JP3013972B2 - Manufacturing method of flat air core coil - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a flat air-core coil applicable to a thin motor or the like.

[0002]

2. Description of the Related Art A flat air-core coil is known as a coil used for a thin motor or the like. Such a flat air-core coil is usually formed by the following procedure. First, a laminated body is formed by forming an insulating layer on the surface of a sheet-shaped conductor foil, and after winding this laminated body a plurality of times along the outer periphery of a rod-shaped core (not shown), a predetermined shape is formed, By pulling out the rod-shaped core, the wound body 3 is obtained as shown in FIG. The cross-sectional shape of the wound body 3 is formed into a trapezoidal shape by molding, and a trapezoidal hole 3a is formed in the center of the wound body 3 by pulling out a rod-shaped core. On the inner surface of the hole 3a, a winding start end 4 when the laminate is wound is located.

Next, the wound body 3 is cut by a wire saw 8 or a dicing saw as shown in FIG. 5 in a direction orthogonal to the direction of the hole 3a, so that an air core as shown in FIG. A coil 1 is obtained. In the air-core coil 1, the insulating layers near the winding start end 4 located on the inner peripheral surface of the hole 3a and near the winding end located on the outer peripheral surface (not shown) are peeled off, and the electrodes 9, 9 'are separated. Is formed.

[0004]

According to the above-described conventional method of manufacturing a flat air-core coil, when the wound body 3 is cut, the winding start end formed on the inner peripheral surface of the hole 3a by stress. 4 may be loosened, and as shown in FIG. 7, a defective air-core coil 1 in which the winding start end 4 is separated from the coil body.
Had occurred many times. Such an air-core coil 1 from which the winding start end 4 is separated is difficult to electrically connect to a substrate or the like, and is not suitable for use.

As a method for preventing the winding start end 4 from being loosened and separated by the stress at the time of cutting, there is a method of reinforcing the inner peripheral surface of the hole 3a with a reinforcing plate 11, as shown in FIG. This method is described in JP-A-63-220735. However, the use of the reinforcing plate 11 can eliminate the loosening and separation of the winding start end 4, but on the other hand, it takes a long time to wind the laminate 3 and the reinforcing process of the winding start end 4. It was not a practical solution.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems of the prior art, and has as its object to provide a method of manufacturing a flat air-core coil in which the winding start end is not loosened.

[0007]

According to the first aspect of the present invention,
The laminate the conductor foils formed of an insulating layer is wound around a core of the wound body
Form and pull out the core from this wound body, core is pulled out
The winding starting end located on the inner peripheral surface of he was wound body after covering with an adhesive, characterized by cutting the wound body to a predetermined thickness.

The invention according to claim 2 is characterized in that a dispenser is inserted into the hole of the laminate, a liquid adhesive is applied from the tip of the dispenser, and the winding start end is covered with the adhesive.

The invention according to claim 3 is characterized in that after a film-like adhesive is inserted into the hole of the laminate, the adhesive is heated and melted to cover the winding start end.

The invention according to claim 4 is characterized in that after inserting a rod-shaped adhesive into the hole of the laminate, the adhesive is heated and melted to cover the winding start end.

[0011]

[Function] An adhesive covers the winding start end of the wound laminate,
Further, in order to reinforce, the flat air core coil is manufactured without the winding start end being loosened at the time of cutting.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for manufacturing a flat air-core coil according to the present invention will be described with reference to the drawings. Note that the basic manufacturing method of the flat air-core coil is the same as that of the conventional example, so that the description is omitted here, and the reinforcement of the winding start end is mainly described.

In FIG. 1, a winding body 3 formed by winding a laminate composed of a sheet-like conductor foil and an insulating layer covering one surface of the conductor foil a predetermined number of times has a hole 3a in the center. ing. The winding direction of the laminate is a direction orthogonal to the paper surface in FIG. The hole 3a is formed by pulling out a core used for winding the laminate, and the winding start end 4 of the laminate is located on the inner peripheral surface. The dispenser 6 is inserted into such a hole 3a of the wound body 3. The inserted dispenser 6 is moved from the end located at the innermost position of the hole 3a to the end on the insertion port side while discharging the liquid adhesive 5 from the end. By doing this,
The winding start end 4 on the inner peripheral surface of the hole 3a is entirely covered with the adhesive 5, and the adhesive 5 hardens to reinforce the winding start end 4. Thereafter, the wound body 3 is cut at a predetermined length in a direction orthogonal to the length direction. In this way, by reinforcing the winding start end 4 with the adhesive 5 released from the dispenser 6, even if the wound body 3 is cut into a predetermined thickness to form a flat air-core coil, the winding start end 4 The part 4 is not loosened and separated. Therefore, the yield can be dramatically improved. In addition, since the reinforcing process of the winding start end portion 4 with the adhesive 5 using the dispenser 6 is performed on the wound body 3 after winding the laminate, it is inexpensive and may cause a rise in cost. Absent. Further, if the adhesive 5 is colored in advance, when the wound body 3 is cut to form a flat air-core coil, it becomes a mark for knowing the electrode position of the coil,
It is possible to reduce mounting errors on the substrate.

If the diameter of the hole 3a of the wound body 3 is reduced, the dispenser 6 cannot be inserted, or a liquid pool 5a is formed in the adhesive 5 as shown in FIG. In some cases, it may not be possible to arrange a magnetic sensor or the like of a brushless motor in the hole 3a. In order to solve such a problem, as shown in FIG. 3A, a film-like adhesive 7 which melts when heat is applied, such as a prepreg, may be used without using the dispenser 6. That is, the film-shaped adhesive 7 is inserted into the hole 3a and overlapped on the winding start end 4, and the wound body 3 is heated in this state. By doing so, the film-like adhesive 7 melts and covers the winding start end portion 4, and is cooled and hardened, whereby the winding start end portion 4 can be reinforced and the loosening and separation at the time of cutting can be prevented. Can be. Further, since the adhesive 7 is in the form of a film, no liquid pool is generated, and therefore, the hole 3a is not completely closed. Further, instead of using the film adhesive 7, FIG.
A stick-shaped adhesive 10 as shown in (b) may be used. As in the case of the film-like adhesive 7, it is melted by heating to cover the winding start end 4, so that the winding start end 4 is reinforced and loosening and separation at the time of cutting can be eliminated.

[0015]

According to the first aspect of the present invention, the conductive foil and
A laminated body made of an insulating layer is wound around a core to form a wound body,
The core is pulled out of the wound body, and the core is pulled out.
After covering the winding start end located on the inner peripheral surface of the winding body with an adhesive, cutting the wound laminated body to a predetermined thickness, to obtain a flat air-core coil with no loosening of the winding start end. Becomes possible.

According to the second aspect of the present invention, a dispenser is inserted into the hole of the laminated body, a liquid adhesive is applied from the tip of the dispenser, and the winding start end is covered with the adhesive. According to the method, it is possible to obtain a flat air-core coil having no loosening at the winding start end.

According to the third aspect of the present invention, since a film-like adhesive is inserted into the hole of the laminated body and then heated and melted and the winding start end is covered with the adhesive, the coil having a small hole diameter can be used. It is possible to obtain a flat air-core coil in which the hole is not closed by the adhesive and the winding start end is not loosened.

According to the fourth aspect of the present invention, the rod-shaped adhesive is inserted into the hole of the laminate, and then heated and melted to cover the winding start end with the adhesive. It is possible to obtain a flat air-core coil that is not blocked by the adhesive and has no looseness at the winding start end.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an example of one step of a method for manufacturing a flat air-core coil according to the present invention.

FIG. 2 is a cross-sectional view showing an example of a method of manufacturing a flat air-core coil according to the present invention in a case where a hole of a wound body is closed with an adhesive.

FIGS. 3A and 3B are perspective views showing an example of one process in which a sheet-like adhesive is used and a bar-like adhesive is used, wherein FIG. 3B is applicable to the method of manufacturing a flat air-core coil according to the present invention. .

FIG. 4 is a cross-sectional view showing an example of one process of a conventional method for manufacturing a flat air-core coil.

FIG. 5 is a sectional view showing an example of one step of the manufacturing method of the flat air-core coil.

FIG. 6 is a perspective view showing an example of the flat air-core coil of the embodiment.

FIG. 7 is a perspective view showing another example of a conventional flat air-core coil.

FIG. 8 is a perspective view showing still another example of the conventional flat air-core coil.

[Explanation of symbols]

 4 Winding end 5 Adhesive 6 Dispenser 7 Film adhesive 10 Rod adhesive

──────────────────────────────────────────────────続 き Continuation of front page (56) References JP-A-61-85807 (JP, A) JP-A-63-293807 (JP, A) JP-A-4-322148 (JP, A) JP-A-5-85 207710 (JP, A) Japanese Utility Model 1987-41044 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) H02K 15/04 H02K 3/04 H01F 41/04

Claims (4)

(57) [Claims] We claim: 1. The conductor foil and laminate consisting of an insulating layer wound <br/> times the core to form a wound body, pull the core from the winding body unplug
After covering the winding start end located on the inner peripheral surface of the wound body from which the core has been pulled out with an adhesive, the flat wound core coil is characterized in that the wound body is cut to a predetermined thickness. Production method. 2. Inserting a dispenser into a hole of the laminate,
Apply liquid adhesive from the tip of this dispenser,
The method for manufacturing a flat air-core coil according to claim 1, wherein the winding start end is covered with an adhesive. 3. The method for producing a flat air-core coil according to claim 1, wherein a film-shaped adhesive is inserted into the hole of the laminate, and then heated and melted to cover the winding start end with the adhesive. 4. The method of manufacturing a flat air-core coil according to claim 1, wherein a rod-shaped adhesive is inserted into the hole of the laminate, and then heated and melted to cover the winding start end with the adhesive.