JP3195750B2 - Coil and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a coil and a method for manufacturing the coil.

[0002]

2. Description of the Related Art In order to improve the magnetic coupling of a coil, there is a coil in which a composite winding in which another winding is sandwiched between a pair of spirally wound windings is one unit.

FIG. 16 is an overall perspective view showing one unit of a conventional composite winding coil, and FIG. 17 is an exploded perspective view showing one unit of the coil of FIG.

In FIGS. 16 and 17, 101, 1
02 is a pair of spiral windings wound in a spiral, 103 is 101
And another rectangular winding sandwiched between the windings 102 and 102. The winding 103 has a wire width larger than the wire diameter of the windings 101 and 102. The windings 101, 102 and 103 constitute one unit of the composite winding coil. Windings 101, 102
The end on the innermost peripheral side of the spiral portion extends over the respective spiral portions and extends outward from the outermost peripheral portion of the spiral portion, and its ends 101a and 102a are joined.

When one unit of the above-described composite winding coil is connected in series and used, an end portion 101 of each winding is used.
b, 102b, 103a and 103b are connected in series with the ends of the other unit winding.

When manufacturing one unit of the composite winding coil, each winding 10 constituting one unit of the composite winding coil is used.
1, 102 and 103 are separately manufactured, and the winding 103 is sandwiched between the windings 101 and 102.
01a and 102a are joined.

[0007]

However, the winding 1
Since the innermost peripheral ends of the spiral portions 01 and 102 extend over the respective spiral portions and extend outward from the outermost peripheral portions of the spiral portions, the thickness of one unit of the above-described composite winding coil is equal to that of the wound portion. Line 1
01 and twice the wire diameter of the winding 102 and the winding 10
3, which is an obstacle to the demand for compactness.

After the windings 101, 102, and 103 are separately manufactured, the winding 103 is connected to the windings 101 and 102.
Since the end portions 101a and 102a need to be joined after that, there is a problem that the number of steps and the cost are high for manufacturing.

The present invention takes into account the problem that the thickness of such a conventional composite coil is large and the number of steps required to manufacture the composite coil is small, and the composite coil is compact and can be manufactured at low cost, and a method of manufacturing the composite coil. The purpose is to provide.

[0010]

In order to solve the above-mentioned problems, a coil according to the present invention comprises one winding having two opposing spirals and another winding sandwiched between the two spirals. a book of the winding, two of the spiral portion of the single winding,
Inside the other winding, the innermost peripheral edges are connected together.
Coil.

[0011] The coil manufacturing method of the present invention is characterized in that a thickness of the one winding is set between a pair of first and second sandwiching members installed facing each other with an interval in consideration of a slight play. With the same outer diameter as the inner diameter of the innermost part of the spiral part of the one winding,
By winding the conductive wire around the shaft passing through the pair of first and second sandwiching members in a state where the inner conductive wire end is released,
Producing one spiral part of the one winding, removing the second sandwiching member, and forming the shaft, the shaft and the end of the conductor at the innermost periphery of the another winding separately manufactured. And inserting a third sandwiching member into the shaft, fixing the distance between the first and third sandwiching members so as to be an interval taking into account some play in the thickness of the coil, The other spiral part of the one winding is manufactured by winding an end of a conductive wire around the shaft.

[0012]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is an overall perspective view showing one unit of a coil according to one embodiment of the present invention, FIG. 2 is an exploded perspective view showing one unit of the coil of FIG. 1, and FIG. FIG.
FIG. 3 is a cross-sectional view taken along the line AA of FIG.

In FIGS. 1, 2 and 3, the main winding 1
Is a single round conductor having two spiral portions 1a and 1b, and the sub winding 2 is a flat rectangular wire sandwiched between the spiral portions 1a and 1b. The main winding 1 and the sub winding 2 are subjected to insulation coating. The sub winding 2 has a wire width larger than the wire diameter of the main winding 1 and has a spiral shape three-dimensionally wound in the rotation axis direction. The main winding 1 and the sub winding 2 constitute one unit of the composite winding coil. The rotation axes of the spiral portions 1a, 1b and the sub winding 2 are substantially the same, and the innermost peripheral edge of the spiral portions 1a, 1b is one line of the main winding 1 from the innermost peripheral edge of the sub winding 2. It exists only inside the diameter. Further, the innermost peripheral edges of the spiral portions 1a and 1b are connected by a connecting portion 1c, and the connecting portion 1c is in contact with the innermost peripheral edge of the sub winding 2. The thickness of one unit of the composite winding coil is determined by the thickness of the spiral part 1a and the spiral part 1a.
The thickness is substantially equal to the sum of the thickness b and the thickness of the sub winding 2.

When a plurality of units of the composite winding coil are connected in series and used, the end portions 1d, 1d,
1e, 2a and 2b are connected in series with the ends of the other unit winding. In the above-described embodiment, the main winding 1 is a round conductor, and the sub winding 2 is a rectangular conductor. However, the present invention is not limited to this, and both the main winding 1 and the sub winding 2 may be round conductors or flat conductors. Or it may be.

In the above-described embodiment, the main winding 1 is formed in a spiral shape. However, the present invention is not limited to this.

In the above-described embodiment, the auxiliary winding 2 has a spiral shape three-dimensionally wound in the direction of the rotation axis. However, the present invention is not limited to this. Alternatively, a rectangular spiral wound three-dimensionally in the rotation axis direction may be used.

Next, a first embodiment of the present invention will be described with reference to the drawings.

This embodiment is a manufacturing method for manufacturing one unit of a coil as one embodiment of the first aspect of the present invention.

First, a coil manufacturing apparatus used in the coil manufacturing method of the present invention will be described.

FIG. 4 is a partial side view of a coil manufacturing apparatus used in a coil manufacturing method according to a ninth embodiment of the present invention (at the time of manufacturing a spiral portion on one side of a main winding). FIG. 5 is a cross-sectional view taken along the line BB of FIG. 4, and FIG. 6 is a partial side view of the coil manufacturing apparatus used in the coil manufacturing method according to the ninth embodiment of the present invention. During the process of manufacturing another helical part of the main winding with opposing parts).

In the main part of the present coil manufacturing apparatus which winds the winding, a first sandwiching member 3 having a main winding one end fixing portion 9 is provided on one side, and is opposed to the first sandwiching member 3. A second sandwiching member 4 having an escape groove 6 is provided movably. The shaft 5 passes through the first sandwiching member 3 and the second sandwiching member 4, and the first sandwiching member 3 is fixed to the shaft 5. The second pinching member 4 can be fixed to the shaft 5 by inserting a single fixing bolt or the like into the positioning hole 7 of the second pinching member 4 and the positioning hole 8 of the shaft 5.

The outer diameter of the shaft 5 is equal to the helical portions 1a, 1b of the main winding 1.
Has the same size as the inner diameter of the innermost peripheral portion of. Escape groove 6
Is a surface 4a of the second sandwiching member 4 facing the first sandwiching member 3.
In addition, it is dug as shown in FIG. d1 and b1 represent the depth and width of the relief groove 6, respectively, and are both dimensions in which the wire diameter of the main winding 1 is considered with some play.

D1 shown in FIG. 4 represents the distance between the opposing surfaces of the first sandwiching member 3 and the second sandwiching member 4 during the step of manufacturing the spiral portion 1a on one side of the main winding 1, and The size of the wire 1 is determined in consideration of a slight play in the wire diameter. At this time,
The second sandwiching member 4 is inserted into the shaft 5 such that the surface of the second sandwiching member 4 facing the first sandwiching member 3 is the surface 4a where the escape groove 6 is dug.

D2 shown in FIG. 6 represents the distance between the opposing surfaces of the first sandwiching member 3 and the second sandwiching member 4 during the step of manufacturing another spiral portion 1b of the main winding 1. The dimensions of one unit of the coil according to the first embodiment of the present invention are set in consideration of a slight play. At this time, the surface of the second sandwiching member 4 facing the first sandwiching member 3 is a surface 4b on which the relief groove 6 is not dug.
The second sandwiching member 4 is inserted into the shaft 5.

Therefore, the positions of the positioning hole 7 of the second holding member 4 and the positioning hole 8 of the shaft 5 are different from those of the first holding member 3.
The distance between the opposing surfaces of the first and second sandwiching members 4 is determined to be D1 in FIG. 4 and D2 in FIG.

Next, a coil manufacturing method according to a first embodiment of the present invention will be described with reference to the drawings.

FIG. 7 is a partial side view of a coil according to a first embodiment of the ninth embodiment of the present invention (at the time of manufacturing a spiral portion on one side of a main winding), and FIG. 9 is a cross-sectional view taken along the line CC of FIG. 9, FIG. 9 is a local cross-sectional view taken along the line DD of FIG. 8, and FIG. FIG. 11 is a cross-sectional view taken along the line EE in FIG. 10, and FIG. 12 is a cross-sectional view taken along the line FF in FIG. 11 (at the time of manufacturing another spiral portion of the main winding in which the one-sided helical portion faces). It is a local sectional view.

First, on the outer peripheral side of the second sandwiching member 4, the main winding 1
The main winding 1 is fitted into the relief groove 6 and fixed so as to leave a wire portion long enough to manufacture the spiral portion 1b and the end portion 1e. The second sandwiching member 4 to which the main winding 1 is fixed is inserted into the shaft 5 such that the surface 4a where the escape groove 6 is dug faces the first sandwiching member 3, and the second sandwiching member 4 is positioned. Hole 7
And, it is fixed by inserting one fixing bolt into the positioning hole 8 of the shaft 5. In this state, the main winding 1 is wound around the shaft 5 in the gap between the first sandwiching member 3 and the second sandwiching member 4 in the direction of W1 in FIG.
a is manufactured (see FIGS. 8 and 9). After the designed number of turns, the remaining end 1d is fixed to the main winding end fixing portion 9 as shown in FIG.
And fix it.

Next, after removing the fixing bolt and removing the second pinching member 4 from the shaft 5 while removing the main winding 1 from the relief groove 6, the diameter of the inner hole is larger than the outer diameter of the shaft 5. The conductor and the shaft 5 on the end 1e side of the main winding 1 are inserted into the inner hole of the sub winding 2 separately manufactured so as to be larger by the wire diameter of the winding 1. In this state, the second pinching member 4 is inserted into the shaft 5 such that the surface 4b on which the escape groove 6 is not dug is opposed to the first pinching member 3, and the positioning hole 7 of the second pinching member 4 is formed.
And, it is fixed by inserting one fixing bolt into the positioning hole 8 of the shaft 5. As a result, the helical portion 1a, the connecting portion 1c of the main winding and the sub winding 2, and the conducting wire on the end 1e side of the main winding 1 are arranged in this order from the first sandwiching member 3 side. And the second sandwiching member 4 is sandwiched in the gap. In this state, the helical portion 1b is manufactured by winding the end of the main winding 1 not wound around the one end fixing portion 9 around the shaft 5 in the direction of W2 in FIG. (Figure 1
1, 12). After winding the designed number of times, pull out the fixing bolt, remove the second pinching member 4 from the shaft 5,
After removing the end 1 d of the main winding from the one end fixing portion 9 of the main winding, the main winding 1 and the sub winding 2 are extracted from the shaft 5, and FIG.
One unit of the composite winding coil as shown in FIG.

Although the sectional shape of the sub winding 2 is as shown in FIG. 3, it is simplified and represented by a rectangle in the drawing for explaining the present coil manufacturing apparatus.

In the coil manufacturing apparatus used in the coil manufacturing method according to the ninth embodiment of the present invention, the main winding 1 is connected to the shaft 5 to manufacture the spiral portions 1a and 1b. However, the main winding may be wound by rotating the shaft 5. Alternatively, the configuration may be such that the shaft 5 is rotated and the main winding 1 is rotated in the opposite direction and wound.

In the above-described coil manufacturing apparatus, the cross section of the shaft 5 is circular. However, the present invention is not limited to this. If the inner peripheral shape of the main winding 1 is elliptical, square, or the like, the shape is adjusted to that. May be.

Next, a second embodiment of the present invention will be described with reference to the drawings.

As in the first embodiment, this embodiment is a method of manufacturing one unit of a coil according to one embodiment of the present invention. Structures and operations that are not described below are not described because they are similar to those of the first embodiment. Therefore,
As for the drawings relating to the present embodiment, only the drawings for explaining those different from the structure and operation of the first embodiment are shown.

FIG. 13 is a partial side view of a coil manufacturing apparatus used in a coil manufacturing method according to a ninth embodiment of the present invention (at the time of manufacturing a spiral portion on one side of a main winding).
FIG. 14 is a cross-sectional view taken along the line GG in FIG. 13, and FIG. 15 is a partial side view in a coil manufacturing state according to the second embodiment of the ninth embodiment of the present invention. Manufacturing process).

The main portion of the present coil manufacturing apparatus for winding the winding is provided with a first sandwiching member 3 having a main winding one end fixing portion 9 on one side. The two sandwiching members 40 are provided movably. The shaft 5 penetrates the first holding member 3 and the second holding member 40, and the first holding member 3 is fixed to the shaft 5. The second pinching member 40 is a relief hole 1 along the through hole 11 through which the shaft 5 passes.
0 and a positioning hole 7 at a position not intersecting with the escape hole 10. The second sandwiching member 40 can be fixed to the shaft 5 by inserting one fixing bolt or the like into the positioning hole 7 of the second sandwiching member 40 and the positioning hole 8 of the shaft 5. d2 and b2 represent the depth and width of the relief hole 10, respectively, and are both dimensions in which the wire diameter of the main winding 1 is considered with some play. Other structures are the same as those of the first embodiment.

Next, a coil manufacturing method according to a second embodiment of the present invention will be described.

First, on the side of the second sandwiching member 4 opposite to the surface facing the first sandwiching member 3, the spiral portion 1b and the end 1 of the main winding 1 are provided.
The main winding 1 is inserted into the relief hole 10 from the surface facing the first sandwiching member 3 and fixed so as to leave a wire portion having a length sufficient to manufacture the e. The second pinching member 4 to which the main winding 1 is fixed is inserted into the shaft 5 such that the entrance side surface of the escape hole 10 faces the first pinching member 3, and the positioning hole 7 of the second pinching member 4 is inserted. And, it is fixed by inserting one fixing bolt into the positioning hole 8 of the shaft 5. In this state, the spiral portion 1a is manufactured by winding the main winding 1 around the shaft 5 in the direction of W1 in FIG. 8 in the gap between the first sandwiching member 3 and the second sandwiching member 4. After winding the designed number of times, the remaining end 1d is wound around the one end fixing portion 9 of the main winding and fixed.
Next, the second holding member 40 is removed from the shaft 5 while removing the fixing bolt and removing the main winding 1 from the relief hole 10. Subsequent steps are the same as those in the first embodiment.

In the coil manufacturing apparatus used in the coil manufacturing method as the second embodiment of the ninth embodiment of the present invention, the relief hole 10 has the second pinch along the through hole 11 through which the shaft 5 passes. Although it penetrates the member 4, the entrance of the escape hole 10 is not limited to this, and the first pinching member 3 of the second pinching member 40
If the surface 40a opposed to the second holding member 40 is opened, it may be bent in the middle and an outlet may be provided on the outer peripheral surface of the second sandwiching member 40. Alternatively, the length of the escape hole 10 is the spiral portion 1b and the end portion 1e.
Need not be penetrated if it is long enough to leave an end long enough to produce

[0041]

As is clear from the above description,
According to the first aspect of the present invention, it is possible to provide a coil in which the thickness of one unit of the coil is small and the number of steps required for manufacturing is small. The present invention according to claim 9 can provide a coil manufacturing method for manufacturing the coil with less man-hours.

[Brief description of the drawings]

FIG. 1 is an overall perspective view showing one unit of a coil according to one embodiment of the present invention.

FIG. 2 is an exploded perspective view showing one unit of the coil shown in FIG. 1;

FIG. 3 is a sectional view taken along the line AA of FIG. 1;

FIG. 4 is a partial side view of a coil manufacturing apparatus used in a coil manufacturing method according to a first embodiment of the present invention (at the time of manufacturing a spiral portion on one side of a main winding).

FIG. 5 is a sectional view taken along the line BB of FIG. 4;

FIG. 6 is a partial side view of a coil manufacturing apparatus used in a coil manufacturing method according to a ninth embodiment of the present invention (another helical portion of a main winding in which the helical portion on one side is opposed); During the manufacturing process)

FIG. 7 is a partial side view in a coil manufacturing state according to the first embodiment of the present invention (at the time of manufacturing a spiral portion on one side of a main winding).

FIG. 8 is a sectional view taken along the line CC of FIG. 7;

9 is a local cross-sectional view taken along a line DD in FIG. 8;

FIG. 10 is a partial side view of the coil according to the first embodiment of the ninth embodiment of the present invention in a state in which another spiral portion of the main winding is opposed to the one spiral portion. )

11 is a cross-sectional view taken along the line EE in FIG. 10;

FIG. 12 is a local cross-sectional view taken along the line FF of FIG. 11;

FIG. 13 is a partial side view of a coil manufacturing apparatus used in a coil manufacturing method according to a ninth embodiment of the present invention (at the time of manufacturing a spiral portion on one side of a main winding).

14 is a cross-sectional view taken along a line GG of FIG.

FIG. 15 is a partial side view in a coil manufacturing state according to a second embodiment of the present invention (at the time of manufacturing a spiral portion on one side of a main winding).

FIG. 16 is an overall perspective view showing one unit of a conventional composite winding coil.

FIG. 17 is an exploded perspective view showing one unit of the coil shown in FIG. 16;

[Explanation of symbols]

D1 Distance between opposing sandwiching members (during the process of manufacturing spiral portion 1a) D2 Distance between opposing sandwiching members (during the process of manufacturing spiral portion 1b) d1, b1 Depth and width of relief groove 6 d2, b2 Relief Depth and width of hole 10 1 Main winding 1a, 1b Spiral part of main winding 1c Connection part of main winding 1d, 1e End of main winding 2 Sub winding 2a, 2b End of sub winding 3 First sandwiching member 4 Second sandwiching member 5 Shaft 6 Relief groove 7 Positioning hole of second sandwiching member 4 8 Positioning hole of shaft 5 9 Main winding one end fixing portion

────────────────────────────────────────────────── ─── Continuation of front page (56) References JP-A-3-270107 (JP, A) JP-A-4-137505 (JP, A) JP-A-5-243036 (JP, A) JP-A-5-230 326290 (JP, A) JP-A-7-235426 (JP, A) JP-A-6-215962 (JP, A) JP-A-4-196507 (JP, A) JP-A-6-36960 (JP, A) JP-A-9-320881 (JP, A) JP-A-7-3120 (JP, U) JP-A-6-86311 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) H01F 5/00 H01F 27/28-27/30 H01F 41/00-41/06

Claims (9)

(57) [Claims] 1. A and one winding having two spiral portions facing, and a other single windings sandwiched by the two spiral portions, two of the spiral of the single winding The part is the other one winding
A coil , wherein the innermost peripheral portions are connected to each other inside the wire. 2. The coil according to claim 1, wherein the two spiral portions of the one winding have the same rotation axis. 3. The coil according to claim 1, wherein the two spiral portions of the one winding and the another winding have the same rotation axis. 4. The coil of claim 1, wherein the thickness of the coil is the sum of the total thickness of said other one of the windings of the thickness of the spiral portion of the single winding. 5. The method according to claim 1, wherein the innermost peripheral edge of the one winding is located inside the innermost peripheral edge of the another winding by the wire diameter of the one winding. The coil according to claim 1, 3 or 4 . 6. The winding of said one winding between a pair of first and second sandwiching members installed facing each other with an interval in consideration of slight play in the thickness of said one winding. By providing an outer diameter that is the same as the inner diameter of the innermost peripheral portion of the spiral portion, and winding the conductive wire around a shaft that has penetrated the pair of first and second sandwiching members with the inner conductive wire end escaped, Manufacture one spiral part of this winding, remove the second sandwiching member, insert the shaft and the end of the conducting wire into the innermost periphery of the other one winding separately manufactured, Insert a third sandwiching member into the shaft, first,
The distance between the third sandwiching members is fixed so as to be a distance in consideration of a slight play in the thickness of the coil, and the other end of the one winding is formed by winding the end of the conductive wire around the shaft. The spiral part of the above is manufactured .
A coil manufacturing method for manufacturing the coil according to 4 or 5 . 7. The method of manufacturing a coil according to claim 6, wherein said end portion of said conductive wire is fitted in a groove dug in a facing portion of said second sandwiching member and released. 8. The coil manufacturing method according to claim 6, wherein the end portion of the conductive wire is inserted into a hole formed in the axial direction of the second sandwiching member and escaped. 9. The coil manufacturing method according to claim 6 , wherein said third sandwiching member is said second sandwiching member.