JP4474426B2 - Coil forming method and coil manufactured by the method - Google Patents

Description

  The present invention relates to a method of forming a coil as an electronic component and a coil manufactured by the method, and more particularly to a method of forming a coil suitable for use as a reactor and a coil manufactured by the method.

  A coil of a rotary motor formed by edgewise winding in which a strip (flat wire) of a flat conductor is bent and wound in the width direction of the strip has been proposed. The coil includes a first bent portion that is bent and a second bent portion that is disposed adjacent to the coil stacking direction of the first bent portion, and the first bent portion and the second bent portion. The positions of the inner portions of the flat conductors are arranged so as to be shifted from each other in the plane direction of the flat conductor. The coil includes a first step of winding a strip of a flat conductor along a combination of some of the divided portions of the bending mold having a plurality of adjacent divided portions, and any one of the plurality of divided portions. It is manufactured by repeating the second step of winding a strip of flat conductors along one or a combination of some of the divisions in a different combination than the first step. According to such a coil, the swelling in the coil stacking direction is reduced, and the coil dimension can be reduced. Moreover, the insulation fall between coil wires is prevented and the reliability of a coil improves. Furthermore, since a step in the stacking direction is formed on the outer periphery of the coil and functions as a heat radiating fin, the heat radiating effect of the coil is improved, and the temperature rise of the coil can be prevented (for example, see Patent Document 1).

JP-A-2005-304244

  Since the conventional coil described above is manufactured by a bending die in which a plurality of divided portions are combined, the shift position between the first bent portion and the second bent portion, that is, the step position in the stacking direction formed on the outer periphery of the coil. When it is desired to change, it is necessary to change the combination of the division parts or to manufacture a new division part, which causes a problem that the troublesome labor and cost increase. Moreover, although the conventional coil mentioned above is used for a rotary electric motor, when using for a reactor, for example, it may be necessary to use a coil having two coil elements, and the bending mold is more complicated. There is a problem that the structure is complicated and the labor and cost increase.

  The objective of this invention is providing the technique which can form the level | step difference of a lamination direction in the arbitrary positions of a coil outer periphery simply and at low cost.

The present inventor has produced a novel coil forming method capable of easily and inexpensively forming a step in the stacking direction at an arbitrary position on the outer periphery of a coil formed by edgewise winding a rectangular wire. I found a coil. In other words, in order to achieve the above object, the coil forming method of the present invention is characterized in that a single rectangular wire is square-wound in an edgewise manner so as to be stacked in a square tube shape and at least the first and second coil elements. Are coils that are continuously formed so that the winding directions are opposite to each other in a parallel state, and the first winding head and the first winding head are spaced apart from each other by a predetermined distance. In the method of forming a coil, the first and second coil elements are continuously formed from the one rectangular wire using a second winding head provided at a distance.
The rectangular wire having a length necessary for winding of the first coil element and the second coil element is prepared, and the rectangular wire is arranged from the second winding head side to the first winding head side. A flat wire first feeding step in which the flat wire is set to a state where the leading end of the flat wire protrudes from the first winding head by a predetermined length;
The rectangular wire is wound up to a predetermined number of turns of the first coil element so that a step in the stacking direction can be formed at an arbitrary position on the outer periphery of the first coil element using the first winding head. Winding the first coil element to form the first coil element;
A second step of feeding a rectangular wire having the first coil element formed at the tip thereof again from the second winding head side to the first winding head side;
Forming the first coil element by bending the entire first coil element to set the first coil element in a predetermined posture state; and
A third feeding step of a rectangular wire material that further feeds the rectangular wire material from the second winding head side to the first winding head side in order to secure the winding amount of the second coil element;
The rectangular wire is wound up to a predetermined number of turns of the second coil element so that a step in the stacking direction can be formed at an arbitrary position on the outer periphery of the second coil element using the second winding head. And winding the second coil element to form the second coil element.

According to such a configuration, it is possible to stack at any position on the outer periphery of the first coil element and the outer periphery of the second coil element only by changing the feed position of the flat wire to the first winding head and the second winding head. Since a step in the direction can be formed, the coil applicable particularly to the reactor can be manufactured easily and at low cost.

In the winding process of the first coil element and the winding process of the second coil element, the step is formed on the open surface side of the first coil element and the second coil element. To do.

With this configuration, since the bottom surfaces of the first coil element and the second coil element can be brought into close contact with the bottom surface of the heat conductive case, for example, the first coil element and the second coil element Heat generation can be efficiently conducted to the heat conductive case to cool the first coil element and the second coil element.

In order to achieve the above object, the coil of the present invention is manufactured by the above-described method for forming each coil.

According to this configuration, it is possible to provide a coil that exhibits the above-described effects.

Further, the first and second coil elements manufactured by the above coil forming method are in a parallel state, and the coil is continuously formed so that the winding directions are opposite to each other. It was stored in the reactor case made.

According to this configuration, in addition to the above-described effects, the dead space of the reactor case with a predetermined dimensional size is reduced, and the reactor case can be stored in a smaller volume case.

According to the present invention, it is possible to stack at any position on the outer periphery of the first coil element and the outer periphery of the second coil element only by changing the feed position of the rectangular wire to the first winding head and the second winding head. Since the step in the direction can be formed, the coil applicable particularly to the reactor can be manufactured easily and at low cost, and the cost of the coil itself can be kept low.

  A coil according to an embodiment of the present invention will be described in detail with reference to the drawings. In the present embodiment, the coil of the present invention is applied to a reactor coil (hereinafter referred to as a reactor coil). FIG. 1 is a perspective view of a reactor as an example including a reactor coil according to an embodiment of the present invention, and FIG. 2 is an exploded perspective view of the reactor shown in FIG. The reactor 10 is used, for example, in an electric circuit of a device having forced cooling means, and includes a reactor coil 12, a reactor core 9, a bobbin 4, a heat conductive case 1, an insulating and heat radiating sheet 7, and the like. As shown in FIG. 1, the reactor 10 has a structure in which a reactor core 9 is inserted into a reactor coil 12, these are accommodated in a heat conductive case 1, and a filler 8 is poured and fixed. . The reactor fixing holes 13 at the four corners of the heat conductive case 1 are screw holes for fixing the heat conductive case 1 to, for example, a forcedly cooled housing.

  As shown in FIG. 1, the reactor coil 12 includes a first coil element 121 and a second coil element 122 that are formed in a rectangular tube shape by winding a single rectangular wire 17 in an edgewise manner. It has. Here, winding in an edgewise manner means a method of winding the flat wire 17 vertically. Square winding refers to winding a coil in a square shape, and is contrasted with winding a coil in a round shape (round winding). And although the details will be described later, the first coil element 121 and the second coil element 122 of the reactor coil 12 are arranged on the outer periphery of the coil, that is, in the present embodiment, the opposing surfaces of the first coil element 121 and the second coil element 122 and each Steps in the stacking direction (shown in FIGS. 3C and 3D) are surrounded by open lines (upper surfaces 121U and 122U and side surfaces 121S and 122S shown in FIG. 3B) excluding the bottom surfaces of the coil elements 121 and 122. The portions ST11, ST12, ST21, ST22) are formed. That is, the reactor coil 12 of the present embodiment is formed such that the rectangular shape of the flat wire 17 constituting the first coil element 121 is alternately repeated at every two turns in two different sizes. Similarly, the rectangular shape of the rectangular wire 17 constituting the second coil element 122 is also formed to be alternately repeated at every two turns with two different sizes.

  Thereby, since the surface area which the 1st coil element 121 and the 2nd coil element 122 touch outside air increases, a cooling effect increases, and it can improve the thermal radiation performance of the reactor coil 12. FIG. In addition, since the distance between the lead portions 121L and 122L and the reactor core 9 can be set to a distance that maintains insulation (hereinafter referred to as an insulation distance), for example, the rectangular wires 17 constituting the lead portions 121L and 122L Even when the coating is peeled off and the conductor is exposed, and a crimp terminal (not shown) is provided to connect to other electrical components, insulation is achieved without assembling an insulating member between the lead portions 121L and 122L and the reactor core 9. Can keep.

  As shown in FIG. 2, the reactor core 9 is composed of two magnetic blocks 3a, six magnetic blocks 3b, and eight sheets 6 inserted as magnetic gaps between the blocks 3b. ing. The shape of the reactor anchor 9 is a substantially ring shape in which two linear portions constituted by the block 3b and the sheet material 6 and the block 3a are coupled. As shown in FIG. 2, the bobbin 4 includes a partition portion 4a and a winding frame portion 4b, and has a structure in which the partition portion 4a and the winding frame portion 4b can be separated from the viewpoint of improving work efficiency.

  The assembly procedure of the reactor 10 having such a configuration is as follows. First, the reactor coil 12 is formed, then the winding frame portion 4b is inserted into the reactor coil 12, and the partition portions 4a are fitted from both ends of the winding frame portion 4b. And the block 3b and the sheet material 6 which comprise the linear part of the reactor core 9 are inserted in the winding frame part 4b, and the block 3a and the sheet material 6 are adhere | attached. Thus, since the reactor coil 12 is formed in each linear part of the reactor core 9 via the winding frame part 4b, predetermined electrical characteristics can be obtained. Further, since the block 3a of the reactor core 9 is bonded to each linear portion of the reactor core 9 via the sheet material 6, the block 3a is structured not to be detached.

  Next, after the insulating and heat radiation sheet 7 is laid on the bottom surface of the heat conductive case 1, the reactor core 9 and the reactor coil 12 are accommodated in the heat conductive case 1. Then, the filler 8 is poured into the heat conductive case 1 to fix the heat conductive case 1, the reactor core 9 and the reactor coil 12. The insulating and heat radiating sheet 7 is disposed between the reactor coil 12 and the heat conductive case 1 to insulate them. In addition, since the insulating and heat radiating sheet 7 uses a sheet having better thermal conductivity than the surrounding filler 8, heat generated from the reactor coil 12 can be efficiently conducted to the heat conductive case 1. . Thereby, the heat generated from the reactor coil 12 is efficiently radiated from the heat conductive case 1 cooled by the forced cooling means.

  As described above, the reactor 10 is stacked in a rectangular tube shape by rounding the rectangular wire 17 and the steps ST11, ST12, ST21, ST22 in the stacking direction (see FIGS. 3C and 3D). ) Includes a reactor coil 12 having a first coil element 121 and a second coil element 122 formed on upper surfaces 121U and 122U (see FIG. 3B) and side surfaces 121S and 122S (see FIG. 3B). Yes. For this reason, while the upper surface and side surface of the 1st coil element 121 and the 2nd coil element 122 exhibit the function of a heat radiating fin, the bottom surface side is formed in the shape of a plane, and the heat conductive case 1 is interposed via the insulating and heat radiating sheet 7 Since it is in close contact with the bottom surface, for example, when a normal coil element stacked in a rectangular tube shape is provided by rectangular winding, and when a rectangular wire is rolled round, it is stacked in a cylindrical shape. Compared with the case where the coil element is provided, the heat dissipation is excellent.

  Similarly, the dead space in the heat conductive case 1 is reduced as compared with the case where the coil elements stacked in a cylindrical shape are provided, and the dead space in the smaller volume can be accommodated. The structure contributes to miniaturization. Furthermore, since the reactor coil 12 includes the first coil element 121 and the second coil element 122 in which the flat wire 17 is wound in an edgewise (vertical) shape, the reactor coil 12 is more wire than in the case of a flat wire having a horizontal winding. The voltage between them can be reduced. Therefore, for example, even in the case of a reactor coil to which a large voltage such as 1000 V is applied, high reliability can be ensured.

  FIGS. 3A, 3 </ b> B, 3 </ b> C, and 3 </ b> D are a perspective view, a front view, a side view, and a top view showing details of the reactor coil 12 shown in FIG. 1. As shown in FIG. 3, the reactor coil 12 is laminated in a rectangular tube shape by winding a single rectangular wire 17 in an edgewise manner, and the steps ST11, ST12, ST21, and ST22 in the lamination direction are on the top surface. The first coil element 121 and the second coil element 122 are formed on the 121U and 122U and the side surfaces 121S and 122S, and the first coil element 121 and the second coil element 122 are arranged in parallel and wound together. It is formed continuously so that the directions are opposite.

  That is, the reactor coil 12 is formed in such a manner that a single rectangular wire 17 is angularly wound in an edgewise manner to be stacked in a rectangular tube shape, and a step ST11 in the stacking direction is formed on the upper surface 121U and the side surface 121S. Further, at the winding end portion 121E of the first coil element 121, the flat wire 17 is projected from the first coil element 121 by the length of the coil interval and bent by approximately 90 degrees, and the stacking direction of the first coil elements 121 (FIG. 3A) In the direction opposite to the winding direction of the first coil element 121 in an edgewise manner so as to be laminated in the opposite direction (indicated by the arrow A in FIG. 3A). The first coil element 1 is wound at the end of winding of the second coil element 122 by being square-wound and forming the step ST12 in the stacking direction on the upper surface 122U and the side surface 122S. Is characterized in that first and second coil elements 122 are formed in parallel state continuously.

  Then, by forming the step ST11, the lead 121L is formed so that the lead 121L formed at the winding start end of the first coil element 121 of the reactor coil 12 is separated from the reactor core 9 by an insulation distance. A rectangular wire 17 constituting one side 121 </ b> A of the first coil element 121 is formed so as to protrude from the outer periphery of the first coil element 121. Further, by forming the step ST12, the second coil including the lead portion 122L is formed such that the lead portion 122L formed at the winding start end portion of the second coil element 122 is separated from the reactor core 9 by an insulating distance. A flat wire 17 constituting one side 122 </ b> A of the element 122 is formed so as to protrude from the outer periphery of the second coil element 122.

  As described above, the upper surface 121U, 122U and the side surfaces 121S, 122S of the first coil element 121 and the second coil element 122 increase the surface area in contact with the outside air, so that the cooling effect is enhanced, and the heat dissipation performance of the reactor coil 12 is improved to This can be significantly improved over the reactor coil. Further, in order to provide a crimp terminal or the like (not shown) to connect to other electrical components, the lead portions 121L and 122L can be connected to the lead portions 121L and 122L even if the covering of the flat wire 17 constituting the lead portions 121L and 122L is peeled off and the conductor is exposed. There is no need to assemble an insulating member that is a separate member between the reactor cores 9, and the insulation between the lead portions 121L, 122L and the reactor core 9 can be maintained. And the rise of the component cost for preparing the insulating member which is another member, and the raise of the work cost for assembling the insulating member which is another member can be suppressed. In addition, since the lead parts 121L and 122L of the two coil elements 121 and 122 are on the same side in the axial direction of the coil elements 121 and 122, a terminal (not shown) is attached to the tip part of the lead parts 121L and 122L. In addition, it is possible to align the positions of the terminals.

  4, FIG. 5, FIG. 6 and FIG. 7 are diagrams for explaining a method of forming the reactor coil 12 shown in FIG. In this method of forming the reactor coil 12, as shown in FIGS. 4A to 7O, the winding head 100 for the first coil element 121, the winding head 200 for the second coil element 122, Wind the wire using. The winding head 100 and the winding head 200 each include two pulley-like head members that are arranged to face each other at a predetermined interval. And by changing the feed position of a flat wire (hereinafter referred to as a flat wire 170) as a wire to the winding heads 100, 200, it can be changed to an arbitrary position on the outer circumference of the first and second coil elements 121, 122. It is characterized in that a step can be formed.

  First, as shown to Fig.4 (a), the flat wire 170 is sent out to a predetermined position (1st feed process of a flat wire). That is, a rectangular wire 170 having a sufficient length for winding the first coil element 121 and the second coil element 122 is prepared, and the rectangular wire 170 is arranged from the winding head 200 side to the winding head 100 side, that is, FIG. (A) It sends to the direction shown by the arrow A, and it passes through the winding head 100, and it sets to the state which the front-end | tip 170f of the flat wire 170 protruded from the predetermined length winding head 100. FIG. Here, the flat wire 170 is a so-called square conducting wire coated with a coating. The flat end 170f of the rectangular wire 170 constitutes a winding start end 121a of the first coil element 121, as will be described later.

  Subsequently, as shown in FIGS. 4B to 6I, the first coil element 121 is wound using the winding head 100 (winding step of the first coil element). This step is one of the major features of the method for forming the reactor coil 12 of the present embodiment. First, as shown in FIG. 4B, the first step including the winding start end portion 121a of the first coil element 121 is performed. After the rectangular wire 170 constituting one side 121A of one coil element 121 is bent, the first winding of the first coil element 121 is started. 3B, the length of one side of the rectangular wire 17 constituting the first coil element 121 shown in FIG. 3B (the distance between the centers of the rectangular wires 170) a is shown. After the flat wire 170 is fed and bent in the direction indicated by arrow B in FIG. 4 (b), the length of one side of the smaller square (the distance between the centers of the flat wire 170) b is as shown in FIG. The flat wire 170 is fed in the direction indicated by the arrow C and bent. And after sending and bending the flat wire 170 in the direction shown by the arrow D in FIG. 4D by the length of the other side of the smaller square (the distance between the centers of the flat wire 170) c, The rectangular wire 170 is fed and bent in the direction indicated by the arrow E in FIG. 5E by the length b of one side of the smaller square. With the above process, the first winding of the first coil element 121 is completed.

  Next, the second winding of the first coil element 121 is started. That is, after the rectangular wire 170 is fed and bent in the direction shown by the arrow F in FIG. 5F by the length c of the other side of the smaller square, the first coil shown in FIG. Of the rectangular shape of the rectangular wire 17 constituting the element 121, the length of the other side of the larger rectangular shape (distance between the centers of the rectangular wires 170) d is the direction indicated by the arrow G in FIG. The flat wire 170 is fed and bent. Then, the flat wire 170 is fed and bent in the direction indicated by the arrow H in FIG. 5H by the length a of one side of the larger square, and then the length of the other side of the larger square. The flat wire 170 is fed in the direction indicated by the arrow I in FIG. The second winding of the first coil element 121 is completed through the above steps.

  Thereafter, by repeating the steps of FIG. 4B to FIG. 6I up to a predetermined number of turns of the first coil element 121, the rectangular shape of the rectangular wire 17 constituting the first coil element 121 becomes two different sizes. Now, it is formed so as to repeat alternately every turn. In FIG. 4B and the subsequent drawings, the first coil element 121 is formed with a predetermined dimension in a direction (the lower surface direction or the upper surface direction of the sheet) orthogonal to the sheet of the drawing. And since the said larger square shape protrudes with respect to the said smaller square shape in the upper surface 121U side and the side surface 121S side of the 1st coil element 121 at that time, it is a lamination direction on the upper surface 121U and the side surface 121S. Steps ST11 and ST21 are formed. The rectangular wire 170 is fed and wound so that the length a of one side of the larger square is the length c of the other side of the smaller square plus the insulation distance. Accordingly, the lead portions 121L and 122L of the first and second coil elements 121 and 122 of the reactor coil 12 can be separated from the reactor core 9 by an insulating distance.

  Subsequently, as shown in FIG. 6 (j), the rectangular wire 170 is again fed out (second rectangular wire feeding step). That is, the front end 170f side of the flat wire 170 is sent in the direction indicated by the arrow J in FIG. At this time, in order to ensure the space between the first coil element 121 and the second coil element 122, the rectangular wire 170 is sent out by an extra length of a predetermined coil interval length T shown in FIG. Then, as shown in FIG. 6 (k), the entire first coil element 121 is formed 90 degrees. That is, the first coil element 121 is set to a predetermined posture state by forming (bending) the rectangular wire 170 by 90 degrees in the direction indicated by the arrow K in FIG. In this case, the rectangular wire 170 is bent 90 degrees using the winding head 100 at a position further protruding from the winding head 100 by the coil interval length T. That is, the entire first coil element 121 is formed by bending the rectangular wire 170 by 90 degrees using the winding head 100 at a position shifted by a predetermined coil interval length T.

  Subsequently, as shown in FIG. 6 (l), the flat wire 170 is further fed (third feed step of the flat wire). That is, the leading end 170f side of the flat wire 170 is further fed in the direction indicated by the arrow L in FIG. In this case, in order to secure the wire length necessary for the winding of the second coil element 122, the rectangular wire until the first coil element 121 and the subsequent rectangular wire 170 are extruded from the winding head 100 over a considerable length. 170 is sent out. In this embodiment, at this time, when a sufficient length is pushed out from the supply source of the flat wire 170, the flat wire 170 is cut, and the end 170b of the flat wire 170 formed thereby is the end of the second coil element 122. The part 122a is configured.

  Next, as shown in FIG. 7 (m), the second coil element 122 is wound in the same manner as the first coil element 121 using the winding head 200 (winding step of the second coil element). This step is one of the major features of the method for forming the reactor coil 12 of the present embodiment, and is performed in the same manner as the steps shown in FIGS. 4 (b) to 6 (i). Then, the rectangular wire 170 is wound in the opposite direction to the first coil element 121 up to a predetermined number of turns of the second coil element 122 to form the second coil element 122. After the winding of the first coil element 121 is completed, the length required for the winding of the second coil element 122 is sent out, and then the second coil element 122 is wound so as to be rewound in the opposite direction. This is one of the major features of the method for forming the reactor coil 12 of the present embodiment. Accordingly, as shown in FIG. 7 (m), the first coil element 121 is moved in the direction indicated by the arrow M in FIG. 7 (m) by the winding of the second coil element 122. To do. That is, the first coil element 121 and the second coil element 122 begin to approach each other.

  Then, as shown in FIG. 7 (n), the winding of the second coil element 122 advances, and the first coil element 121 and the second coil element 122 further approach each other. At this time, as shown in FIG. 7 (n), the first coil element 121 is detached from the winding head 100 and approaches the second coil element 122 in the direction indicated by the arrow N in FIG. 7 (n). Therefore, it is desirable to provide a mechanism for raising the first coil element 121 so that the first coil element 121 is disengaged upward from the winding head 100.

  Finally, as shown in FIG. 7 (o), the second coil element 122 is further wound 1/4 turn (90 degrees) from the state shown in FIG. Is completed, the winding of the coil elements 121 and 122 is completed, and the reactor coil 12 of this embodiment is formed and completed. In this completed state, the end 121a of the first coil element 121 and the end 122a of the second coil element 122 are in the same direction as shown in FIG. As shown, the lead portions 121L and 122L are formed by bending in the coil axis direction. In addition, although it is necessary to remove the completed reactor coil 12 which consists of both the coil elements 121 and 122 from the winding head 200, it raises so that both the coil elements 121 and 122 may remove | deviate from the winding head 200 to the upper side. It is desirable to provide a simple mechanism.

  According to the above forming method, the steps ST11, ST12, ST21, ST22 in the stacking direction can be easily and inexpensively formed on the upper surfaces 121U, 122U and the side surfaces 121S, 122S of the first and second coil elements 121, 122. Therefore, the steps ST11, ST12, ST21, and ST22 exhibit the function of the radiating fins to increase the cooling effect, and the heat dissipation performance of the reactor coil 12 can be greatly improved. In the conventional coil described above, it is difficult to attach to a heatsink that directly touches the metal from the viewpoint of insulation, and the expected effect on the heatsink cannot be obtained because an insulating material is sandwiched between them. In the reactor coil 12 according to the embodiment, since the step ST11, ST12, ST21, ST22 in the stacking direction is formed on the upper surfaces 121U, 122U and the side surfaces 121S, 122S of the first and second coil elements 121, 122, the first coil element The surface area of the 121 and the second coil element 122 that come into contact with the outside air can be increased to enhance the cooling effect.

  Further, the lead portion 121L formed at the winding start end portion of the first coil element 121 of the reactor coil 12 and the lead portion 122L formed at the winding start end portion of the second coil element 122 are insulated from the reactor core 9. The flat wire 17 constituting one side 121A of the first coil element 121 including the lead portion 121L and the flat wire 17 constituting one side 122A of the second coil element 122 including the lead portion 122L are first The reactor coil 12 formed so as to protrude from the outer periphery of the coil element 121 is obtained. In the coil of the conventional example described above, in order to provide a crimp terminal or the like on the coil terminal and connect it to other electrical components or the like, an insulating member is incorporated between the coil terminal and the core to ensure insulation. In the reactor coil 12 of the present embodiment, an insulating member that is a separate member between the lead portions 121L and 122L and the reactor core 9 even if the covering of the flat wire 17 constituting the lead portions 121L and 122L is peeled off and the conductor is exposed. Since the insulation between the lead portions 121L, 122L and the reactor core 9 can be maintained, the cost of parts for preparing an insulating member as a separate member is increased, and the insulating member as a separate member is provided. An increase in work costs for assembly can be suppressed.

  In the above-described embodiment, the reactor coil 12 having the two coil elements 121 and 122 has been described. However, the same applies to a reactor coil in which two single coils are combined or a reactor coil having only a single coil. Can be applied to. In addition, the steps ST11, ST12, ST21, and ST22 in the stacking direction are formed on the upper surfaces 121U and 122U and the side surfaces 121S and 122S of the first and second coil elements 121 and 122, but the present invention is not limited to this. In other words, by changing the feed position of the rectangular wire 170 with respect to the winding heads 100 and 200, any position on the outer periphery of the first and second coil elements 121 and 122, for example, the first and second coil elements 121 and 122, respectively. Steps can be formed on only the upper surfaces 121U and 122U, only the side surfaces 121S and 122S, or other surfaces. Further, since steps in the stacking direction can be easily and inexpensively formed on various coils, the step is formed not only in the reactor coil but also in accordance with the shape of the coil such as a motor. It can be greatly improved.

  While the present invention has been described based on the embodiments, the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the scope of the claims.

  The present invention is not limited to a coil of a reactor, as long as it is a coil that is stacked in a rectangular tube shape by winding a single rectangular wire in an edgewise manner, and it can be applied to coils of other electronic components such as a transformer. Widely applicable.

It is a perspective view of the reactor as an example containing the coil of the embodiment of the present invention. It is a disassembled perspective view of the reactor shown in FIG. It is the perspective view of the reactor coil of embodiment of this invention, a front view, a side view, and a top view. It is a 1st figure for demonstrating the formation method of the reactor coil of embodiment of this invention. It is a 2nd figure for demonstrating the shaping | molding method of the reactor coil of embodiment of this invention. It is a 3rd figure for demonstrating the formation method of the reactor coil of embodiment of this invention. It is a 4th figure for demonstrating the shaping | molding method of the reactor coil of embodiment of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Thermal conductive case, 4 Bobbin, 7 Insulation and heat radiation sheet, 8 Filler, 9 Reactor door, 10 Reactor, 12 Reactor coil, 13 Reactor fixing hole, 17 Flat wire, 121 1st coil element, 122 2nd coil Element, 121L, 122L Lead part, 121U, 122U top surface, 121S, 122S side surface, ST11, ST12, ST21, ST22 Step, 100 winding head, 200 winding head, 170 rectangular wire

Claims (4)

One rectangular wire is square-wound in an edgewise manner so that it is laminated in a rectangular tube shape, and at least the first and second coil elements are in a parallel state and continuous so that the winding directions are opposite to each other. A method of forming a coil formed by using the first winding head and the first winding head and the second winding head provided apart from the first winding head by a predetermined distance. In a coil forming method for continuously forming the first and second coil elements from a rectangular wire,
  The rectangular wire having a length necessary for winding the first coil element and the second coil element is prepared, and the rectangular wire is arranged from the second winding head side to the first winding head side. A flat wire first feeding step in which the flat wire is set to a state where the leading end of the flat wire protrudes from the first winding head by a predetermined length;
  The rectangular wire is wound up to a predetermined number of turns of the first coil element so that a step in the stacking direction can be formed at an arbitrary position on the outer periphery of the first coil element using the first winding head. Winding the first coil element to form the first coil element;
  A second step of feeding a rectangular wire having the first coil element formed at the tip thereof again from the second winding head side to the first winding head side;
  Forming the first coil element by bending the entire first coil element to set the first coil element in a predetermined posture state; and
  A third feeding step of a rectangular wire material that further feeds the rectangular wire material from the second winding head side to the first winding head side in order to secure the winding amount of the second coil element;
  The rectangular wire is wound up to a predetermined number of turns of the second coil element so that a step in the stacking direction is formed at an arbitrary position on the outer periphery of the second coil element using the second winding head. And a winding step of the second coil element forming the second coil element. 2. The coil forming method according to claim 1, wherein in the winding step of the first coil element and the winding step of the second coil element, the first coil element and the second coil element are opened. A method for forming a coil, wherein the step is formed on a surface side. A coil manufactured by the method for forming a coil according to claim 1. A coil formed continuously by the first and second coil elements manufactured by the method for forming a coil according to claim 2 in a parallel state and having mutually opposite winding directions is a predetermined dimension. A reactor characterized in that it is housed in a reactor case of a specified size.

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