JP2013051261A - Coil component and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil component and a manufacturing method of the same, capable of increasing a diameter of a distribution center of an AC current, increasing an inductance of a winding, and downsizing a coil component which is made possible as a result.SOLUTION: The coil component comprises a winding 1 formed by winding an element wire around a winding shaft 2. An average distance from the winding shaft 2 to a portion where an AC current in the element wire concentrates in a radial direction orthogonal to an axial direction of the winding shaft 2 is larger than an average radius of the winding 1.

Description

  The present invention relates to a wire ring component such as a choke coil or a motor used in an electric device, an automobile, or the like, and a manufacturing method thereof.

  2. Description of the Related Art Conventionally, there is known an edgewise wound electromagnetic coil in which a plurality of edgewise wound electromagnetic coils having different inner diameters or outer diameters are assembled in a laminated shape and connected to lead wires, for example (see Patent Document 1).

JP 2007-188988 A

  However, in the edgewise wound electromagnetic coil described in Patent Document 1, by incorporating a plurality of edgewise wound electromagnetic coils in a laminated form, the number of turns is increased within a predetermined space factor range, and the inductance is increased. However, the increase in the number of turns using this method has a physical limit, and there is a problem that the increase in inductance is limited.

  Further, it is possible to increase the inductance by increasing the winding diameter of the winding, but in this case, there is a problem that the winding is enlarged.

  In general, as a design element for increasing the inductance of the winding, it is well known that the winding diameter of the winding is increased when the conditions such as the number of windings and the winding height are the same. Is equivalent to the fact that the diameter of the distribution center of the alternating current in the winding is large, and Patent Document 1 does not consider the distribution of the alternating current in the winding.

  Therefore, the present invention solves the conventional problems, that is, the object of the present invention is to increase the diameter of the distribution center of the alternating current in the winding, increase the inductance of the winding, and thereby An object of the present invention is to provide a wire ring component and a method for manufacturing the wire ring component that can reduce the size of the wire ring component.

  The wire ring component of the present invention includes a winding formed by winding a strand around a winding shaft, and an alternating current in the strand from the winding shaft in a radial direction perpendicular to the axial direction of the winding shaft is generated. Since the average distance to the concentrated part is larger than the average radius of the winding, the above-described problem is solved.

  The aspect ratio of the cross section of the strand may be 2 or more, and an average distance from the winding axis in the radial direction to a short side portion of the cross section of the strand may be larger than an average radius of the winding. .

  When a unit formed by arranging a plurality of strands electrically connected in parallel in a row in an adjacent state is a parallel unit, the cross-sectional aspect ratio of the parallel unit is 2 or more, and the winding shaft in the radial direction The average distance from the short side of the cross section of the parallel unit to the average radius of the winding may be larger.

  The aspect ratio of the cross section of the strand is 2 or more, and when a unit formed by arranging two strands electrically connected in series with the short sides adjacent to each other is a series unit, An average distance from the winding axis in the radial direction to the short side portion of the series unit may be larger than an average radius of the winding.

  When a unit formed by arranging a plurality of wires connected in parallel in a row in an adjacent state is a parallel unit, the aspect ratio of the cross section of the parallel unit is 2 or more, and the short sides are adjacent to each other. In this state, when a unit formed by arranging two parallel units electrically connected in series is a series unit, the average distance from the winding shaft in the radial direction to the short side of the series unit is It may be larger than the average radius of the winding.

  A winding formed by winding the first strand and the second strand around the winding axis, and the aspect ratio of the cross section of the first strand is 2 or more, and a plurality of wires connected in parallel electrically When the unit in which the second strands are arranged in a row in the adjacent state is a parallel unit, the cross-sectional aspect ratio of the parallel unit is 2 or more, and the short sides are electrically adjacent to each other. When a unit formed by arranging one first strand connected in series and one parallel unit is a series unit, an average distance from the winding axis in the radial direction to the short side portion of the series unit is The average radius of the winding may be larger.

  All the short sides of the cross section of the strands, all the short sides of the cross section of the parallel unit, or all the short sides of the cross section of the series unit are separated from the winding shaft in the radial direction. The distance may be arranged at a position farther than the average radius of the winding.

  In the method for manufacturing a wire ring component according to the present invention, after the strand is wound around the winding shaft to form the winding, an alternating current in the strand is concentrated from the winding shaft in the radial direction. The problem described above is solved by adjusting the shape of the winding so that the average distance to the part is larger than the average radius of the winding.

  Another method of manufacturing a wire ring component according to the present invention is the manufacturing method of the wire after the wire is processed so that the shape of the wire becomes a predetermined shape, or so that the shape of the wire becomes a predetermined shape. While processing the wire, around the winding shaft, the average distance from the winding shaft in the radial direction to the portion where the alternating current in the strand is concentrated is larger than the average radius of the winding. The above-described problems are solved by winding the strands to form the windings.

  The other manufacturing method of the wire ring component of the present invention is such that an average distance from the winding shaft in the radial direction to a portion where the alternating current in the strand is concentrated is larger than an average radius of the winding. The above-described problems are solved by winding the wire around the winding shaft to form the winding.

  In the present invention, since it is possible to increase the diameter of the distribution center of the alternating current in the winding, it is possible to increase the inductance of the wire ring component, and accordingly, a smaller wire ring component can be obtained. .

It is explanatory drawing which shows distribution of alternating current at the time of arrange | positioning two strands connected in series in the proximity | contact state. It is explanatory drawing which shows distribution of an alternating current at the time of arrange | positioning three or more strands connected in series in the proximity | contact state. It is explanatory drawing which shows distribution of the alternating current at the time of arrange | positioning the several strand connected in parallel in the proximity | contact state, and distribution of the alternating current in a rectangular wire. It is a graph which shows the relationship between the aspect ratio of a strand, and the concentration degree of the electric current to the short side part of the cross section of a strand. It is explanatory drawing which shows the winding in 1st Example of this invention in cross section. It is explanatory drawing which shows the winding in 2nd Example of this invention in sectional view. It is explanatory drawing which shows the winding in 3rd Example of this invention in cross section. It is explanatory drawing which shows sectional view the winding in 4th Example of this invention. It is explanatory drawing which shows the winding in 5th Example of this invention in cross section. It is explanatory drawing which shows an example of the manufacturing method of the winding of wire ring components.

  Hereinafter, the configuration and operation according to the present invention will be described.

  First, the feature of the present invention is that it focuses on the proximity effect that strongly forms the distribution of alternating current in the winding, and the diameter of the distribution center of alternating current in the winding (from the winding axis in the radial direction perpendicular to the winding axis). Increase the inductance of the winding wire, thereby realizing a reduction in the size of the wire ring component.

  In general, as a design element for increasing the inductance of the winding, it is well known to increase the winding diameter of the winding when the conditions such as the number of windings and the winding height are the same. This is equivalent to the large diameter of the distribution center of the alternating current in the winding. In addition, it is possible to improve the winding space factor by devising the winding method and shape of the winding, but it is natural to improve the winding space factor. There is a limit, and if the winding diameter of the winding is simply increased, there arises a problem that the winding becomes larger.

  Therefore, the present applicant has discovered by analyzing the action and properties of the proximity effect that has a strong influence on the distribution of alternating current in the winding, and by utilizing the proximity effect, the applicant can determine the center of distribution of the alternating current in the winding. The diameter was increased, the winding inductance was increased, and the wheel ring components that were made possible thereby were reduced in size.

  Here, the action and property of the proximity effect found by the applicant will be described below.

  First, one of the properties of the proximity effect is that the alternating current is concentrated on the surface from the inside of the strand. The concentration of the alternating current on the surface of the strand does not occur when the diameter of the strand itself is small. Specifically, in the example of an alternating current of 10 kHz, when the strand is a round wire (or a square wire), if the strand diameter is 1 mm, the concentration of the alternating current on the surface does not occur, and the strand The tendency of alternating current to concentrate on the surface from the inside becomes prominent when the diameter exceeds 2 mm.

In the case of a rectangular wire having a certain aspect ratio or more in the cross section, an alternating current is concentrated on the short side portion side of the cross section of the rectangular wire due to the proximity effect.
In the present specification, a rectangular wire means that the aspect ratio of the cross section is 2 or more, and a square line means that the aspect ratio of the cross section is less than 2.

  In addition, as shown in FIG. 1, when two round wires (or square wires) connected in series are arranged close to each other and current flows in the same direction in the two strands, In the cross section, alternating current concentrates in the direction away from each other, and alternating current does not concentrate in the direction between the lines.

  In addition, as shown in FIG. 2, when three or more round wires (or square wires) connected in series are arranged in close proximity and current flows in the same direction in the three or more strands, In the cross section of the line, the alternating current concentrates in the direction away from each other, and the alternating current also concentrates in the direction between the lines.

  Further, as shown in FIG. 3, when three or more round wires (or square wires) electrically connected in parallel are arranged in a row in an adjacent state, these three or more wires are related to the AC current distribution. The parallel wires can be regarded as one parallel unit, and this parallel unit has been found to exhibit the same behavior as the rectangular wire described above with respect to the distribution of alternating current. That is, an alternating current is concentrated on the short side of the cross section of the parallel unit, and no alternating current is generated in the direction toward the line.

In addition, regarding the aspect ratio of the cross section of the rectangular wire and the parallel unit described above, when the aspect ratio is 2 or more, preferably 4 or more, the phenomenon that the alternating current concentrates on the short side due to the proximity effect becomes prominent. There was found.
The graph of FIG. 4 showing the relationship between the aspect ratio of the strand and the degree of concentration of alternating current, which is the ratio of the alternating current density between the central portion and the short side portion (end portion) of the strand cross section. Specifically, first, in the graph of T2 in which the plate thickness is set to 2 mm, since there is an inflection point at a portion with an aspect ratio of 2, when the aspect ratio is 2 or more, the short side portion side is changed. It can be seen that the concentration of alternating current becomes remarkable, and in the graph of T1 where the plate thickness is set to 1 mm, there is an inflection point at the aspect ratio of 4, and therefore the short side when the aspect ratio is 4 or more. It can be seen that the concentration of the alternating current on the part side becomes more remarkable.
Furthermore, when the aspect ratio is preferably 10 or more, and more preferably 100 or more, the process of bending the rectangular wire is facilitated so that the short side of the rectangular wire cross section is the outer peripheral side of the winding window.

Moreover, the resistivity of the conductor (elementary wire) which comprises a winding is also mentioned as conditions which produce a proximity effect. Specifically, when the resistivity of the conductor is 10 ⁻⁵ Ω / cm, since the resistance of the conductor is high, an eddy current does not easily flow inside the conductor, and the proximity effect hardly occurs. On the other hand, when the resistivity of the conductor is 10 ⁻⁸ Ω / cm, the proximity effect due to the eddy current occurs because the resistivity of the conductor is low.

  Next, an alternating current distribution in a winding having a general winding structure will be described.

First, in edgewise winding windings (windings that are wound in a solenoid shape with the short side of the flat wire as the inner peripheral surface), as described above, alternating current is concentrated on the short side of the cross section of the flat wire. Therefore, the alternating current is concentrated on the inner and outer sides of the winding window due to the proximity effect, and the winding of the flat-wise winding (the long side of the flat wire is wound in a spiral shape with the inner peripheral surface as the inner peripheral surface). As described above, since the alternating current concentrates on the short side of the rectangular wire cross section, the alternating current concentrates on the upper and lower sides of the winding window due to the proximity effect.
The term “wind window” used in the present invention means that when a winding is cut on a plane including a winding axis, two cross-sectional shapes are arranged symmetrically across the winding axis. Means one of them.

  As a result, since the center of the alternating current is close to the center of the winding window in the radial direction perpendicular to the winding axis, in common with both the edgewise winding and the flatwise winding, Compared with the case where the center of the alternating current is arranged on the outer peripheral side of the winding window with respect to the winding axis, the diameter of the distribution center of the alternating current in the winding is small, and the inductance value is small.

  Further, even in a winding formed by aligning round wires (or square wires) in series, the center of the alternating current is close to the center of the winding window in the radial direction perpendicular to the winding axis. Compared to the case where the center of the alternating current is arranged on the outer peripheral side of the winding window with respect to the axis, the diameter of the distribution center of the alternating current in the winding is small, and the inductance value is small.

  And in this invention, in order to eliminate the trouble in the winding which has the above general winding structure, and to improve the inductance of a winding, specifically, the following structures are employ | adopted. .

That is, in the present invention, by utilizing the proximity effect, the alternating current is concentrated on the short side of the flat wire or the cross section of the parallel unit, and the winding window shape of the winding is adjusted to thereby remove the winding from the radial winding axis. The winding is configured so that the average distance to the short side of the cross section of the flat wire or parallel unit is larger than the average radius of the winding, and more preferably all the short sides of the cross section of the flat wire or parallel unit Is disposed at a position where the distance from the winding axis in the radial direction is farther than the average radius of the winding.
Thereby, the diameter of the distribution center of the alternating current can be made larger than the mechanical average diameter of the winding window, the inductance of the winding can be increased, and the size reduction of the winding that can be realized thereby can be realized, Furthermore, when the winding is reduced in size, it is possible to realize a reduction in loss and a reduction cost due to a decrease in DC resistance and AC resistance.

  Hereinafter, a plurality of specific examples of the wire ring component of the present invention will be described.

  Common to all the embodiments, the wire ring component is composed of a soft magnetic core (not shown) and a winding 1 composed of a strand. Moreover, the part shown with the code | symbol 5 has shown the part where alternating current concentrates by a proximity effect.

  First, as shown in FIG. 5, in the wire ring component according to the first embodiment, the winding wire 1 is constituted by a flat wire having an aspect ratio of 2 or more in the cross section, and the cross section of the flat wire is curved into a U shape. Accordingly, the short side portion of the cross section of the rectangular wire where the alternating current is concentrated by the proximity effect is arranged on the outer peripheral side of the winding window (that is, the position where the distance from the winding shaft 2 is farther than the average radius of the winding wire 1). Has been. Thereby, since the diameter of the distribution center of the alternating current in the winding becomes large, the inductance of the winding 1 can be increased.

  Next, as shown in FIG. 6, in the wire ring component according to the second embodiment, the winding wire 1 is formed of a flat wire, and the cross-section of the flat wire is bent into a U-shape, whereby an alternating current is generated due to the proximity effect. The short side part of the cross section of the flat wire where the is concentrated is arranged on the outer peripheral side of the winding window. The effect of the second embodiment is the same as that of the first embodiment.

  Next, as shown in FIG. 7, in the wire ring component according to the third embodiment, the winding 1 is constituted by a round wire, and a plurality of round wires electrically connected in parallel are arranged in a row in an adjacent state. When the unit is regarded as one parallel unit 3, by curving the cross section of the parallel unit 3 in a U-shape, the short side of the cross section of the parallel unit 3 where the alternating current is concentrated by the proximity effect Arranged on the outer periphery of the winding window. The effect of the fourth embodiment is the same as that of the first embodiment. In the fourth embodiment, the round line may be replaced with a square line, and the cross section of the parallel unit 3 may be curved in a U shape.

Next, in the fourth embodiment shown in FIG. 8, the winding 1 is divided into two at a center perpendicular to the winding shaft 2 at the center of the winding 1 in the axial direction of the winding shaft 2, and the upper winding formed by a rectangular wire. The wire part 1a and the lower winding part 1b are connected in series.
As shown in FIG. 8, in the state where the short side portion of the cross section of the flat wire constituting the upper winding portion 1a and the short side portion of the cross section of the flat wire constituting the lower winding portion 1b are adjacent to each other, A winding part 1a and a lower winding part 1b are arranged.
In this case, the short side of the cross section of the series unit 4 composed of the flat wire constituting the upper winding portion 1a and the rectangular wire constituting the lower winding portion 1b arranged with the short side portions adjacent to each other. Alternating current concentrates on the part.
And the short side part of the cross section of the series unit 4 where an alternating current concentrates is arrange | positioned at the outer peripheral side of a winding window, as shown in FIG. 8, and there exists an effect similar to the case of a 1st Example.

Next, in the fifth embodiment shown in FIG. 9, the winding 1 is divided into two at the center of the winding 1 in the axial direction of the winding shaft 2 at a plane orthogonal to the winding shaft 2, and the upper winding formed by a rectangular wire. The lower winding part 1b comprised by the wire part 1a and the round wire is connected in series.
As shown in FIG. 9, in the state where the short side portion of the cross section of the rectangular wire constituting the upper winding portion 1a and the short side portion of the cross section of the parallel unit 3 of the lower winding portion 1b are adjacent to each other, The wire part 1a and the lower winding part 1b are arrange | positioned.
In this case, the short side part of the cross section of the series unit 4 comprised of the flat wire which comprises the upper side winding part 1a arrange | positioned in the state which adjoined the short side parts, and the parallel unit 3 of the lower side winding part 1b. AC current concentrates on
And the short side part of the cross section of the series unit 4 where an alternating current concentrates is arrange | positioned at the outer peripheral side of a winding window, as shown in FIG. 9, and there exists an effect similar to the case of a 1st Example.
In addition, you may comprise the lower winding part 1b from a square wire.

  In the fourth embodiment shown in FIG. 8, the upper winding portion 1a and the lower winding portion 1b are made of flat wires, and in the fifth embodiment shown in FIG. 9, the upper winding portion 1a is made of a flat wire. It comprises, and the lower side winding part 1b is comprised from the round wire (or square wire). However, the upper winding portion 1a and the lower winding portion 1b may be configured by round wires (square wires), and in this case, the short side portion and the lower winding in the cross section of the parallel unit 3 of the upper winding portion 1a. In a state where the short side portion of the cross section of the parallel unit 3 of the wire portion 1b is adjacent, the upper winding portion 1a and the lower winding portion 1b are arranged, and the short cross section of the series unit 4 where the alternating current is concentrated. What is necessary is just to arrange | position a side part to the outer peripheral side of a winding window.

Next, a method for manufacturing a wire ring part of the present invention will be described with reference to FIG.
In the manufacturing method shown in FIG. 10, after forming the winding 1 by winding a flat wire, the shape of the winding 1 is adjusted to a predetermined shape by pressing from the outer peripheral side, and the alternating current is obtained by the proximity effect. The short side portion side of the cross section of the rectangular wire where current is concentrated is arranged on the outer peripheral side.
However, after processing the strand in advance (for example, processing for bending the cross-sectional shape of the flat wire into a U shape) so that the strand shape becomes a predetermined shape, or while processing the strand, You may arrange | position the short side part side of the cross section of a flat wire to the outer peripheral side by winding the strand and comprising the winding 1. FIG.
Moreover, in the manufacturing method shown in FIG. 10, although the winding 1 comprised only from a flat wire was made into the object of manufacture, when manufacturing the winding 1 which contains a round wire (or square wire) as a component, The winding wire 1 may be configured by winding a round wire (or a square wire) so that the winding wire 1 has a final shape, or the winding wire 1 may be wound by winding a round wire (or a square wire). After the formation, the winding 1 may be pressed to adjust the shape of the winding 1 to a predetermined shape.

DESCRIPTION OF SYMBOLS 1 ... Winding 2 ... Winding shaft 3 ... Parallel unit 4 ... Series unit

Claims (11)

Provided with a winding formed by winding a wire around the winding axis,
An average distance from the winding shaft to a portion where the alternating current in the element wire is concentrated in a radial direction perpendicular to the axial direction of the winding shaft is larger than an average radius of the winding wire. parts. The aspect ratio of the cross section of the strand is 2 or more,
The wire ring component according to claim 1, wherein an average distance from the winding axis in the radial direction to a short side portion of a cross section of the strand is larger than an average radius of the winding. When a unit composed of a plurality of strands electrically connected in parallel and arranged in a row in an adjacent state is a parallel unit,
The aspect ratio of the cross section of the parallel unit is 2 or more,
The wire ring component according to claim 1, wherein an average distance from the winding shaft in the radial direction to a short side portion of a cross section of the parallel unit is larger than an average radius of the winding. The aspect ratio of the cross section of the strand is 2 or more,
When a unit formed by arranging two strands electrically connected in series with the short sides adjacent to each other is a series unit,
The wire ring component according to claim 1, wherein an average distance from the winding shaft in the radial direction to a short side portion of the series unit is larger than an average radius of the winding. When a unit composed of a plurality of strands electrically connected in parallel and arranged in a row in an adjacent state is a parallel unit,
The aspect ratio of the cross section of the parallel unit is 2 or more,
When a unit formed by arranging two parallel units electrically connected in series with the short sides adjacent to each other is a series unit,
The wire ring component according to claim 1, wherein an average distance from the winding shaft in the radial direction to a short side portion of the series unit is larger than an average radius of the winding. A winding formed by winding the first strand and the second strand around the winding axis;
The aspect ratio of the cross section of the first strand is 2 or more,
When a unit formed by arranging a plurality of second strands electrically connected in parallel in a row in an adjacent state is a parallel unit,
The aspect ratio of the cross section of the parallel unit is 2 or more,
When a unit formed by arranging one first strand electrically connected in series and one parallel unit with the short sides adjacent to each other is a series unit,
The wire ring component according to claim 1, wherein an average distance from the winding shaft in the radial direction to a short side portion of the series unit is larger than an average radius of the winding.   All the short sides of the cross section of the strands, all the short sides of the cross section of the parallel unit, or all the short sides of the cross section of the series unit are separated from the winding shaft in the radial direction. The wire ring component according to any one of claims 2 to 6, wherein the distance is arranged at a position farther than an average radius of the winding.   The wire ring component according to any one of claims 1 to 7, further comprising a soft magnetic core. In the manufacturing method of the wire ring component according to any one of claims 1 to 8,
After forming the winding by winding the wire around the winding shaft,
The shape of the winding is adjusted so that an average distance from the winding axis in the radial direction to a portion where the alternating current in the strand is concentrated is larger than an average radius of the winding. A method of manufacturing a wire ring part. In the manufacturing method of the wire ring component according to any one of claims 1 to 8,
After processing the strand so that the strand shape becomes a predetermined shape, or while processing the strand so that the shape of the strand becomes a predetermined shape,
The strand is wound around the winding shaft so that an average distance from the winding shaft in the radial direction to a portion where the alternating current in the strand is concentrated is larger than an average radius of the winding. A method of manufacturing a wire ring part, wherein the winding is formed. In the manufacturing method of the wire ring component according to any one of claims 1 to 8,
The strand is wound around the winding shaft so that an average distance from the winding shaft in the radial direction to a portion where the alternating current in the strand is concentrated is larger than an average radius of the winding. A method of manufacturing a wire ring part, wherein the winding is formed.

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