JPH0474942B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a coil that can be used for various coils such as coils for coreless motors, transformers, etc., and power generation coils for cartridges.

Conventionally, this type of coil has been manufactured by winding an insulated electric wire such as enameled copper wire with a circular cross section to a required number of turns while applying tension to a winding frame.

In this way, since the wire is wound with a certain tension applied to it, the wire itself stretches to some extent, resulting in accidents such as wire breakage due to the current flowing through the coil.

Further, since the electric wire has a circular cross section, spaces are created between the wound electric wires, so that it is not possible to increase the density beyond a certain limit.

Furthermore, there have been other drawbacks such as poor coating of the insulating material, such as pinholes, and scratches on the wire, which can lead to wire breakage and interlayer short circuits.

The present invention increases coil density and has high insulation properties by forming coils using conductive metal foil and insulating thermoplastic film, while eliminating the drawbacks of conventional coils in large quantities. The present invention provides a method of manufacturing a coil that can extremely easily manufacture coils with uniform characteristics.

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

A thermoplastic film 1 having insulation properties such as polyethylene, and a metal foil 2 having conductivity properties such as aluminum foil.
The starting end is fixed to a winding frame 3 whose cross section has the same shape as the air core of the coil, and a thermoplastic film 1 is placed on the winding frame 3 for the required number of turns as a coil.
The polymer of metal foil 2 and metal foil 2 is wound up while applying a necessary tension to form a cylindrical wound body 4 having a desired coil cross-sectional shape and a desired number of turns.

This cylindrical winding body 4 is used as a space where the coil is used.
Alternatively, the coil material 5 is obtained by cutting into circular slices to a required thickness t in consideration of current and the like.

At this point, the cut end surface of the coil material 5 has burrs etc. generated on the metal foil 2 due to cutting, and these may come into contact and cause an interlayer short circuit.
In such a case, the required number of turns will not be obtained.

Next, this coil material 5 is immersed in an etching solution that etches only the metal foil 2 but does not have any effect on the thermoplastic film 1 for a necessary time.

This immersion not only removes cutting burrs etc. from the metal foil 2 and eliminates interlayer short circuits, but also etches the cut end surface of the metal foil 2 and cuts the thermoplastic film 1, as shown in FIG. It will be in a concave state than the end face.

When this state is reached, the coil material 5 is taken out of the etching solution, the etching action is stopped by washing with water, immersion in a neutralizing solution, etc., and it is dried by a drying process such as hot air drying to remove each layer. The metal foil 2 is insulated by the thermoplastic film 1.

Further, the dried coil material 5 is heated to a temperature higher than the softening temperature of the thermoplastic film 1 using an infrared oven or the like.

In this heating, heating power such as infrared rays is first applied to the cut end surface of the thermoplastic film 1, so this part first reaches the softening temperature and the thermoplastic film 1 begins to shrink, as shown in FIG. The end face of the metal foil 2 is insulated by the thermoplastic film 1, and when this state is achieved, the coil is completed when taken out from the heating furnace.

Since the end faces of this coil are also insulated by the shrinkage of the thermoplastic film 1, there is no risk of short circuiting even if a conductive substance comes into contact with this end face, resulting in a completely insulated coil.

Since the metal foil 2 with a flat coil cross section is used, there is no wasted space, and the effective utilization rate of the coil cross section is increased.By reducing the thickness of the thermoplastic film 1 and the metal foil 2, the coil Density can be increased.

However, since the weight of the metal parts can be reduced, the weight of the coil can also be reduced, preventing short circuits between layers due to poor insulation, such as with electric wires insulated with insulating paint.
A coil without the risk of disconnection can be obtained.

The coil of the present invention is suitable as a coil with a small current, such as a coreless motor, a transformer coil, or a Coatlige power generation coil.

As described above, according to the present invention, a cylindrical wound body is formed by polymerizing and winding a metal foil and a thermoplastic film, and the coil material is formed by cutting this into round slices of a predetermined width. A large number of coil materials can be easily manufactured at the same time.

Then, these go through the steps of etching, neutralization, and heating to remove interlayer short circuits caused by cutting burrs, etc., and to insulate the end surfaces. Since it is not necessary to carry out the process for each coil material and a large number of processes can be carried out at the same time, a large number of coils can be manufactured easily and in a short time.

[Brief explanation of the drawing]

Figure 1 is a diagram of the winding process for a cylindrical wound body, Figure 2 is a cutaway diagram of the coil material, Figure 3 is an enlarged sectional view of the main part of the coil material after etching, and Figure 4 is the finished product. FIG. 3 is an enlarged cross-sectional view of main parts. 1...Thermoplastic film, 2...Metal foil, 3...
... Winding frame, 4... Cylindrical winding body, 5... Coil material.

Claims (1)

[Claims] 1. A step of polymerizing a conductive metal foil and an insulating thermoplastic film and winding the film a required number of turns so that its cross section has a desired shape; A process of obtaining a coil material by cutting the coil material into rings of the required width, and immersing only the metal foil of the coil material in an etching solution capable of etching the cut end of the metal foil from the cut end of the thermoplastic film. The coil material that has been etched is heated to a temperature higher than the softening temperature of the thermoplastic film, and the cut end surface of the thermoplastic film is fused to cover the cut end surface of the metal foil for insulation treatment. A coil manufacturing method consisting of a process and.