaped steel shape.
One parallel part of the H-shaped steel of the core 11 constitutes a base part 13, and the other parallel part constitutes a head part 14. The surface of the base portion 13 opposite to the head portion 14 is formed as an arc surface that protrudes outward, and the surface of the head portion 14 opposite to the base portion 13 is formed as an arc surface recessed inward. The arc of the base 13 and the arc of the head 14 are set to be concentric circles.
A portion connecting the base portion 13 and the head portion 14 of the core 11 constitutes a magnetic pole portion 15. The magnetic pole part 15 has a rectangular parallelepiped shape.

The insulator 20 is molded into a bobbin (pincushion) shape using an insulating resin, and the bobbin portion 21 of the insulator 20 covers the magnetic pole portion 15 on the core 11 as shown in FIG. It is put on.
The bobbin portion 21 includes a body portion 22 where the coil wire 30 is wound, and a base side flange portion 23 and a head side flange portion 24 formed at both ends of the body portion 22. The body portion 22 is formed in a rectangular cylinder shape that covers the magnetic pole portion 15 of the core 11. The base side flange 23 is formed in a rectangular frame plate shape that covers the inner plane of the base 13 of the core 11. The head side collar 24 is formed in a rectangular frame plate shape that covers the outer plane of the head 14 of the core 11.

  Relief grooves 25 and 25 as relief portions are formed annularly at the corners of the bobbin portion 21, that is, at both ends of the body portion 22, respectively. The groove widths of both escape grooves 25, 25 are set smaller than the outer diameter of the coil wire 30.

As shown in FIG. 2, the insulator 20 is composed of a pair of divided bodies 26, 26 at the top and bottom, and both the divided bodies 26, 26 are molded by injection molding using an insulating resin. Yes. Both the divided bodies 26 and 26 are formed in a shape that is substantially vertically symmetrical with each other by dividing the insulator 20 into two in the thickness direction.
By fitting both the divided bodies 26 and 26 to the core 11 from above and below and aligning them in the middle, the core 20 having the base portion 13 and the head portion 14 on both sides can be covered with the insulator 20.
End face portions 27 and 27 are respectively provided at the upper end and the lower end of the base side flange portion 23 of both divided bodies 26 and 26 so as to project at right angles in the outer direction.
A pair of terminal pieces 28 and 28 are implanted in one end surface portion 27. As shown in FIG. 1, a winding start end 31 and a winding end end 32 of a coil wire 30 are connected to both terminal pieces 28, 28, respectively.

  Next, the manufacturing method of the coil apparatus 10 is demonstrated.

When a plurality of core materials 12 are laminated, the core 11 is assembled.
Next, one divided body 26 is mounted on the upper side of the core 11, and the other divided body 26 is mounted on the lower side of the core 11.
As a result, the upper side of the core 11 is covered with the one divided body 26 and the lower side of the core 11 is covered with the other divided body 26, and the core members 12 are Therefore, the core 11 is integrated.

Next, the coil wire rod 30 having a square cross section is wound around the bobbin portion 21 of the insulator 20 with a specified number of turns, and the coil is wound around the magnetic pole portion 15 of the core 11.
When the coil wire 30 is wound around the bobbin portion 21, the core material 12 is tightly bound between the upper and lower divided bodies 26 and 26 by the winding force of the coil wire 30. It becomes a state.

By the way, as shown in FIG. 3A, it is common that the corner of the bobbin portion 21 of the molded insulator is rounded.
Since the radius of the round 29 is about 0.2 mm, as shown in FIG. 3A, alignment is ensured when the coil wire 30 ′ having a circular cross section is wound on the bobbin portion. As a result, the space factor of the coil wire 30 'does not decrease.
That is, since the radius of the coil wire 30 ′ having a circular cross section is much larger than 0.2 mm, the roundness 29 having a radius of 0.2 mm can be sufficiently absorbed.

However, when the coil wire 30 having a quadrilateral cross section is wound on the bobbin portion, the corner (edge) of the cross section quadrilateral of the coil wire 30 runs on the round 29 as shown in FIG. Since it is in a tilted state, the alignment becomes worse and eventually the space factor is lowered.
That is, as the coil wire 30 wound on the coil wire 30 in a tilted state further tilts, the alignment property deteriorates synergistically.
In addition, although the corner (edge) of the coil wire rod 30 having a square cross section is not a perfect right angle (sharp right angle), the radius of the round is 0.03 mm or less, so it rides on the round 29 of about 0.2 mm It becomes a state.

However, in the present embodiment, as shown in FIG. 3C, the rounding 29 is removed by forming the relief groove 25 in the body portion 22 of the bobbin portion 21. In the case where the rectangular coil wire 30 is wound on the bobbin portion 21, the phenomenon that the corners (edges) of the cross-sectional rectangle of the coil wire 30 run round cannot necessarily occur.
Therefore, the coil wire 30 having a quadrangular cross section does not lean on the roundness, but the coil wire 30 wound on the coil wire 30 in the tilted state further tilts, and the alignment property deteriorates synergistically. Nor.
As a result, even when the coil wire 30 having a rectangular cross section is wound on the bobbin portion 21, the proper alignment can be ensured, so that the space factor can be increased.

FIG. 4 is a plan view showing a stator according to an embodiment of the present invention.
The stator 40 according to the present embodiment is constructed by arranging 12 coil devices 10 according to the above configuration in a circular ring shape.
Adjacent coil devices 10 and 10 may be combined and integrated with each other by welding or the like, but a cylindrical yoke is fitted and fixed to the outer periphery of a group of 12 coil devices 10 arranged in a circular ring shape. May be.

  According to the stator 40 according to the present embodiment, since the space factor of the coil wire 30 in each coil device 10 is high, a large field force can be obtained.

FIG. 5 is a plan view showing a brushless motor according to an embodiment of the present invention.
The brushless motor 50 according to the present embodiment includes a stator 40 constructed by arranging twelve coil devices 10 according to the above configuration in a circular ring shape, and a plurality of stator devices 40 are arranged on the center line of the stator 40. A rotor (armature) 51 having a magnet (permanent magnet) 52 is arranged and constructed.

  According to the brushless motor 50 according to the present embodiment, since the space factor of the coil wire 30 in each coil device 10 is high, a large field force can be obtained in the stator 40, and thus a large rotational torque in the rotor 51. Can be obtained.

  Needless to say, the present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the scope of the invention.

  For example, the relief portion is not limited to the annular groove 25 formed on the end side of the body portion of the bobbin portion, but is formed on the side surface of the end portion of the body portion 22 as shown in FIG. You may comprise by the vertical groove 25A made.

  Further, as shown in FIG. 6B, it may be constituted by a longitudinal groove 25 </ b> B formed at the boundary with the end side of the body portion 22 of the flange portion 23 (24) of the bobbin portion 21.

Furthermore, the relief portion is not limited to being disposed at both ends of the bobbin portion, but may be disposed at one end.
The relief portion may be formed such that the corner 29 of the bobbin portion 21 is not rounded 29 and the relief groove is not disposed.

The coil apparatus which is one embodiment of this invention is shown, (a) is a top view, (b) is front sectional drawing in alignment with the bb line of (a), (c) is c of (a). It is side surface sectional drawing which follows the -c line. It is a disassembled perspective view which shows the principal part. It is each fragmentary sectional view explaining alignment, (a) shows the case where a coil wire with a circular section is wound on a bobbin part with roundness, (b) shows a coil wire with a square cross section on a bobbin part with roundness. A case of winding is shown, and (c) shows a case of winding a coil wire having a square cross section on a bobbin portion having a relief groove. It is a top view which shows the stator which is one embodiment of this invention. It is a top view which shows the brushless motor which is one embodiment of this invention. (A) is a fragmentary sectional view which shows the 1st modification of the escape groove of the coil apparatus which concerns on embodiment of this invention, (b) is the 2nd of the escape groove of the coil apparatus which concerns on embodiment of this invention. It is a fragmentary sectional view showing a modification.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Coil apparatus, 11 ... Core, 12 ... Core material, 13 ... Base part, 14 ... Head part, 15 ... Magnetic pole part, 20 ... Insulator, 21 ... Bobbin part, 22 ... Trunk part, 23 ... Base side collar part, 24 ... head side flange, 25 ... annular groove (relief part), 25A ... vertical groove (relief part) on the side of the torso, 25B ... longitudinal groove (relief part) on the buttocks, 26 ... divided body, 27 ... end face part 28 ... terminal piece, 29 ... roundness, 30 ... coil wire with a square cross section, 30 '... coil wire with a circular cross section, 31 ... winding start end, 32 ... winding end end, 40 ... stator, 50 ... brushless motor, 51: Rotor (armature), 52: Magnet (permanent magnet).

Claims (3)

  A core formed of a magnetic material, and an insulator that is covered with the core and wound with a coil wire around the bobbin portion, and that a relief portion is formed at a corner of the bobbin portion of the insulator. Coil device characterized.   A stator having a plurality of coil devices according to claim 1 arranged in a circular ring shape.   A motor comprising a rotor arranged on a center line of a stator in which a plurality of coil devices according to claim 1 are arranged in a circular ring shape.

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