JPH05176503A - Thin type coil and manufacture thereof - Google Patents

Abstract

PURPOSE:To eliminate an inter-winding layer short-circuit in a condition that a winding unit of laminated material, formed of conductive foil and an insulating layer is cut, so that a process of etching a cut section for eliminating the short- circuit is not provided after a cutting process. CONSTITUTION:In a thin type coil formed by winding a laminated material, consisting of conductor foil and an insulating layer, cut into a predetermined thickness, a method is for manufacturing the thin type coil with surface roughness of a cut section set to 0.48 to 0.14mum and for manufacturing the thin type coil, having a process of obtaining a winding unit 1 by winding the laminated material consisting of the conductor foil and the insulating layer and a cutting process of obtaining the thin type coil by using a wire saw to cut the winding unit 1 into a predetermined thickness, to use a wire 4 of 0.08 to 0.20mm diameter and a #1200 to #6000 abrasive grain (9.5 to 2.0mum grain size).

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thin coil applicable to, for example, a face-to-face motor and a manufacturing method thereof.

[0002]

2. Description of the Related Art For example, a face-to-face motor is characterized in that it can be flattened, but in order to make it even flatter, it is required to make the drive coil thinner. As a thin coil that can meet such requirements, a laminated body having a conductor foil and an insulating layer is wound a predetermined number of times to obtain a wound body,
There is known a thin coil obtained by cutting the wound body into a predetermined thickness in a sliced shape. FIG. 3 schematically shows the manufacturing process of such a thin coil. As shown in FIG.
One side edge of a laminate 16 having a conductive foil as a material and an insulating layer formed on the surface is temporarily fixed to the core 15, and an adhesive is applied to the laminate 16 and then wound around the core 15 a predetermined number of times. The wound body is wound to obtain the laminated body 16, and after the layers of the laminated body 16 are completely adhered to each other, the winding core 15 is extracted, and then, as shown in (b), the wound body is sliced into a predetermined thickness. A large number of thin coils 17 are obtained by cutting.

As a method of cutting the above-mentioned wound body into a sliced shape, an electric discharge machining method as described in JP-A-63-7608 or JP-A-61-231852 is disclosed. There is also a method of using a multi-wire saw, and there is also a method of using a band saw.

[0004]

No matter which of the above methods is used to cut the wound body of the laminated body composed of the conductor foil and the insulating layer, the cutting does not result in burrs, curls or chips. Since the winding layers are short-circuited, it was necessary to provide a step of etching the cut surface after the cutting step in order to eliminate the short circuit.

An object of the present invention is to eliminate a short circuit between winding layers in a state where a wound body of a laminated body composed of a conductive foil and an insulating layer is cut, and therefore, after the cutting process, a cut surface is etched to eliminate the short circuit. It is an object of the present invention to provide a thin coil that does not require a treatment step and a manufacturing method thereof.

[0006]

The invention according to claim 1 is
A thin coil obtained by winding a laminated body composed of a conductor foil and an insulating layer and cutting the laminated body to a predetermined thickness has a surface roughness of a cut surface of 0.48 to 0.14 μm.

According to a second aspect of the present invention, a step of winding a laminate having a conductor foil and an insulating layer a predetermined number of times to obtain a wound body, and using a wire saw, the wound body has a predetermined thickness. And a wire having a diameter of 0.08 to 0.20 mm in the cutting step using the wire saw.
Abrasive grains of 1200 to # 6000 (average grain size of 9.5 to 2.0
μm) is used.

[0008]

By setting the surface roughness of the cut surface to 0.48 to 0.14 μm, burrs, curls, chips, etc. on the cut surface become extremely small, and these do not extend over the winding layers.
A short circuit between winding layers is eliminated, and an etching process for eliminating the short circuit is unnecessary. Further, in a cutting process using a wire saw, a wire having a diameter of 0.08 to 0.20 mm and abrasive grains of # 1200 to # 6000 (average particle diameter of 9.5) are used.
.About.2.0 .mu.m), the surface roughness of the cut surface can be set to 0.48 to 0.14 .mu.m, whereby short-circuit between winding layers can be eliminated.

[0009]

Embodiments of the thin coil according to the present invention and a method for manufacturing the same will be described below with reference to FIGS. In FIGS. 1 and 2, the wound body indicated by reference numeral 1 is
A laminate having a conductor foil and an insulating layer is formed by winding a predetermined number of times as described with reference to FIG. As the conductor foil, for example, a copper foil having a thickness of about 18 to 35 μm can be used. The thickness of the insulating layer is 2
It is about 5 μm. A plurality of the winding bodies 1 are arranged in parallel on a holding base 2 made of carbon, and the winding bodies 1 adjacent to each other and between the winding body 1 and the holding base 2 are fixed with a wax 3, A plurality of winding bodies 1 are fixed on a holding table 2.

As described above, the plurality of winding bodies 1 are attached to the holding table 2
In the state of being fixed on the top, it is subjected to a cutting process using a multi-wire saw. In FIGS. 1 and 2, a plurality of winding bodies 1 are crossed in a widthwise direction with wires 4 constituting a multi-wire saw. The wire 4 is, for example, one piano wire, and the wire 4 is spirally laid between the supports arranged at regular intervals, so that the wire 4 is wound on the plurality of winding bodies 1 as described above. It crosses many times. The wire 4 is reciprocally moved in the lengthwise direction together with its support, and the wire 4 itself is also conveyed in one direction at a constant speed, and the wire 4 relatively moves with respect to the winding body 1 at a relatively high speed.
In this state, the wire 4 is pressed against each winding body 1, and the oil 5 in which abrasive grains are dispersed is supplied to the portion where the wire 4 and each winding body 1 are in contact with each other, and the above-mentioned abrasive grains dispersed in the oil 5 are wound in each winding. Cut the body 1 into slices. In FIG. 1, the one-dot chain line 4A shows the position of the wire 4 in the middle of the cutting process, and the two-dot chain line 4B shows the position of the wire 4 when the cutting is completed. When the cutting is completed, the wire 4 also cuts a part of the support base 2. After cutting,
A thin coil can be obtained by removing the wax 3 with methyl alcohol or another solvent. The width of the coil is 0.4 to 1.2
It is about mm.

The above cutting method itself using a multi-wire saw is known. The feature of the present invention is not in the cutting method itself using the multi-wire saw, but in the wire 4 and the abrasive grains used in the cutting step by the multi-wire saw, and by using the wire 4 and the abrasive grains. The surface roughness of the cut surface of the thin coil obtained.
That is, the diameter of the wire 4 of the multi-wire saw used in the cutting step of the wound body 1 is 0.08 to 0.20 mm,
Further, # 1200 to # 6000 abrasive grains (average grain size of 9.5
˜2.0 μm) dispersed in oil 5 for use.

When the wound body 1 is cut by setting the conditions of the wire 4 and the abrasive grains as described above, the surface roughness of the cut surface becomes 0.48 to 0.14 μm. If the surface roughness is within this range, burrs and curls on the cut surface are extremely small, and the particle size of the cutting chips is also very small. Therefore, it is not necessary to perform an etching process for eliminating a short circuit after the cutting process, and there is also an advantage that a waste amount due to etching is reduced. In order to more surely eliminate the short circuit between the winding layers, the diameter of the abrasive grains may be further reduced to further reduce the surface roughness of the cut surface.
If it is smaller than μm, the time required for cutting becomes long, which is not preferable in terms of production efficiency.

Further, by setting the conditions of the wire 4 and the abrasive grains in combination as described above, the width of each coil is uniform, the wire 4 is not thin, and the productivity is good. In addition to being a processing method suitable for cutting various coils, the coil produced under the above conditions has an advantage that, as already described, there is no short circuit between winding layers even without etching treatment.

By the way, the grain size of the abrasive grains used when the wound body 1 of the laminated body consisting of the conductor foil and the insulating layer is cut with a wire saw, and the surface of the cut surface when cut with the abrasive grains. The relationship of roughness is as follows: surface roughness is 0.48 μm for # 1200 abrasive grains, 0.24 μm for # 3000 abrasive grains, and 0.24 μm for # 6000 abrasive grains. Was 0.14 μm.

The thin coil obtained as described above is
A final thin coil is completed through a rust-proof coating process on the cut surface. The completed thin coil can be used as a drive coil of a face-to-face motor.

[0016]

According to the present invention, in a thin coil formed by winding a laminate consisting of a conductor foil and an insulating layer and cutting the laminate to a predetermined thickness, the cut surface has a surface roughness of 0.48 to 0.
Since it is 14 μm, burrs and curls on the cut surface are extremely small, and the grain size of the chips is also extremely small, so that the winding layers are not short-circuited by these burrs, curls, chips, etc. There is no need to perform an etching step to eliminate the waste, and the effect of reducing the amount of waste due to etching is obtained.

Further, a step of winding a laminated body having a conductor foil and an insulating layer a predetermined number of times to obtain a wound body, and cutting the wound body to a predetermined thickness with a wire saw to reduce the thickness. In the method for manufacturing a thin coil, which comprises a cutting step for obtaining a coil, the cutting step with a wire saw has a diameter of 0.08.
~ 0.20mm wire and # 1200- # 6000
The surface roughness of the cut surface of the coil is 0.48 to 0.14 by using the abrasive grains (average particle diameter of 9.5 to 2.0 μm).
μm, and a thin coil having the above-mentioned effect can be obtained.

[Brief description of drawings]

FIG. 1 is a front view showing an example of a manufacturing stage of a thin coil according to the present invention.

FIG. 2 is a plan view of the same.

FIG. 3 is a perspective view showing an example of a conventionally known method for manufacturing a thin coil.

[Explanation of symbols]

 1 winding body 4 wire

Claims (2)

[Claims] 1. A thin coil obtained by winding a laminated body having a conductor foil and an insulating layer a predetermined number of times and cutting this into a predetermined thickness, the cut surface having a surface roughness of 0.48 to 0. .14
A thin coil characterized by being μm. 2. A step of winding a laminated body having a conductor foil and an insulating layer a predetermined number of times to obtain a wound body, and cutting the wound body to a predetermined thickness with a wire saw to reduce the thickness. In the method for manufacturing a thin coil, which comprises a cutting step for obtaining a coil, the cutting step with the wire saw has a diameter of 0.08.
~ 0.20mm wire and # 1200- # 6000
2. The method for producing a thin coil, characterized in that the abrasive grains (average particle diameter of 9.5 to 2.0 μm) are used.