JP4834057B2 - Coil manufacturing method - Google Patents

Description

  The present invention belongs to a technical field related to a coil which is a structural unit of a coil component incorporated in various electronic devices, electromagnetic devices and the like.

  In recent years, electronic devices, electromagnetic devices, and the like tend to increase the number of turns of the coil electric wire as the current supplied to the coil increases. The increase in the number of turns of the coil electric wire leads to an increase in the size of the coil component, making it difficult to incorporate the coil component into an electronic device or electromagnetic device. For this reason, there is a demand for the development of a technique for reducing the size of the coil component corresponding to the increase in energization.

2. Description of the Related Art Conventionally, for example, the following technologies are known as techniques aimed at coping with downsizing of coil parts.
Japanese Patent Laid-Open No. 2001-45688 discloses a coil in which a part of a winding bundle in which an electric wire is spirally wound at high density is bent and deformed so as to expand both sides in the axial direction of the winding. Are listed.

  The coil according to Patent Document 1 is a compact coil component while increasing the number of turns of an electric wire by forming a coil component by densely stacking so as to fit each other by using the step of the bending deformation portion of the winding bundle. Can be achieved.

  In the coil according to Patent Document 1, a pair of clampers locked at two opposite positions of the winding bundle are slid so as to be separated to both sides in the axial direction of winding of the wire by a feed screw mechanism. A manufacturing method is adopted in which the two opposing portions are expanded and bent so as to be separated from each other.

  The method for manufacturing a coil according to Patent Document 1 is effective for a wire bundle in which a wire bundle is formed in multiple layers in the axial direction and the radial direction of the winding. However, in the case of a single layer in the radial direction, there is a problem that the possibility is low because a plurality of wires in the axial direction of the winding are irregularly deformed due to the slide and the winding alignment is lost. There is a point. In addition, there is a problem that it is difficult to apply to a flat disk-shaped coil component by forming a winding bundle in which the electric wire is multilayered in the axial direction and the radial direction of winding.

  The present invention has been made in consideration of such problems, and can form a step by precise bending deformation in a coil in which the winding of the electric wire is a single layer in the radial direction, and is a flat disk shape. It is an object of the present invention to provide a coil manufacturing method that can be easily applied to a coil component.

  In order to solve the above-described problems, the coil manufacturing method according to the present invention employs means described in each of the claims.

  That is, according to the first aspect of the present invention, the inner wire is regulated by the pair of end guides and the center guide that is positioned at the center of the end guides and linearly regulates a part of the hooked wires. A winding process in which a plurality of layers are wound in a spiral shape with a part being linear so as to form a single layer or a plurality of layers in the radial direction, and the central guide is rotated by using a straight line passing through both end guides as a rotation axis. An expanding step is performed in which the rotated electric wire is moved so as to expand to both sides in the axial direction in the vicinity of the center portion guide.

  In this means, when the electric wire is spirally wound so as to be a single layer in the radial direction with a plurality of layers in the axial direction in the winding process, a bulging space is formed by the central portion guide, and the central portion in the expanding step. By rotating the bulge space by rotating the guide and moving the electric wire so that it expands to both sides in the axial direction in the vicinity of the central guide, the step due to bending deformation is maintained in a state where the winding alignment of the electric wire is maintained. It is formed. In addition, a part of the wire wound in a spiral shape of a plurality of layers in the axial direction and a single layer in the radial direction becomes a straight line, thereby making the radial arrangement interval approach using the straight part. Can do.

  According to a second aspect of the present invention, the electric wire is axially controlled while regulating the inner periphery by a pair of end guides and a central portion guide that is positioned at the center of the end guides and linearizes a part of the hung wire. A winding process in which a plurality of layers are wound in a spiral shape with a part being linear so as to form a single layer or a plurality of layers in the radial direction, and both end guides are rotated simultaneously with a straight line passing through both end guides as a rotation axis. An expanding step of moving the wound electric wire so as to expand to both sides in the axial direction in the vicinity of the central portion guide is performed.

  In this means, when the electric wire is spirally wound so as to be a single layer in the radial direction and in a plurality of layers in the axial direction in the winding process, the bulging space is formed by the center guide, and the end portion in the expansion process By rotating the bulge space by the rotation of the guide and moving the electric wire to both sides in the axial direction in the vicinity of the central portion guide, a step due to bending deformation is formed in a state where the winding alignment of the electric wire is maintained. In addition, a part of the wire wound in a spiral shape of a plurality of layers in the axial direction and a single layer in the radial direction becomes a straight line, thereby making the radial arrangement interval approach using the straight part. Can do.

  Further, in claim 3, in the coil manufacturing method according to claim 1 or 2, before the expanding step after the winding step, the center portion is restrained with the pressing die on the electric wire wound around the both end guides. The drawing step is characterized in that a drawing step is performed in which the length of contact with the center guide of the electric wire is increased by pressing in the guide direction.

  In this means, the holding force of the wire winding alignment is strengthened by lengthening the contact length of the wire with the central guide in the drawing step before the expanding step after the winding step.

  According to a fourth aspect of the present invention, in the coil manufacturing method according to the third aspect of the present invention, the narrowing step is continuously performed in the expansion step.

  With this means, the holding process of the wire winding alignment is further strengthened by continuing the drawing process in the expanding process.

  Moreover, in Claim 5, in the manufacturing method of the coil in any one of Claims 1-4, after the expansion process, the press process which presses the expanded electric wire with a press die to the radial direction of winding is implemented. It is characterized by that.

  In this means, by performing a pressing step of pressing the expanded electric wire with a press die in the radial direction of the winding, the electric wire in which a step due to bending deformation is formed is flattened.

  According to a sixth aspect of the present invention, in the method for manufacturing a coil according to any one of the first to fifth aspects, the portion wound around one end guide of the electric wire is subjected to an inclination process.

  With this means, the end portion of the electric wire can be arranged in an overlapping manner by subjecting the portion wound around the one end guide of the electric wire to an inclined process.

  The coil manufacturing method according to the present invention includes, as a first aspect, a center portion guide when the electric wire is spirally wound so as to be a single layer or a plurality of layers in the radial direction and a plurality of layers in the axial direction in the winding step. In the expansion process, the bulge space is rotated by the rotation of the central guide, and the wire is moved to both sides in the axial direction near the central guide, so that the winding alignment is maintained. Since a step due to bending deformation is formed in this state, there is an effect that the step due to bending deformation can be precisely formed in a coil in which the winding of the electric wire is a single layer in the radial direction. In addition, a part of the wire wound in a spiral shape of a plurality of layers in the axial direction and a single layer in the radial direction becomes a straight line, thereby making the radial arrangement interval approach using the straight part. Therefore, there is an effect that it can be easily applied to a flat disk-shaped coil component.

  Further, as claimed in claim 2, when the wire is spirally wound so as to be a single layer or a plurality of layers in the radial direction in a plurality of layers in the axial direction in the winding step, a bulging space is formed by the central portion guide, In the expansion process, the bulge space is rotated by rotating the end guide, and the electric wire is moved to both sides in the axial direction near the central guide, so that the step due to bending deformation is maintained while maintaining the winding winding alignment. Therefore, there is an effect that a step due to bending deformation can be precisely formed in the coil in which the winding of the electric wire is a single layer in the radial direction. In addition, a part of the wire wound in a spiral shape of a plurality of layers in the axial direction and a single layer in the radial direction becomes a straight line, thereby making the radial arrangement interval approach using the straight part. Therefore, there is an effect that it can be easily applied to a flat disk-shaped coil component.

  Further, as claimed in claim 3, in order to reinforce the holding force of the wire winding alignment by lengthening the contact length to the central portion guide of the wire in the drawing step before the expanding step after the winding step, There is an effect that a step due to bending deformation can be precisely formed by a coil in which the winding of the electric wire is a single layer in the radial direction.

  Furthermore, as the fourth aspect of the present invention, the wire winding is a single layer in the radial direction in order to further strengthen the holding power of the wire winding alignment by continuously carrying out the drawing step in the expansion step. There is an effect that a step due to bending deformation can be formed in the coil even more precisely.

  Furthermore, as claimed in claim 5, by performing a pressing step of pressing the expanded electric wire in the radial direction of the winding with a press die, the electric wire in which the step due to the bending deformation is flattened. There is an effect that is useful for the configuration of the coil component.

  Furthermore, as claimed in claim 6, since the portion wound around the one end guide of the electric wire is inclined, it becomes possible to arrange the end portions of the electric wire in an overlapping manner. There exists an effect which becomes easy to apply to a coil component.

  The best mode for carrying out a method for manufacturing a coil according to the present invention will be described below with reference to the drawings.

  1 to 7 show a first example of the best mode for carrying out the method for manufacturing a coil according to the present invention.

  In the first example, a wire using a flat wire (flat wire) is shown as the electric wire 1.

  In the first example, a winding process, a drawing process, an expanding process, and a pressing process are sequentially performed.

  In the winding step, as shown in FIGS. 1 (A) and 2 (A), a pair of relatively small end guides 2 having a circular cross-sectional shape and a center of the end guide 2 are used. The electric wire 1 is wound by using a relatively large central portion guide 3 which is an oval shaped columnar shape having a circular cross section and a combination of straight lines. That is, the electric wire 1 is hung on the end guide 2 and the center guide 3 to restrict the inner periphery, and is wound spirally so as to have a plurality of layers in the axial direction and a single layer in the radial direction. As shown in FIG. 1A, the wound electric wire 1 has a shape in which a straight line portion is formed at a corner in the end axis direction of the rhombus as viewed from the direction of the axis of winding, and the central guide 3 A bulging space a bulging outward is formed in the vicinity.

  In the drawing step, as shown in FIGS. 1 (B) and 2 (B), the contact length of the electric wire 1 wound using the pressing die 4 to the central portion guide 3 is increased. That is, the wound wire 1 is pressed toward the center guide 3 while the portion wound around the both ends guide 2 is restrained by the pressing die 4, and the four sides of the rhombus are bent inward. The appearance (appearance in which the bulging space a is narrowed down) becomes longer and the contact length with the central guide 3 becomes longer.

  This drawing process is continued in the subsequent expansion process.

  In the expanding step, as shown in FIGS. 1C and 2C, the electric wire 1 wound by rotating the central guide 3 by 90 degrees about the straight line passing through the both end guides 2 as the rotation axis is left-handed. The half part 11 and the right half part 12 are expanded. About this rotation angle, it is not limited to 90 degree | times, It can change according to the coil to manufacture. The wound wire 1 is, as shown in FIGS. 3 and 4, the folded portion 13, which is a portion wound around the both ends guide 2, is restrained by the both ends guide 2 by the pressing die 4. The center guide 3 is rotated together with the center guide 3 while standing up from the center guide 3 against the twisting force associated with the rotation of the center guide 3, and is moved so as to be spread from the inside by the center guide 3 so that the whole is twisted. Without being bent, the bent portion 13 is partially twisted and expanded to the left half portion 11 and the right half portion 12. Each of the left half portion 11 and the right half portion 12 is formed with a straight portion 14 in part. The electric wire 1 is erected reliably because the contact length of the electric wire 1 with respect to the central guide 3 is increased in the drawing process and the folding portion 13 is effectively restrained. However, in order to assist the standing of the electric wire 1, the raising piece 5 which hooks the electric wire 1 can also be provided in the rotation outer periphery vicinity of the center part guide 3 (refer FIG. 4). In addition, the above-mentioned bulging space a forms the space part between the left half part 11 and the right half part 12 which the electric wire 1 was expanded as it is, and the whole electric wire 1 will be twisted. Help to avoid. Further, the presence of the bulging space a and the folded portion 13 having the arc shape of the electric wire 1 are a twisting force, a compressive force, and an extension due to a difference in movement amount of each wire in the left half portion 11 and the right half portion 12 of the electric wire 1. The force is absorbed to prevent the alignment of the lines in the left half portion 11 and the right half portion 12 from being broken.

  In the pressing step, as shown in FIG. 1D, the electric wire 1 that has been expanded to the left half portion 11 and the right half portion 12 is pressed with a press die 6. That is, the expanded electric wire 1 corrects subtle irregularities and inclinations of the left half portion 11 and the right half portion 12 by pressing the press die 6 from the winding axial direction, and flattens the whole. The press die 6 is configured not to press the portion of the folded portion 13 of the electric wire 1. Accordingly, the folded portion 13 of the electric wire 1 remains circular without being flattened.

  As shown in FIGS. 5 and 6, the coil manufactured in the first example has a step b formed between the left half portion 11 and the right half portion 12 of the electric wire 1 despite being flattened. Yes. That is, a step due to a precise bending deformation is formed in a coil in which the winding of the electric wire 1 is a single layer in the radial direction. Therefore, as shown in FIG. 7, the coil component can be configured by densely stacking so as to be fitted to each other using the step b. At this time, by passing the guide wire 7 through the folded portion 13 of the electric wire 1, the coils can be assembled and arranged precisely and easily.

  Moreover, since the left half part 11 and the right half part 12 of the electric wire 1 are not completely curved but partly straight (straight line part 14), it is possible to make adjacent intervals close to each other by using a straight line. Therefore, application to a flat disk-shaped coil component is facilitated.

  FIG. 8 shows a second example of the best mode for carrying out the coil manufacturing method according to the present invention.

  In the second example, a press die 6 that presses even the folded portion 13 of the electric wire 1 in the pressing step is used.

  The coil manufactured in the second example is flattened (thinned) more than the coil manufactured in the first example by flattening the circular folded portion 13 of the electric wire 1. Therefore, it is suitable for application to a coil component incorporated in a flat type motor or the like.

  9 and 10 show a third example of the best mode for carrying out the method for manufacturing a coil according to the present invention.

  In the third example, the folded portion 13 which is one end portion of the electric wire 1 is subjected to an inclination process (see FIG. 9).

  According to the third example, as shown in FIG. 10, the adjacent intervals between the coils can be made closer by overlapping the folded portions 13 that are subjected to the inclination processing of the electric wire 1 on the inner peripheral side. Therefore, it is suitable for application to a coil component incorporated in a flat type motor or the like.

    FIG. 11 shows a fourth example of the best mode for carrying out the method for manufacturing a coil according to the present invention.

  The fourth example employs four rollers as the central guide 3.

  According to the 4th example, the friction to the electric wire 1 in an expansion process can be reduced, and the damage of the electric wire 1 can be avoided.

  As described above, in addition to the illustrated examples, the central guide 3 can be in the shape of an elliptic cylinder, a prism, or the like.

  Furthermore, it is also possible to rotate the both end guides 2 instead of the center guide 3 in the expanding step.

Furthermore, the electric wire 1 can be made into a plurality of layers in the radial direction.

BRIEF DESCRIPTION OF THE DRAWINGS It is a side view of the 1st example of the best form for implementing the manufacturing method of the coil which concerns on this invention, and the process is shown in order of (A)-(D). FIG. 2 is a front view of FIG. 1, in which (A) corresponds to FIG. 1 (A), (B) corresponds to FIG. 1 (B), and (C) corresponds to FIG. 1 (C). 2A and 2B are perspective views of main parts of FIG. 1, in which FIG. 1A corresponds to FIG. 1B and FIG. 1B corresponds to FIG. FIG. 2 is a simplified diagram of the operation from FIG. 1B to FIG. It is a front view of the coil manufactured by FIG. FIG. 6 is a side view of FIG. 5. It is a front view which shows the structural example to the coil components of FIG. It is a side view of the 2nd example of the best form for enforcing the manufacturing method of the coil concerning the present invention. It is a side view from the folding | turning part side of the 3rd example of the best form for implementing the manufacturing method of the coil which concerns on this invention. It is a front view which shows the structural example to the coil components of FIG. It is a side view of the 4th example of the best form for enforcing the manufacturing method of the coil concerning the present invention.

1 Electric Wire 11 Left Half 12 Right Half 14 Straight Line (Linear)
2 End guide 3 Center guide 4 Stamping die 6 Pressing die b Step

Claims (6)

  The inner wire is restricted by a pair of end guides and a center guide that is positioned at the center of the end guides to straighten a part of the wire that is hung, and the wires are axially multi-layered in the radial direction. A winding process in which a part or a plurality of layers are spirally wound, and a central part is rotated with a straight line passing through both end guides as a rotation axis, and the wound electric wire is in the central part. The coil manufacturing method which performs the expansion process which moves so that it may expand to both sides of an axial direction in the vicinity of a guide.   The inner wire is restricted by a pair of end guides and a center guide that is positioned at the center of the end guides to straighten a part of the wire that is hung, and the wires are axially multi-layered in the radial direction. A winding process in which a part or a plurality of layers are spirally wound, and both ends are simultaneously rotated with a straight line passing through both ends as a rotation axis, and the wound wire is in the center. The coil manufacturing method which performs the expansion process to which it moves so that it may expand to both sides of an axial direction in the vicinity of a part guide.   3. The coil manufacturing method according to claim 1 or 2, wherein before the spreading step after the winding step, the electric wire wound around the both end guides is pressed in the direction of the central portion while being restrained by a pressing die. A coil manufacturing method comprising: performing a drawing step of increasing a contact length with a central portion guide.   4. The method for manufacturing a coil according to claim 3, wherein the drawing step is continuously performed even in the expansion step.   The coil manufacturing method according to any one of claims 1 to 4, wherein after the expanding step, a pressing step of pressing the expanded electric wire with a press die in a radial direction of the winding is performed. Production method. The coil manufacturing method according to any one of claims 1 to 5, wherein a portion of the wire wound around one end guide is inclined.

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