JPH04298013A - Foil-wound coil - Google Patents

Abstract

PURPOSE:To prevent breakdown of a layer insulating material by folding and compressing both side edges of a conductive material foil in a direction wherein a burr part of a cutting line is opposite to a surface of the conductive material foil. CONSTITUTION:A band-like conductive material foil 1 which is cut to a specified width is folded in a direction opposite to a surface thereof and overlapped parts 3, 3 are folded and compressed. Thereby, a burr part 2 us not opposite to a layer insulating material 13. The burr part 2 of a cutting line of the conductive material foil 1 is not opposite to the insulating material 13 and does not break the insulating material 13 even if the burr part 2 is not removed. Therefore, there is no possibility of layer shortcircuiting even if a thickness of a layer insulating material is reduced, thereby realizing compactness of an entire and enabling cost reduction.

Description

[Detailed description of the invention]

[Object of the invention]

0002

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foil-wound coil used in electromagnetic devices such as noise filters and transformers.

0003

2. Description of the Related Art Conventional foil-wound coils of this type have a structure in which a strip-shaped conductive material foil such as copper foil or aluminum foil is wound with an insulating film or plate interposed therebetween.

0004

[Problems to be Solved by the Invention] Since the foil-wound coil of the above-mentioned conventional structure is formed into a strip by cutting a wide conductive material foil into a predetermined width, the cut edges on both sides have burrs and burrs. The cut edge has a sharp edge, and there is a risk that the cut edge will bite into the insulating film or insulating paper between the layers, breaking the insulating film or insulating paper, and causing an interlayer short circuit. In order to prevent the occurrence of this interlayer short circuit, burrs and burrs formed on the cut edge of the conductive material foil may be removed, but if the thickness of the conductive material foil is 0.3 mm to 0.03 m.
It is difficult to mechanically remove burrs and curvatures in the case of m, and although the burrs and burrs can be removed by etching, there is a problem in that the number of etching steps is large and the cost is high. For this reason, thick materials have traditionally been used for the insulating film or insulating paper between the layers, but the thick insulating film or insulating paper increases the external dimensions of the coil, which is an obstacle to downsizing. , and also has the problem of high cost.

The present invention has been developed in view of the above-mentioned problems, and it is possible to prevent damage to the insulating material between layers and prevent short circuits between layers without removing burrs and burrs that occur on both cut edges of a conductive material foil. To provide a foil-wound coil that is free from danger, can be downsized, and can be obtained at low cost.

[Configuration of the invention]

[0007]

[Means for Solving the Problems] The foil-wound coil of the present invention is a coil in which a band-shaped conductive material foil cut to a predetermined width is wound with an interlayer insulating material interposed therebetween, in which both edges of the conductive material foil are cut off. The edge burrs and bent portions are folded back and compressed in the direction facing the surface of the conductive material foil.

[0008]

[Operation] The foil-wound coil of the present invention is produced by compressing a strip-shaped conductive material foil cut to a predetermined width by folding and compressing the burrs and curved portions of the cut edges on both sides in a direction facing the surface of the conductive material foil.
Since the burrs and burrs do not face the interlayer insulating material, the burrs and burrs do not destroy the insulating material, and even if the thickness of the interlayer insulating material is reduced without removing the burrs and burrs, the interlayer There is no risk of short circuits, the overall size can be reduced, and manufacturing can be done at low cost.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The structure of an embodiment of the present invention will be explained with reference to the drawings.

1 is a strip-shaped conductive material foil such as copper foil or aluminum, and as shown in FIGS. 1 and 2, this conductive foil material 1 is made by cutting a wide conductive material foil to a predetermined width and cutting both side edges. The edge burrs and turned portions 2 are folded back in a direction facing the surface of the conductive material foil 1 so that the burrs and turned portions 2 are on the inside to form overlapping portions 3, 3. is compressed between compression rollers 4, 4 rotating in opposite directions to bring the folded overlapping parts 3, 3 into close contact.

The roll former device for cutting a wide conductive material foil into a predetermined width has, as shown in FIG. 6 is installed, this cutting roller 6, 6
By inserting the cutting rollers 6 and 6 between them and cutting with the edge blades 7 of the cutting rollers 6, 6, the burrs and burrs 2 of the cutting edges on both sides are in the same direction.

Next, as shown in FIG. 4, a plurality of cylindrical caulking portions 12 formed on the terminal piece 11 having a lead wire connection portion 10 at one end are used to secure the conductive material foil 1 at the winding start and end portions. Connect by caulking. In addition, if an intermediate tap is required, the terminal piece 11 is caulked to the intermediate tap portion of the conductive material foil 1.

Then, as shown in FIG. 3, an interlayer insulating material 13 such as an insulating film or insulating paper is superimposed on the folded overlapping portions 3, 3 of the conductive material foil 1 to which the terminal piece 11 is bonded, and a coil bobbin 14 is wound. It is wound around the winding part 15. This coil bobbin 14 is constructed by fitting the terminal piece 11 into notches 17 formed in the flanges 16 at both ends of the winding part 15, and using adhesive tape to cover the beginning of the winding of the conductive material foil 1 together with the insulating material 13 at the winding part of the coil bobbin 14. 15, and in this state, the conductive material foil 1 is sequentially wound together with the insulating material 13 around the winding portion 15 to form the insulating material 13.
Laminated with intervening. Then, the terminal pieces 11 at the intermediate tap portion and the winding end portion are fitted into the notch portions 17 of the collar portion 16. Next, as shown in FIG. 5, the insulating material 13 is wound a plurality of times from the end of the winding of the conductive material foil 1 as insulation, and is fixed with an adhesive tape to complete the process.

Next, the operation of this embodiment will be explained.

By folding and compressing the overlapping portions 3, 3 in the direction in which the burrs and bent portions 2 of both cut edges of the strip-shaped conductive material foil 1 cut to a predetermined width face the surface of the conductive material foil 1, The burrs and bent portions 2 are not opposed to the interlayer insulating material 13. Further, the burrs and burrs 2 on the cut edge of the conductive material foil 1 do not face the insulating material 13 side, and even if the burrs and burrs 2 are not removed, the insulating material 13 will not be destroyed.

[0016]

Effects of the Invention According to the present invention, since the conductive material foil is compressed by folding the both sides of the conductive material foil in a direction in which the burrs of the cut edge and the curved portions face the surface of the conductive material foil, the conductive material foil has both cut edges. The burrs and burrs do not destroy the insulating material between layers, there is no need for processing to remove burrs and burrs, and there is no risk of interlayer short circuits even when the thickness of the burrs and burrs is reduced.
The overall size can be reduced and manufacturing can be done at low cost.

[Brief explanation of drawings]

FIG. 1 is an explanatory cross-sectional view of a foil-wound coil showing one embodiment of the present invention.

FIG. 2 is an explanatory diagram of a step of compressing the folded overlapping portion of the conductive material foil as described above.

FIG. 3 is an exploded perspective view of the foil-wound coil.

FIG. 4(a) is a longitudinal cross-sectional view of the same terminal piece, and FIG. 4(b) is a perspective view of the same terminal piece.

FIG. 5 is a perspective view of the same foil-wound coil as above.

FIG. 6 is an explanatory diagram of a roll former for cutting the conductive material foil.

[Explanation of symbols]

1 Conductive material foil 13 Insulating material

Claims (1)

[Claims] 1. A coil in which a strip-shaped conductive material foil cut to a predetermined width is wound with an interlayer insulating material interposed therebetween, wherein the conductive material foil has both side edges formed by the burrs of the cut edge, and the curved portions of the conductive material foil. A foil-wrapped coil characterized by being folded and compressed in the direction facing the surface.