JPH04139709A - Manufacture of planar winding and plane inductance element - Google Patents

Abstract

PURPOSE:To efficiently manufacture planar winding by coiling a conductor coated with a resin having heat deformation property to a spiral while the conductor is heated and cooling and solidifying the resin. CONSTITUTION:The leading end section of a conductor 14 coated with a resin 13 having a heat deformation property is tentatively fixed to the outer periphery of the base section of a rotating shaft 17. Then a rotary disk 16 is rotated and, at the same time, the resin 13 is melted by heating the conductor 14 with a heater 20. As a result, the conductor 14 is closely wound around the outer periphery of the base section of the shaft in a spiral form on the upper surface of the disk 16 while the conductor 14 is always pushed inward by means of a winding press 18. Since the resin 13 coating the conductor 13 sticks to each other by fusion on the inner and outer peripheries of the planar spiral and is cooled and solidified as the resin 13 comes into contact with the upper surface of the disk 16, this planar winding 11 is manufactured. Therefore, the winding 11 can be always manufactured easily by taking up the conductor 14 with this manufacturing device 15 and, as a result, the manufacturing time can be shortened and manufacturing cost can be reduced.

Description

[Detailed Description of the Invention] [Object of the Invention] (Industrial Field of Application) The present invention relates to the manufacture of a small and thin planar inductance element suitable as an inductance element for power supplies, inverters, oscillators, etc. and its planar winding. Regarding the method.

(Prior Art) Conventionally, as this type of planar winding, there is a sliced coil 1 configured as shown in FIG. copper foil 2
Apply electrically insulating adhesive 3 to one side of the entire surface.

Next, as shown in FIG. 11, the copper foil 2 is wound around the outer periphery of the rotating shaft 4 with the electrically insulating adhesive 3 inside to form a spiral cylindrical body.

Thereafter, this spiral cylindrical body is sliced at a required narrow pitch using a cutter such as a wire saw to obtain the sliced coil 1 shown in FIG.

(Problem to be Solved by the Invention) However, since such a conventional sliced coil 1 requires a large number of manufacturing steps, it requires a lot of manufacturing time and cost. There is a problem that insulation defects are likely to occur.

The present invention has been made in consideration of these circumstances, and its purpose is to provide a planar winding wire that is easy to manufacture and inexpensive, and a method for manufacturing a planar inductance element including the same.

[Structure of the invention]

(Means for Solving the Problems) The present invention is configured as follows in order to solve the above problems.

The invention according to claim 1 of the present application (hereinafter referred to as the first invention) is to form a conducting wire by covering a linear conductor with a heat-deformable resin, heat the conducting wire, and tightly wind the conducting wire in a planar spiral shape. The heat deformable resin is fused to each other on the inner and outer peripheries of the spiral, and then cooled and solidified.

The invention according to claim 2 of the present application (hereinafter referred to as the second invention) is characterized in that the heat deformable resin-coated conductor wire is heated by heating a jig for winding the conductor wire into a plane spiral shape. .

The invention according to claim 3 of the present application (hereinafter referred to as the third invention) is a method for applying a heat-deformable resin-coated conductive wire to a conductive wire while applying tension thereto.
It is characterized by being wound into a flat spiral shape using a jig.

The invention according to claim 4 of the present application (hereinafter referred to as the fourth invention) is characterized in that a plurality of the planar windings according to claim 1 are stacked and bonded under heat and pressure.

(Function) <First invention> A planar winding wire can be manufactured by a step of heating a conducting wire coated with a thermodeformable resin and winding it into a planar spiral shape, and a step of cooling and solidifying the wire. , manufacturing of the planar winding becomes simple, and both manufacturing time and cost can be reduced.

<Second Invention> The thermodeformable resin-coated conducting wire in the first invention is heated by heating a jig for winding it into a flat spiral shape.

Therefore, since the conductor is directly heated by the winding jig, it is heated almost uniformly, and the conductor can be wound in a plane spiral and heated at the same time, reducing manufacturing time. can.

<Third invention> Since the thermodeformable resin-coated conductive wire in the first invention is wound up on the winding jig while being under tension, the conductive wire can be evenly and uniformly wound into a flat spiral shape. The yield of winding wire manufacturing can be increased.

<Fourth invention> Since a plurality of planar windings manufactured according to the first invention are stacked and heat-pressed, the heat-deformable resins of these planar windings are fused together at the inner and outer peripheries of the spiral and are integrated. Laminated on.

Therefore, since the planar inductance can be manufactured without requiring adhesive, cost reduction can be achieved.

(Example) Examples of the first to fourth inventions of the present application will be described below based on FIGS. 1 to 8.

FIG. 2 is a perspective view of a planar winding 11 manufactured according to an embodiment of the first invention of the present application, and an example of its manufacturing method will be described next.

First, as shown in FIG. 3, the outer periphery of the linear conductor 12 is entirely covered with a heat deformable (thermoplastic) resin 13 to form a covered conductor 14.

Next, the coated conductive wire 14 is tightly wound in a planar spiral shape while being heated.

Then, the heated thermodeformable resin 13 melts and is fused to each other on the inner and outer peripheries of the plane spiral. Therefore, after this, this is cooled and solidified to fix its planar spiral shape, and the planar winding 1
Get 1.

Therefore, according to this embodiment, since the heat-deformable resin-coated conductive wire 14 is heated to fuse the heat-deformable resins to each other on the inner and outer peripheries of the plane spiral, the step of applying an adhesive to the outer periphery of the coated conductor wire 14; Since the adhesive can be omitted, the planar winding 11 can be manufactured easily, and the number of manufacturing steps can be reduced.

As a result, both manufacturing time and costs can be reduced.

Next, an apparatus for manufacturing this planar winding 11 will be explained.

The manufacturing apparatus 15 shown in FIG. 1 has a rotating shaft 17 fixed concentrically to a rotating disk 16, and rotates the tip of a coated conductive wire 14 coated with a thermodeformable resin 13 on the upper surface of the rotating disk 16 in the figure. It is temporarily fixed to the outer periphery of the base end of the shaft 17, and the rotary disk 16 is rotated in one direction.

Then, the covered conductive wire 14 is wound around the base end of the rotating shaft 17, and the covered conductive wire 14 is tightly wound in a planar spiral shape.

On the rotating disk 16, a winding presser 18 is installed which constantly presses the outer layer of the planar spirally wound portion of the coated conductive wire 14 inwardly so as to be slidable both inward and outward in the radial direction.

Further, the manufacturing device 15 includes a pinch roller 19 that applies tension to the coated conductor wire 14, and a pinch roller 19 that applies tension to the coated conductor wire 14, and a contact between the pinch roller 19 and the rotating disk 16 to the outer circumferential surface of the coated conductor wire 14 in the middle of the coated conductor wire 14, so that the coated conductor wire 14 is A heater 20 is provided that heats the heat-deformable resin 13 to a complete melting temperature of about 120° C. and melts the heat-deformable resin 13.

Next, an example of a method for manufacturing the planar winding 11 shown in FIG. 2 using this manufacturing apparatus 15 will be described.

First, the distal end portion of the coated conducting wire 14 coated with the heat deformable resin 13 is temporarily fixed to the outer periphery of the base end portion of the rotating shaft 17 .

Next, the rotary disk 16 is rotated and heated by the heater 20 to melt the heat deformable resin 13.

Then, the coated conducting wire 14 is tightly wound around the outer periphery of the base end of the rotating shaft 17 while being constantly pressed inward by the winding presser 18 on the upper surface of the rotating disk 16, and is formed into a planar spiral shape.

For this reason, the heat deformable resin 13 of the covered conductor 14 is fused to each other at the inner and outer peripheries of the plane spiral, and the rotating disk 1
6, the wire is cooled and solidified, and the planar winding 11 shown in FIG. 3 is manufactured.

Therefore, by winding the coated conductive wire 14 using this manufacturing device 15, the planar winding 11 shown in FIG. 2 can be manufactured very easily, and as a result, the manufacturing time and cost can be reduced. can.

Moreover, since the heat-deformable resin 13 is fused to each other at the inner and outer peripheries of the plane spiral, the step of applying an adhesive to the outer periphery of the heat-deformable resin 13 and the adhesive can be omitted. The manufacturing cost can be reduced. Further, since the coated conductor wire 14 is wound up in a planar spiral shape by the rotary disk 16 while applying tension to the coated conductor wire 14 by the pinch roller 19, the winding can be performed evenly and uniformly, and the yield can be increased.

Incidentally, the winding presser 18 may be replaced with a heatable winding presser bar 18a shown in FIG. 4. This winding presser bar 1
8a is fixed to the base end of the rotary shaft 170 along the diameter direction with a gap approximately matching the diameter of the coated conductor 14 on the upper surface of the rotating disk 16, and constantly presses the coated conductor 14 downward and heats it. The heat deformable resin 13 is then heated to a melting temperature.

According to this, since the winding presser bar 18a integrates the winding presser 18 and the heater 20 shown in FIG. 1, the number of parts can be reduced accordingly, and costs can be reduced accordingly. can.

In addition, another manufacturing apparatus 22 for the planar winding 11 shown in FIG.
A circumferential groove 25 having a required depth approximately matching the diameter of the coated conductive wire 14 is bored in the side circumferential surface of a heatable rotary disk 24 to which a rotary shaft 23 is fixed concentrically.

Then, while heating the rotating disk 24, the coated cylinder conducting wire 14 is wound in a planar spiral shape in the circumferential groove 25, and the planar winding 1
1 is being manufactured.

In other words, as shown in FIG. 6, this manufacturing apparatus 22 has a method of heating the covered conducting wire 14 by blowing hot air 27 from a nozzle 26 on the outside thereof, without configuring the rotating disk 24 to be freely heated. If you think about it, the following drawbacks can be considered, so this is an improvement.

In other words, in the manufacturing apparatus shown in FIG. 6, the coated conductive wire 14 is heated by hot air 27 and then wound into the circumferential groove 25 of the rotating disk 24, so that the previously wound portion comes into contact with the rotating disk 24, so that the coated conductive wire 14 It is cooled by the rotating disk 24, which has a much larger heat capacity and is highly effective in dissipating heat.

For this reason, if complete thermal fusion of the heat deformable resin is prevented, or if hot air is blown at a temperature high enough to reach the temperature required for thermal fusion on the rotating disk 24, the temperature of the covered conductor 14 will become higher. If it becomes too much, it may cause carbonization or thermal deterioration of the heat deformable resin 13, and there is a conceivable drawback that it becomes difficult to supply the planar winding wire 11 of stable quality.

Therefore, according to the manufacturing apparatus shown in FIG. 5, the coated conductive wire 14 is directly heated by the rotating disk 24, so the heating is uniform and stable, and temperature control is simplified.
The drawbacks of the manufacturing apparatus shown in FIG. 6 can be eliminated.

FIG. 7 is a perspective view showing the heat-pressing process of an embodiment of the fourth invention, and this embodiment is a method for manufacturing one planar inductance element by laminating a plurality of planar windings 30. , which will be explained next.

First, the conductive wire 14 coated with the heat-deformable resin 13 is heated to a temperature of 60 to 80°C, which is the incomplete melting temperature of the heat-deformable resin 13.
It is heated to about 0° C. to form a planar spiral coil 30 similar to the planar coil 11 shown in FIG. I'll keep it.

Next, the planar winding wires 30 are made into a pair of, for example, two wires.
If necessary, an electrically insulating film 31 is interposed between each pair, and the electrically insulating film 31 is heated to a temperature of, for example, 110 to 120° C.
Pressing is performed while heating to the complete melting temperature of the heat deformable resin 13.

Then, the heat deformable resin 13 of the planar winding 30 is completely melted, and each planar winding 30 is fused to each other, and the planar winding 30 and the electrical insulating film 31 are fused to form one planar inductance element. Manufactured.

Therefore, according to this embodiment, the step of applying an adhesive to the outer periphery of the heat deformable resin 13 and the adhesive are not necessary, so that cost reduction can be achieved.

In each of the above embodiments, the planar spiral shape of the planar winding 11.30 is formed into a circular shape, but the invention is not limited to this. For example, the planar spiral shape shown in FIG. The plane spiral shape may be formed into a rectangular shape like the coil 40.

〔Effect of the invention〕

As explained above, the first invention of the present application involves heating a conductive wire coated with a thermodeformable resin and winding it in a planar spiral shape.
Planar windings are manufactured by cooling and solidifying, so
In addition to being easier to manufacture than conventional sliced coils, the number of manufacturing steps can be reduced. Therefore, both manufacturing time and cost can be reduced.

Furthermore, the second invention heats the heat-deformable resin of the conductive wire by heating the jig for winding the heat-deformable resin-coated conductive wire of the first invention into a planar spiral shape. The heat deformable resin of the conducting wire can be directly heated.

For this reason, the heating temperature of the heat deformable resin can be stabilized and made uniform, and the yield of manufacturing each planar winding wire can be increased.

Furthermore, in the third invention, the heat deformable resin-coated conductive wire of the second invention is wound in a planar spiral shape while applying tension.
This conducting wire can be evenly and uniformly wound into a planar spiral shape, and the yield of manufacturing the planar winding wire can be increased.

Furthermore, in the fourth invention, a plurality of planar windings manufactured according to the first invention are laminated by stacking them and heat-pressing them, so that a plurality of planar windings can be laminated without using an adhesive. It is possible to reduce costs.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of an example of a planar winding manufacturing apparatus including the first to third inventions of the present application, and FIG. 2 is a perspective view of a planar winding manufactured by the manufacturing apparatus shown in FIG. FIG. 3 is a sectional view taken along the line mm in FIG. 2, FIGS. 4 to 6 are perspective views of a manufacturing apparatus according to another embodiment of the present invention, and FIG. 7 is a planar inductance according to the fourth invention of the present application. FIG. 8 is a perspective view of a planar coil having a rectangular planar spiral shape; FIG. 9 is a perspective view of a conventional sliced coil; FIGS. The figures are perspective views showing a part of the manufacturing process of the sliced coil shown in FIG. 9, and FIG. 12 is a sectional view taken along the line X[1-XII in FIG. 9. 11... Planar winding, 12... Linear conductor, 13...
- Heat deformable resin, 14... Covered conductive wire, 15... Manufacturing equipment, 16... Rotating disk (winding jig), 17...
- Rotating shaft, 19... pinch roller, 20... heater, 27... hot air, 31... electrical insulation film,
40... Square spiral planar winding.

Claims (4)

[Claims] 1. forming a conductor by covering a linear conductor with a heat-deformable resin; heating the conductor to tightly wind the conductor in a planar spiral shape; and melting the heat-deformable resin to each other at the inner and outer peripheries of the spiral;
A method for manufacturing a planar winding wire, which is then cooled and solidified. 2. 2. The method of manufacturing a planar winding wire according to claim 1, wherein the heat deformable resin-coated conducting wire is heated by heating a jig for winding the conducting wire into a planar spiral shape. 3. 3. The method of manufacturing a planar winding wire according to claim 2, wherein the heat deformable resin-coated conductor wire is wound into a planar spiral shape using a jig while applying tension to the conductor wire. 4. A method for manufacturing a planar inductance element, comprising stacking a plurality of planar windings according to claim 1 by overlapping and heat-pressing them.