JP2022013979A - Coil body, stator, rotary machine, manufacturing method of coil body, and print circuit board - Google Patents

Abstract

To provide a coil body capable of realizing a rotary machine of which an output is large while having a small size.SOLUTION: In a coil body 3 which is formed in a cylindrical shape having a plurality of layers to which a print circuit board 6 is wound, when a wiring pattern positioned at one end part of the print circuit board 6 and structuring a coil of a first phase is an innermost layer end part wiring pattern 74, a wiring pattern positioned at the other end part of the print circuit board 6, and structuring the coil of a second phase is an outermost layer end part wiring pattern 75, a boundary line between the first phase and the second phase is a first phase boundary line 14, a distance of the first phase boundary line 14 and the innermost layer end part wiring pattern 74 is d2, a distance of the first phase boundary line 14 and the outermost layer end part wiring pattern 75 is d3, and a distance from the wiring pattern of the first phase and the second phase excluding the first phase boundary line 14, the innermost layer end part wiring pattern 74, and the outermost layer end part wiring pattern 75 is d1, at least one of the d2 and d3 is larger than d1.SELECTED DRAWING: Figure 3

Description

The present application relates to a coil body, a stator, a rotating machine, a method for manufacturing a coil body, and a printed wiring board.

In the coil body used for the stator of the rotating machine, the coil body is made thin by winding the printed wiring board on which the wiring pattern is formed multiple times and forming it into a tubular shape, thereby making the coil body thinner and making the rotating machine smaller. (For example, see Patent Document 1).

Japanese Unexamined Patent Publication No. 62-0222669

In the conventional coil body, the spiral wiring pattern is made smaller in order to make the thickness of the cylinder uniform when the printed wiring board is wound multiple times to form the tubular coil body, and the output of the rotating machine is reduced. There was a problem that it became smaller.

The present application has been made to solve the above-mentioned problems, and an object of the present application is to provide a coil body that realizes a rotary machine having a small size and a large output.

The coil body disclosed in the present application is a coil body formed into a tubular shape having a plurality of layers by winding a printed wiring board a plurality of times around a central axis, and the printed wiring board is formed into a tubular shape. The spiral wiring patterns that make up the coils of each phase are arranged side by side on both the front and back sides of the insulating substrate along the circumferential direction of the time, and when the printed wiring board is wound and formed into a tubular shape, each The wiring patterns are overlapped so that the centers of the wiring patterns that make up the phase coil match, and they are located in the layer closest to the central axis and are located at one end of the printed wiring board to form the first phase coil. The wiring pattern to be used is defined as the innermost layer end wiring pattern, and the wiring pattern located at the other end of the printed wiring plate located in the layer farthest from the central axis to form the second phase coil is defined as the outermost layer end wiring pattern. , The boundary line between the first phase and the second phase is defined as the first phase boundary line, and the distance from the first phase boundary line to the nearest end of the innermost layer end wiring pattern is d2, from the first phase boundary line. When the distance to the nearest end of the outermost layer end wiring pattern is d3, from the first phase boundary line to the nearest end of the wiring pattern in the layer excluding the layer closest to the central axis in the first phase. The distance and the distance from the first phase boundary line to the nearest end of the wiring pattern in the layer excluding the layer farthest from the central axis in the second phase are equal d1, and at least one of d2 and d3 is more than d1. Is also characterized by being large.

The coil body disclosed in the present application is a coil body formed into a tubular shape having a plurality of layers by winding a printed wiring board a plurality of times around a central axis, and the printed wiring board is formed into a tubular shape. The spiral wiring patterns that make up the coils of each phase are arranged side by side on both the front and back sides of the insulating substrate along the circumferential direction of the time, and when the printed wiring board is wound and formed into a tubular shape, each The wiring patterns are overlapped so that the centers of the wiring patterns that make up the phase coil match, and they are located in the layer closest to the central axis and are located at one end of the printed wiring board to form the first phase coil. The wiring pattern to be used is defined as the innermost layer end wiring pattern, and the wiring pattern located at the other end of the printed wiring plate located in the layer farthest from the central axis to form the second phase coil is defined as the outermost layer end wiring pattern. , The boundary line between the first phase and the second phase is defined as the first phase boundary line, and the distance from the first phase boundary line to the nearest end of the innermost layer end wiring pattern is d2, from the first phase boundary line. When the distance to the nearest end of the outermost layer end wiring pattern is d3, from the first phase boundary line to the nearest end of the wiring pattern in the layer excluding the layer closest to the central axis in the first phase. The distance and the distance from the first phase boundary line to the nearest end of the wiring pattern in the layer excluding the layer farthest from the central axis in the second phase are equal d1, and at least one of d2 and d3 is more than d1. Since it is also large, it is possible to increase the spiral wiring pattern in a thin tubular coil body, and it is possible to realize a rotating machine that is small and has a large output.

It is a perspective view of the rotary machine according to Embodiment 1. FIG. It is sectional drawing of the rotary machine according to Embodiment 1. FIG. It is sectional drawing of the coil body by Embodiment 1. FIG. It is sectional drawing of the modification of the coil body by Embodiment 1. FIG. It is sectional drawing of the coil body by the comparative example 1. FIG. It is sectional drawing of the coil body by the comparative example 2. FIG. FIG. 5 is a diagram showing the relationship between the angle formed by each end of the innermost layer end wiring pattern and the outermost layer end wiring pattern in the coil body according to the first embodiment and the radial thickness at the phase boundary line of the coil body. .. It is sectional drawing which shows the outline of the printed wiring board by Embodiment 1. FIG. It is a figure which shows the wiring pattern in the printed wiring board by Embodiment 1. FIG. It is a figure explaining the state of connection of the wiring pattern in the printed wiring board by Embodiment 1. FIG. It is a figure which shows the wiring pattern in the printed wiring board by the comparative example 1. FIG. It is a figure which shows the position where the adhesive is applied in the coil body by Embodiment 1. FIG. It is a process drawing of the manufacturing method of the coil body by Embodiment 1. FIG. It is a perspective view of the rotary machine according to Embodiment 2. FIG. It is sectional drawing of the rotary machine by Embodiment 2. FIG. It is a figure which shows the printed wiring board by Embodiment 2. FIG.

Hereinafter, the coil body according to the embodiment for carrying out the present application will be described in detail with reference to the drawings. In each figure, the same reference numerals indicate the same or corresponding parts.

Embodiment 1.
FIG. 1 is a perspective view of the rotary machine 100 according to the first embodiment. FIG. 2 is a cross-sectional view showing a cross section taken along the line AA in FIG. The rotor 100 according to the first embodiment includes a tubular stator 1 and a rotor 2 provided inside the stator 1 and rotating around the central axis 200 of the stator 1. The rotor 100 includes a case for accommodating the stator 1 and the rotor 2, but is omitted in FIG. The stator 1 includes a coil body 3 and a core 4. The core 4 has a cylindrical shape and is arranged outside the coil body 3. The inner peripheral portion of the core 4 is in contact with the outer peripheral surface of the coil body 3. The core 4 is made of a magnetic material, and is, for example, one formed from a dust core or one in which electromagnetic steel sheets are laminated. The terminal connection portion 5 is a portion for connecting the power supply line to the coil body 3.

FIG. 3 shows the details of the coil body 3 in FIG. 2, and is a cross-sectional view of the coil body 3. The coil body 3 in FIG. 3 is formed by winding a sheet-shaped printed wiring board 6 three times to form a cylinder, and has a structure in which the printed wiring boards 6 are stacked in three layers in the radial direction about the central axis 200. It has become. The number of times the printed wiring board 6 is wound is not limited to three times, and may be a plurality of times. Further, the shape around which the printed wiring board 6 is wound may be a circular shape or a polygonal shape when the wound printed wiring board 6 is cut along a plane orthogonal to the central axis 200.

In FIG. 3, the portion shown by the thick line is the wiring pattern provided on the printed wiring board 6. The coil body 3 shown in FIG. 3 is a coil body driven by a three-phase power supply, and the first-phase wiring pattern 71 is formed by superimposing three layers of wiring patterns to form a first-phase coil. Similarly, in the second phase wiring pattern 72 and the third phase wiring pattern 73, the three layers of wiring patterns are overlapped to form the second phase and third phase coils, respectively. The number of coils of the coil body 3 shown in FIG. 3 is 3, and the coils are arranged so as to be offset by 120 degrees by the mechanical angle. Therefore, the first phase center line 11 which is the center of the first phase wiring pattern 71 in the circumferential direction and the second phase center line 12 which is the center of the second phase wiring pattern 72 in the circumferential direction are displaced by 120 degrees. be. Similarly, the second phase center line 12 and the third phase center line 13, which are the centers in the circumferential direction of the second phase wiring pattern 72, are located at positions shifted by 120 degrees.

When the printed wiring board 6 is wound in a cylindrical shape, in the first phase wiring pattern 71, the wiring pattern 711 of the first phase first layer, the wiring pattern 712 of the first phase second layer, and the wiring of the first phase third layer All the centers of the pattern 713 are wound so as to coincide with the first phase center line 11. The same applies to the second phase wiring pattern 72 and the third phase wiring pattern 73. When N is an integer of 2 or more and the coil body 3 is composed of N layers, the center of the wiring pattern of each layer from the first layer to the Nth layer in the first phase wiring pattern 71 is the first phase center line 11. Wrapped to match. The same applies to the second phase wiring pattern 72 and the third phase wiring pattern 73.

The hardness of the printed wiring board 6 varies depending on a plurality of factors such as the material and thickness of the insulating board, the shape and thickness of the wiring pattern, and thereby, when the printed wiring board 6 is wound in a cylindrical shape, it is between the layers. The size or shape of the gap changes. Therefore, verification such as trial production is performed, and the shape and position of the wiring pattern are determined so that the centers of the wiring patterns of each phase match in the order of the first layer to the Nth layer.

In order to increase the output of the rotor 100, it is necessary to interlink a large amount of magnetic flux of the magnet of the rotor 2 with the wiring pattern of the coil body 3. Therefore, it is important that the outer circumference forming angle θ1, which is the angle formed by the outer end of the wiring pattern of each phase, approaches the mechanical angle of 120 degrees. When the inner circumference formation angle θ2, which is the angle formed by the inner end of the wiring pattern, is small, the interlinking magnetic flux is small, but the copper loss calculated by “resistance * (current squared)” is due to the resistance of the wiring. Generates and generates heat. In the case of centralized winding, when the ratio of the number of poles of the rotor 2 to the number of coils is 4: 3 and θ1 is 120 degrees, the optimum value for θ2 is 25 degrees. Actually, in the arrangement of the wiring pattern, it is necessary to secure the insulation distance from the adjacent phases, and θ1 is not 120 degrees, so θ2 is calculated and obtained. Further, in order to keep the induced voltage of the first phase to the third phase uniform, the magnitude of θ2 may be changed in some layers.

In the coil body 3 shown in FIG. 3, the wiring pattern 711 of the first phase first layer, which is a wiring pattern located at one end of the printed wiring board 6 in the layer closest to the central axis 200, is wired at the innermost layer end. The pattern 74 is defined as the wiring pattern 723 of the second phase third layer, which is a wiring pattern located at the other end of the printed wiring board 6 in the layer farthest from the central axis 200, and is defined as the outermost layer end wiring pattern 75. Further, the boundary line between the first phase and the second phase is set as the first phase boundary line 14, the boundary line between the second phase and the third phase is set as the second phase boundary line 15, and the third phase and the first phase are used. Let the boundary line of be the third phase boundary line 16. The first phase boundary line 14 is, for example, a line that bisects the angle formed by the first phase center line 11 and the second phase center line 12 when viewed from the central axis 200. The second phase boundary line 15 is, for example, a line that bisects the angle formed by the second phase center line 12 and the third phase center line 13 when viewed from the central axis 200. The third phase boundary line 16 is, for example, a line that bisects the angle formed by the third phase center line 13 and the first phase center line 11 when viewed from the central axis 200. At this time, the distance from the first phase boundary line 14 to the end closest to the first phase boundary line 14 in the innermost layer end wiring pattern 74, and the distance from the third phase boundary line 16 to the innermost layer end wiring pattern 74. Let d2 be the distance to the nearest end. Further, the distance from the first phase boundary line 14 to the nearest end of the outermost layer end wiring pattern 75 and the distance from the second phase boundary line 15 to the nearest end of the outermost layer end wiring pattern 75. , D3. For the third phase, in the wiring pattern in the layer farthest from the central axis 200, the distance from the second phase boundary line 15 to the nearest end of the wiring pattern, and the most of the wiring pattern from the third phase boundary line 16. The distance to the near end is d4. The wiring patterns excluding the innermost layer end wiring pattern 74, the outermost layer end wiring pattern 75, and the wiring pattern in the layer farthest from the central axis 200 in the third phase are wiring patterns from the adjacent phase boundary lines. Let d1 be the distance to the nearest end of. At this time, in the coil body 3 according to the first embodiment, at least one of d2 and d3 is made larger than d1. In the coil body 3 shown in FIG. 3, both d2 and d3 are made larger than d1, and the closest ends of the innermost layer end wiring pattern 74 and the outermost layer end wiring pattern 75 when viewed from the central axis 200. When the angle formed by each other is θ3, the line that bisects θ3 and the first phase boundary line 14 are made to coincide with each other.

In the coil body 3, if at least one of d2 and d3 is larger than d1, the line that bisects θ3 and the first phase boundary line 14 do not necessarily have to coincide. FIG. 4 shows a modified example of the coil body 3, and shows an example in which the line that bisects θ3 and the first phase boundary line 14 do not match.

Further, d2 and d3 do not have to be the same size. When d2 and d3 have different sizes, either d2 or d3 may have the same size as d1.

When the magnetic flux interlinking the wiring pattern of the first phase and the magnetic flux interlinking the wiring pattern of the second phase are different, the induced voltages of the first phase and the second phase are different, so that the first phase and the second phase are different. There is a problem that the generated torque is different and the vibration of the rotating machine 100 becomes large. Therefore, d2, d3 and d1 are determined so that the induced voltages of the first phase and the second phase are equal to each other.

In the coil body 3 shown in FIG. 3, since the third phase is not the end portion of the printed wiring board 6, the wiring pattern of the third phase is from the viewpoint of making the thickness of the coil body 3 in the radial direction uniform. It is not necessary to increase the distance from the phase boundary to the end of the wiring pattern. However, from the viewpoint of equalizing the induced voltage of each phase, the distance from the phase boundary line to the end of the wiring pattern may be increased in the wiring pattern of any layer of the third phase. In the coil body 3 according to the first embodiment shown in FIG. 3, in the wiring pattern of the third phase in the layer farthest from the central axis 200, the distance from the second phase boundary line 15 to the end of the wiring pattern, and The distance from the third phase boundary line 16 to the end of the wiring pattern is d4, which is larger than d1. Further, d4 has the same size as d3.

Although d1, d2, d3 and d4 are described as linear distances in FIG. 3, since the coil body 3 is formed by winding the printed wiring board 6 into a tubular shape, the printed wiring board 6 is formed into a flat plate. When the shape is formed, the wiring pattern is arranged by converting it into the distance on the surface of the printed wiring board 6.

FIG. 5 is a cross-sectional view of the coil body 301 according to Comparative Example 1, in which a sheet-shaped printed wiring board 601 is wound three times and formed into a cylindrical shape. The coil body 301 shown in FIG. 5 has d2, d3 and d4 having the same size as d1 shown in FIG. In the coil body 301, the end portion of the innermost layer end wiring pattern 741 which is a wiring pattern located at one end of the printed wiring board 601 in the layer closest to the central axis 200 and the layer farthest from the central axis. Yes The distance from the end of the outermost layer end wiring pattern 751, which is a wiring pattern located at the other end of the printed wiring board 601, is close. As a result, the radial thickness of the coil body 301 is the radial thickness d5 at the second phase boundary line 15 which is the boundary line between the second phase and the third phase, which is equivalent to three printed wiring boards 601. Regarding the thickness, the radial thickness d6 at the first phase boundary line 14, which is the boundary line between the first phase and the second phase, is the thickness of four printed wiring boards 601. That is, the coil body 301 according to Comparative Example 1 is larger than the coil body 3 according to the first embodiment. Therefore, for example, when the coil body must be arranged in a space having a thickness of three printed wiring boards, the coil body 3 according to the first embodiment shown in FIG. 3 can be arranged, but FIG. 5 shows. The coil body 301 according to Comparative Example 1 shown cannot be arranged.

FIG. 6 is a cross-sectional view of the coil body 302 according to Comparative Example 2. In the coil body 302 shown in FIG. 6, the distance from the phase boundary line to the end of the wiring pattern in all the wiring patterns of the first phase is d2 shown in FIG. 3, and the phase boundary line is set in all the wiring patterns of the second phase. The distance from to the end of the wiring pattern is d3 shown in FIG. 3, and the distance from the phase boundary line to the end of the wiring pattern in all the wiring patterns of the third phase is d4 shown in FIG. The radial thickness of the coil body 302 according to Comparative Example 2 is the thickness of three printed wiring boards at all positions, as in the coil body 3 according to the first embodiment. However, since the wiring pattern of the coil body 302 according to Comparative Example 2 is smaller than the wiring pattern of the coil body 3 according to the first embodiment, the output of the rotating machine becomes small.

The coil body 3 according to the first embodiment realizes a rotary machine having a large output while being as small as the coil body 302 according to the comparative example 2.

FIG. 7 is an angle formed by the closest ends of the innermost layer end wiring pattern 74 and the outermost layer end wiring pattern 75 when viewed from the central axis 200 in the coil body 3 shown in FIG. When the θ3 ”is changed, the radial thickness d6 of the coil body 3 on the first phase boundary line 14, which is the boundary line between the first phase and the second phase, and the boundary between the second phase and the third phase. It is a figure which shows the result of having verified about the change of the value of "d6-d5" which is the difference of the thickness d5 of the coil body 3 in the radial direction in the 2nd phase boundary line 15 which is a line. Although the vertical axis in FIG. 7 is "d6-d5", the thickness of the coil body 3 is the same except in the vicinity of the first phase boundary line 14, which is the boundary line between the first phase and the second phase. Therefore, "d6-d5" is obtained by subtracting the radial thickness of the coil body 3 other than the vicinity of the first phase boundary line 14 from the radial thickness d6 of the coil body 3 at the first phase boundary line 14. Same as "value". In "d6-d5" shown on the vertical axis in FIG. 7, "0" indicates that d6 and d5 are equal, and "1" means that d6 is thicker than d5 by one printed wiring board 6. Represents. Further, in FIG. 7, the dotted line shows the measurement result of the soft printed wiring board having the thickness of the wiring pattern of 15 μm, and the solid line shows the measurement result of the hard printed wiring board having the thickness of the wiring pattern of 50 μm. In the soft printed wiring board, when θ3 was 10 degrees or more, d6 and d5 became equal, and the thickness of the coil body 3 became uniform. On the other hand, in the hard printed wiring board, when θ3 was 30 degrees or more, d6 and d5 became equal, and the thickness of the coil body 3 became uniform.

As described above, in the coil body 3 according to the first embodiment, by making at least one of d2 and d3 larger than d1, the innermost layer end wiring pattern 74 and the outermost layer end when viewed from the central axis 200 The angle θ3 formed by the respective closest ends to the wiring pattern 75 can be set to 10 to 30 degrees, and the thickness of the coil body 3 in the radial direction becomes uniform. As a result, a large wiring pattern can be arranged, and a small rotating machine with a large output can be realized. In the coil body 3 according to the first embodiment, the ratio of the number of poles of the rotor 2 to the number of coils is 4: 3 in the centralized winding, but the ratio of the number of poles of the rotor to the number of coils may be another value. Furthermore, distributed winding may be used.

FIG. 8 is a cross-sectional view showing an outline of the printed wiring board 6 according to the first embodiment. The printed wiring board 6 uses a double-sided copper foil substrate in which copper foils are attached to both sides of the insulating substrate 61, and the front surface wiring pattern 62 and the back surface wiring pattern 63 are formed by forming the copper foil into a spiral shape by etching or the like. do. Further, in order to insulate the wiring pattern from the outside, an insulating layer 64 is formed on the surface of the surface wiring pattern 62. In the printed wiring board 6 shown in FIG. 8, the insulating layer 64 is formed only on the front surface of the front surface wiring pattern 62, but the insulating layer may also be formed on the surface of the back surface wiring pattern 63.

FIG. 9 is a diagram showing a state of the wiring pattern arranged on the insulating substrate 61 in the printed wiring board 6 according to the first embodiment. The upper figure of FIG. 9 shows the wiring pattern when the surface wiring pattern 62 in FIG. 8 is viewed from the upper direction to the lower direction in FIG. The lower figure of FIG. 9 shows a perspective view of the wiring pattern when the back surface wiring pattern 63 in FIG. 8 is viewed from the upper direction to the lower direction in FIG. In FIG. 9, the y direction is the direction parallel to the central axis 200 in FIG. 3, and the x direction is the circumferential direction in FIG. In FIG. 9, the position in the x direction where the first phase center line 11, the second phase center line 12, the third phase center line 13 and the first phase boundary line 14 intersect with the printed wiring board 6 in FIG. 3 is set. It is shown by a broken line. The terminal connection portion 5 is a portion for connecting a power line. In the printed wiring board 6, a margin in which the wiring pattern is not arranged on the insulating substrate 61 at the end in the x direction in the left-right direction of FIG. 9 or the end in the y direction in the up-down direction in FIG. However, it is omitted in FIG.

The dummy pattern 76 is a metal pattern electrically isolated from the spiral wiring pattern, and is arranged inside each spiral wiring pattern. When the printed wiring board 6 is wound to form a cylinder, the portion having the wiring pattern is hard and the portion without the wiring pattern is soft, so that it may be difficult to make the cross section of the coil body 3 circular. In the printed wiring board 6 according to the first embodiment, by providing the dummy pattern 76 inside each spiral wiring pattern, the hardness of the printed wiring board 6 becomes uniform, and the printed wiring board 6 is wound around the cylinder. When formed into a shape, it becomes easy to make the cross section circular. The dummy pattern 76 may be an integral metal pattern, but in this case, heat is generated by the eddy current when the magnetic flux passes through. The dummy pattern 76 is preferably a divided metal pattern in order to prevent the generation of eddy currents. do.

In the printed wiring board 6 shown in FIG. 9, spiral wiring patterns are arranged on both the front and back surfaces of the insulating substrate 61, and the wiring pattern 703 of the third layer, the wiring pattern 702 of the second layer, and the first layer are arranged. The wiring patterns 701 are arranged in order along the x direction, which is the circumferential direction in FIG. In the wiring pattern 703 of the third layer, the wiring pattern 723 of the second phase third layer, the wiring pattern 733 of the third phase third layer, and the wiring pattern of the first phase third layer, which is the outermost layer end wiring pattern 75. The 713s are arranged in order along the x direction. In the wiring pattern 702 of the second layer, the wiring pattern 722 of the second phase second layer, the wiring pattern 732 of the third phase second layer, and the wiring pattern 712 of the first phase second layer are sequentially arranged in the x direction. They are lined up. In the wiring pattern 701 of the first layer, the wiring pattern 721 of the second phase first layer, the wiring pattern 731 of the third phase first layer, and the wiring pattern of the first phase first layer which is the innermost layer end wiring pattern 74. The 711s are arranged in order along the x direction. When the printed wiring board 6 is wound to form a cylinder, three wirings of the wiring pattern 711 of the first phase first layer, the wiring pattern 712 of the first phase second layer, and the wiring pattern 713 of the first phase third layer. The patterns overlap to form the first phase wiring pattern 71 shown in FIG. The same applies to the second phase wiring pattern 72 and the third phase wiring pattern 73.

FIG. 10 is a diagram illustrating a state of connection of wiring patterns in the printed wiring board 6 shown in FIG. Similar to FIG. 9, the upper diagram of FIG. 10 shows the wiring pattern when the surface wiring pattern 62 in FIG. 8 is viewed from the upper direction to the lower direction in FIG. 8. The lower figure of FIG. 10 shows a perspective view of the wiring pattern when the back surface wiring pattern 63 in FIG. 8 is viewed from the upper direction to the lower direction in FIG. From the left side of FIG. 10, the wiring pattern of the second phase, the wiring pattern of the third phase, and the wiring pattern of the first layer are arranged repeatedly three times in this order. The wiring pattern of the second phase starts from 2A and connects to 2C through a through hole in 2B. 2C is connected to 2D, and subsequently, 2D, 2E, 2F, and 2G are connected to the neutral point 400 in this order, and the second phase is configured. Phase 3 starts at 3A and leads to 3C through through holes in 3B and leads to 3D. It is connected to 3G through 3E and 3F because it collides with the second phase wiring in 3D. Hereinafter, the neutral point 400 is connected in the order of 3G, 3H, 3I, 3J, 3K, 3L, 3M, 3N, and 3O, and the third phase is configured. The first phase starts from 1A and leads to the neutral point 400 in the order of 1A, 1B, 1C, 1D, 1E, 1F, 1G, 1H, 1I, 1J, 1K, 1L, 1M, 1N, 1O. The first phase is configured.

FIG. 11 is a diagram showing a wiring pattern in the printed wiring board 601 constituting the coil body 301 according to Comparative Example 1 shown in FIG. The coil body 301 shown in FIG. 5 has d2, d3 and d4 having the same size as d1 shown in FIG. Therefore, in the printed wiring board 601 in FIG. 11, the wiring pattern is very close to the first phase boundary line 14 which is the boundary line between the first phase and the second phase at the end portion in the x direction in the left-right direction of FIG. It is in a close position. As a result, when the printed wiring board 601 according to Comparative Example 1 is wound and formed into a cylindrical shape to form the coil body 301 shown in FIG. 5, the diameter of the coil body 301 is formed at the position of the first phase boundary line 14 shown in FIG. It can be seen that the thickness in the direction becomes thicker.

As the insulating substrate 61 in FIG. 8, a general insulating substrate can be used. Typical insulating substrates include flexible substrates and rigid substrates. Specifically, the material of the flexible substrate includes polyester, polyimide, liquid crystal polymer and the like, and the material of the rigid substrate includes paper phenol, paper epoxy, glass composite, glass epoxy, Teflon (registered trademark) and the like. The film thickness of the insulating substrate 61 is not particularly limited as long as the printed wiring board 6 can be easily wound when the coil body 3 is formed, and is preferably in the range of 5 μm to 1 mm, for example.

The insulating layer 64 in FIG. 8 is made of an insulating material, and for example, a solder resist is used. The insulating layer 64 insulates the wiring pattern from the outside and protects the wiring pattern from dust, dirt and moisture. By covering the wiring pattern with a protective film such as gold plating, the wiring pattern may be protected from environmental disturbances such as humidity or mechanical disturbances such as impact.

In the coil body 3 shown in FIG. 3, each layer of the wound printed wiring board 6 is adhered by an adhesive layer made of an adhesive for adhering the wound printed wiring board 6. As the adhesive, a sheet-like adhesive or a liquid adhesive made of an insulating material is used. The adhesive is arranged on one side or both sides of the printed wiring board 6 and adheres each layer on the wound printed wiring board 6.

FIG. 12 is a diagram showing a position where the adhesive is applied in the coil body 3 shown in FIG. The first adhesive 81 shown by the dotted line in FIG. 12 adheres between the respective layers of the printed wiring board 6 in the coil body 3. Further, by using an insulating material for the first adhesive 81, it is possible to secure insulation between the respective layers of the printed wiring board 6 in the coil body 3. The second adhesive 82 shown by a thick line in FIG. 12 is arranged on the outer peripheral surface of the coil body 3 and adheres the coil body 3 and the core 4. Further, by using an insulating material for the second adhesive 82, it is possible to secure the insulation between the coil body 3 and the core 4. Further, the first adhesive 81 and the second adhesive 82 also have a role of dissipating heat generated by the coil body 3. The region to which the first adhesive 81 and the second adhesive 82 are applied may be the entire area or a part of one side of the printed wiring board 6, or may be the entire area or a part of both sides of the printed wiring board 6. The larger the arrangement area of the first adhesive 81, the more reliably the adhesiveness and the insulating property between the respective layers of the printed wiring board 6 are ensured when the printed wiring board 6 is wound in a cylindrical shape. ..

When a sheet-like adhesive is used for the first adhesive 81 and the second adhesive 82, there is no particular limitation as long as it is curable. Examples of the sheet-like adhesive include a UV curable adhesive, a heat-curable adhesive, a honeymoon adhesive used by stacking a plurality of sheets, and a heat-adhesive adhesive. Examples of the UV curable adhesive include an epoxy adhesive and an acrylic adhesive. Examples of the heat-curable adhesive include an epoxy adhesive, an acrylic adhesive, an epoxy and acrylic hybrid adhesive, and a polyimide adhesive. Examples of the honeymoon-based adhesive include an epoxy-based adhesive and an acrylic-based adhesive. Examples of the heat-bonding adhesive include an olefin-based adhesive and a polyester-based adhesive. The sheet-shaped adhesive may be used alone or may be used in a plurality of types at the same time.

When a liquid adhesive is used for the first adhesive 81 and the second adhesive 82, there is no particular limitation as long as it is curable. Examples of the liquid adhesive include a solvent type adhesive, a water-based type adhesive, a hot melt adhesive, an elastic adhesive, a heat-curable reaction type adhesive, and a pressure-sensitive adhesive. Solvent-type adhesives include rubber-based adhesives and resin-based adhesives. Examples of the rubber-based adhesive include a chloroprene rubber-based adhesive, a styrene-butadiene rubber-based adhesive, a nitrile rubber-based adhesive, and a natural rubber-based adhesive. Examples of the resin-based adhesive include a vinyl chloride resin-based adhesive, a vinyl acetate resin-based adhesive, an acrylic resin-based adhesive, and a urethane resin-based adhesive. Examples of the water-based adhesive include water-soluble adhesives, emulsion-based adhesives, and latex adhesives. Examples of the hot melt adhesive include a thermoplastic elastomer hot melt adhesive and an ethylene vinyl acetate Copolymer (EVA) -based hot melt adhesive. Examples of the elastic adhesive include a silicone-based adhesive, a modified silicone-based adhesive, and a silylated urethane adhesive. Examples of the heat-curable reactive adhesive include a heat-curable epoxy adhesive, a photocurable epoxy adhesive, a urethane adhesive, a urea-based adhesive, a melamine-based adhesive, a phenol-based adhesive, and an anaerobic acrylic. There are system adhesives, second generation acrylic adhesives, photocurable acrylic adhesives, and cyanoacrylate adhesives. Examples of the pressure-sensitive adhesive include an acrylic pressure-sensitive adhesive, a rubber-based pressure-sensitive adhesive, and a silicone-based pressure-sensitive adhesive. The liquid adhesive may be used alone or may be used in a plurality of types at the same time. If these adhesives have good thermal conductivity, they can also contribute to heat dissipation from the coil, so that the current flowing through the wiring pattern can be increased and the output of the rotating machine 100 can be increased. Can be done.

Next, a method of manufacturing the coil body 3 according to the first embodiment will be described. FIG. 13 is a process diagram of a method for manufacturing a coil body according to the first embodiment. The details of each step will be described below.

In the step of creating the printed wiring board in step S101, the front surface wiring pattern 62 and the back surface wiring pattern 63, which are spiral wiring patterns, are formed on both the front and back surfaces of the insulating substrate 61, and the printed wiring board 6 as shown in FIG. 9 is formed. create.

The method for forming the front surface wiring pattern 62 and the back surface wiring pattern 63 on the insulating substrate 61 is not particularly limited. For example, a copper layer is formed on the surface of the insulating substrate 61 by electroless plating or electrolytic plating, then a resist is formed, and the resist is used as a mask to pattern the copper layer to obtain a spiral wiring pattern. Further, a solder resist may be formed on the surface of the surface wiring pattern 62 as an insulating layer 64 to protect the wiring pattern from dust, dust and moisture, and to secure the insulating property. When the wiring patterns of the first phase, the second phase, and the third phase are formed on both the front and back surfaces of the insulating substrate 61, it is necessary to form the wiring patterns in different phases so as not to mix with each other.

In the adhesive application step of step S102, the first adhesive 81 is applied to one side or both sides of the flat printed wiring board 6. For example, one side or both sides of the printed wiring board 6 is covered with a sheet-like adhesive or a liquid adhesive. The portion covered with the sheet-like adhesive or the liquid adhesive may be whole or a part on one side or both sides.

In the coil body forming step of step S103, the printed wiring board 6 is wound and formed into a cylindrical shape. In the adhesive curing step of step S104, the first adhesive 81 is cured by room temperature curing, heat curing, photocuring or moisture curing, depending on the type of the first adhesive 81. This results in a tubular coil body 3. When the printed wiring board 6 formed into a cylindrical shape is viewed in the radial direction, the wiring patterns of the plurality of wound layers overlap, and the wiring patterns of the overlapped phases are electrically connected as shown in FIG. Has been done.

By these steps, the coil body 3 is obtained. After that, in the step of confirming the thickness of the coil body, the angle formed by the closest ends of the innermost layer end wiring pattern 74 and the outermost layer end wiring pattern 75 when viewed from the central axis 200 is predetermined. After confirming the angle, the radial thickness d6 at the first phase boundary line 14, which is the boundary line between the first phase and the second phase, and the thickness of other parts, for example, the second phase. The radial thickness d5 at the second phase boundary line 15 which is the boundary line between the third phase and the third phase is measured, and it is confirmed whether the thickness is a predetermined value.

Further, the stator 1 is obtained by arranging the second adhesive 82 on the outer peripheral surface of the coil body 3, arranging the core 4 on the outside of the coil body 3, and adhering the coil body 3 and the core 4. When a liquid adhesive is used as the adhesive, it is necessary to separate the application process of the first adhesive 81 and the application process of the second adhesive 82, but when a sheet-like adhesive is used as the adhesive, the first adhesion is performed. It is not necessary to separate the coating process of the agent 81 and the coating process of the second adhesive 82. In this way, the bonding process may be changed depending on the type of adhesive.

As described above, the coil body 3 according to the first embodiment is a coil body 3 formed into a tubular shape having a plurality of layers by winding the printed wiring plate 6 a plurality of times around the central axis 200. The printed wiring board 6 is formed by arranging spiral wiring patterns constituting the coils of each phase on both the front and back surfaces of the insulating substrate 61 along the circumferential direction when the printed wiring board 6 is formed. The wiring patterns are overlapped so that the centers of the wiring patterns constituting the coils of each phase match when they are wound and formed into a tubular shape. The wiring pattern that is located at one end and constitutes the first phase coil is the innermost layer end wiring pattern 74, which is located in the layer farthest from the central axis 200 and is located at the other end of the printed wiring board 6. The wiring pattern constituting the second phase coil is defined as the outermost layer end wiring pattern 75, the boundary line between the first phase and the second phase is defined as the first phase boundary line 14, and the first phase boundary line 14 to the innermost layer end. When the distance to the nearest end of the part wiring pattern 74 is d2 and the distance from the outermost layer end wiring pattern 75 to the nearest end of the outermost layer end wiring pattern 75 is d3, the first phase boundary line 14 The distance from the first phase to the nearest end of the wiring pattern in the layer excluding the layer closest to the central axis 200, and the layer excluding the layer farthest from the central axis in the first phase boundary line 14 to the second phase. Since the distance to the nearest end of the wiring pattern in is equal d1, and at least one of d2 and d3 is greater than d1, the spiral wiring pattern can be made larger in a thin tubular coil body. It is possible to realize a rotating machine that is small and has a large output.

Embodiment 2.
FIG. 14 is a perspective view of the rotary machine 100a according to the second embodiment. FIG. 15 is a cross-sectional view showing a BB cross section in FIG. Comparing the rotary machine 100a according to the second embodiment with the rotary machine 100 according to the first embodiment, the stator 1 composed of the coil body 3 and the core 4 is changed to the stator 1a composed of the coil body 3a and the core 4a. There is. The core 4a is slotted and has teeth. The core 4a in the second embodiment has a structure of three divisions, and has a structure of being fitted from the outside of the tubular coil body 3a. By fitting the core 4a with a slot into the coil body 3a, the induced voltage of the coil body 3a becomes large, and the output of the rotary machine 100a becomes large.

FIG. 16 is a diagram showing a printed wiring board 6a according to the second embodiment. Comparing the printed wiring board 6a according to the second embodiment and the printed wiring board 6 according to the first embodiment, the printed wiring board 6a according to the second embodiment is in the portion where the dummy pattern 76 is located in the printed wiring board 6 according to the first embodiment. Then, a hole is made, and when the printed wiring board 6a is wound and formed into a tubular shape to form a coil body 3a, the tooth of the core 4a is inserted into this hole.

The method for determining θ2 when the core 4a with a slot is used is different from the method for determining θ2 when the cylindrical core 4 is used in the first embodiment. When θ2 is small, the magnetic flux density passing through the core 4a with a slot becomes high, and magnetic saturation occurs. On the other hand, when θ2 is large, the problem of magnetic saturation disappears, but since the space for arranging the wiring pattern becomes small, the cross-sectional area of the wiring pattern becomes small, the resistance value of the wiring pattern becomes large, and the copper of the wiring pattern becomes large. There is a problem that the loss becomes large, so the size of θ2 is determined in consideration of the copper loss and the iron loss.

As described above, by using the core 4a with a slot, in addition to the effect of the first embodiment, the induced voltage of the coil body 3a becomes large, and the output of the rotary machine 100a can be increased.

Although the present application describes various exemplary embodiments, the various features, embodiments, and functions described in one or more embodiments are limited to the application of the particular embodiment. Rather, it can be applied to embodiments alone or in various combinations.
Therefore, innumerable variations not exemplified are envisioned within the scope of the techniques disclosed in the present application. For example, it is assumed that at least one component is modified, added or omitted, and further, at least one component is extracted and combined with the components of other embodiments.

1, 1a stator, 2 rotor, 3, 3a coil body, 4, 4a core, 5 terminal connection, 6, 6a printed wiring board, 11 1st phase center line, 12 2nd phase center line, 13 3rd Phase center line, 14 Phase 1 boundary line, 15 Phase 2 boundary line, 16 Phase 3 boundary line, 61 Insulated substrate, 62 Front surface wiring pattern, 63 Back surface wiring pattern, 64 Insulation layer, 71 Phase 1 wiring pattern, 72 Phase 2 wiring pattern, 73 Phase 3 wiring pattern, 74 Innermost layer end wiring pattern, 75 Outermost layer end wiring pattern, 76 Dummy pattern, 81 First adhesive, 82 Second adhesive, 100, 100a rotation Machine, 200 central axis, 301 coil body, 302 coil body, 400 neutral point, 601 printed wiring board, 701 1st layer wiring pattern, 702 2nd layer wiring pattern, 703 3rd layer wiring pattern, 711th 1st phase 1st layer wiring pattern, 712 1st phase 2nd layer wiring pattern, 713 1st phase 3rd layer wiring pattern, 721 2nd phase 1st layer wiring pattern, 722 2nd phase 2nd layer wiring pattern Wiring pattern, 723 2nd phase 3rd layer wiring pattern, 731 3rd phase 1st layer wiring pattern, 732 3rd phase 2nd layer wiring pattern, 733 3rd phase 3rd layer wiring pattern, 741 innermost layer End wiring pattern, 751 Outermost layer end wiring pattern.

Claims (10)

A coil body in which a printed wiring board is wound multiple times around a central axis and formed into a cylindrical shape having a plurality of layers.
The printed wiring board is formed by arranging spiral wiring patterns constituting the coils of each phase on both the front and back surfaces of the insulating substrate along the circumferential direction when the printed wiring board is formed into a cylindrical shape.
When the printed wiring board is wound and formed into a cylindrical shape, the wiring patterns are overlapped so that the centers of the wiring patterns constituting the coils of each phase coincide with each other.
The wiring pattern that is located in the layer closest to the central axis and is located at one end of the printed wiring board to form the first phase coil is defined as the innermost layer end wiring pattern.
The wiring pattern located in the layer farthest from the central axis and located at the other end of the printed wiring board to form the second phase coil is defined as the outermost layer end wiring pattern.
The boundary line between the first phase and the second phase is defined as the first phase boundary line.
The distance from the first phase boundary line to the nearest end of the innermost layer end wiring pattern is d2.
When the distance from the first phase boundary line to the nearest end of the outermost layer end wiring pattern is d3,
The distance from the first phase boundary line to the nearest end of the wiring pattern in the layer excluding the layer closest to the central axis in the first phase, and from the first phase boundary line to the second phase. The distance to the nearest end of the wiring pattern in the layer excluding the layer farthest from the central axis is equal d1.
A coil body characterized in that at least one of d2 and d3 is larger than d1. Claim 1 is characterized in that the angle formed by the closest ends of the innermost layer end wiring pattern and the outermost layer end wiring pattern when viewed from the central axis is 10 to 30 degrees. The coil body described in. The line that bisects the angle formed by the closest ends of the innermost layer end wiring pattern and the outermost layer end wiring pattern when viewed from the central axis coincides with the first phase boundary line. The coil body according to claim 1 or 2, wherein the coil body is characterized in that. The printed wiring board has a dummy pattern electrically isolated from the wiring pattern inside the wiring pattern.
The coil body according to any one of claims 1 to 3, wherein the dummy pattern is an integral metal pattern or a divided metal pattern. The coil body according to any one of claims 1 to 4, and the coil body.
A stator characterized by having a tubular core arranged on the outside of the coil body. The coil body according to any one of claims 1 to 3 and the coil body.
A stator characterized by having a core with a slot arranged on the outside of the coil body. The layers of the printed wiring board are glued together with a first adhesive.
The stator according to claim 5 or 6, wherein the coil body and the core are adhered to each other with a second adhesive. The stator according to any one of claims 5 to 7 and the stator.
A rotary machine provided inside the stator and provided with a rotor that rotates about the central axis. The method for manufacturing a coil body according to claim 1.
The process of creating a printed wiring board to create the printed wiring board, and
An adhesive application step of applying the first adhesive to one side or both sides of the printed wiring board, and
The coil body forming process of winding the printed wiring board and forming it into a cylinder,
A method for manufacturing a coil body, which comprises an adhesive curing step of curing the first adhesive. A printed wiring board that is wound around a central axis multiple times and formed into a cylindrical coil body having multiple layers.
The spiral wiring patterns that make up the coils of each phase are arranged side by side on both the front and back sides of the insulating substrate along the circumferential direction when formed into a cylindrical shape.
The wiring pattern is arranged so that the centers of the wiring patterns constituting the coils of each phase coincide with each other when they are wound and formed into a cylindrical shape.
The wiring pattern that is located at one end of the insulating substrate and constitutes the coil of the first phase is defined as the innermost layer end wiring pattern.
The wiring pattern that is located at the other end of the insulating substrate and constitutes the second phase coil is defined as the outermost layer end wiring pattern.
The boundary line between the first phase and the second phase when formed into a tubular shape is defined as the first phase boundary line.
Let d2 be the distance from the first phase boundary line when formed into a cylindrical shape to the nearest end of the innermost layer end wiring pattern.
When the distance from the first phase boundary line when formed into a cylindrical shape to the nearest end of the outermost layer end wiring pattern is d3,
The distance from the first phase boundary line when formed into a tubular shape to the nearest end of the wiring pattern in the layer excluding the layer closest to the central axis in the first phase, and the first phase. The distance from the boundary line to the nearest end of the wiring pattern in the layer excluding the layer farthest from the central axis in the second phase is equal d1.
A printed wiring board characterized in that at least one of d2 and d3 is larger than d1.

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