JPH0662505U - Thin coil - Google Patents

Abstract

(57) [Summary] (Corrected) [Purpose] The wound body can be cut without removing the core,
Moreover, even if there is a winding core, the electrode is formed on the inner peripheral side of the coil. A coil formed by winding a metal foil, which is obtained by coating a surface of a conductor layer with an insulating layer, on a winding core and cutting the metal foil into a predetermined thickness. The winding core has a substantially C-shaped cross section. The bobbin 1 is formed in the shape of a ring, and the opening 1a of the bobbin 1 is formed.
The electrode part 5 exposing the conductor layer of the coil is arranged in the. [Effect] Since the electrode portion can be provided in the opening of the bobbin, it is not necessary to remove the winding core from the winding body. As a result, it is possible to prevent damage or deformation of the coil inner peripheral portion that occurs when the winding core is pulled out.

Description

[Detailed description of the device]

[0001]

[Industrial applications]

 The present invention relates to a thin coil arranged in a stator of a flat facing type brushless motor, for example.

[0002]

[Prior art]

 This type of thin coil is arranged, for example, in a two-phase or three-phase configuration on the stator substrate of a flat-opposed brushless motor, and is excited by energizing each thin coil with a predetermined phase current to generate a thin coil. The drive magnet of the rotor, which faces the coil in a plane, is rotationally biased. As such a thin coil, a laminated body in which an insulating layer is laminated on a conductor layer made of metal foil is wound a predetermined number of times to obtain a wound body, and the wound body is cut into a predetermined thickness in a circular slice. Known is a thin coil.

FIG. 5 shows a forming process of a thin coil, FIG. 5A shows a metal foil 10 for obtaining a thin coil, and a metal foil 10 is a wide conductor layer 11 made of a copper foil or an aluminum foil. The insulating layer 12 is made of, for example, poly-amide-imide resin, epoxy resin, or ceramic composite polymer, which is laminated or applied on one surface of the conductor layer 11. The insulating layer 12 may be laminated or applied on both sides of the conductor layer 11. An adhesive is applied to the surface of the metal foil 10 configured as described above, and as shown in FIG. 5 (b), the circumference of the winding core 13 having a predetermined cross-sectional shape is intervened by the presence of the adhesive. After being wound a predetermined number of times, the metal foils 10 are overlapped with each other and adhered to each other with the above adhesive to form a wound body 14 as shown in FIG. 5C.

As shown in FIG. 5 (d), the wound body 14 is obtained by extracting the winding core 13 as shown in FIG. 5 (c), and then cutting the wound core 14 into a sliced shape with a predetermined thickness by a multi-wire saw or band saw. Such a thin coil 15 is formed. Electrodes 16 and 17 are formed at the winding start of the inner peripheral surface and the winding end of the outer peripheral surface of the thin coil 15 thus formed. These electrodes 16 and 17 are formed by scraping off the insulating layer 12 at the front end portion of the metal foil 10 with a paper file or by dissolving with a solvent to remove a part of the end portion in a step before winding the metal foil 10. The electrode 16 on the inner peripheral side is formed, and after the metal foil 10 is wound a predetermined number of times, the end portion is peeled off similarly to the winding start portion on the rear end portion to form the electrode 17 on the outer peripheral side. In some cases, the winding core 14 may be cut into a ring-shaped shape with a predetermined thickness without removing the winding core 13 from the winding body 14.

[0005]

[Problems to be solved by the device]

 However, in the above thin coil, after winding a metal foil around a winding core to form a wound body, the winding core is extracted and cut into slices. There was a problem that the inner peripheral surface of the thin coil was damaged, and the inner peripheral part of the thin coil was deformed after extraction. Further, when the wound body is cut without removing the winding core, there is a problem that it is difficult to provide an electrode on the inner peripheral surface of the coil.

The present invention has been made in order to solve such a problem, and the wound body can be cut without pulling out the winding core, and even if there is a winding core, the inner circumference side of the coil can be cut. It is an object of the present invention to provide a thin coil capable of forming an electrode on a coil.

[0007]

[Means for Solving the Problems]

 The present invention is a coil formed by winding a metal foil, which is obtained by coating an insulating layer on the surface of a conductor layer, and cutting the metal foil to a predetermined thickness. It is characterized in that it is composed of a C-shaped bobbin, and that the coil has an electrode portion in which the conductor layer of the coil is exposed.

[0008]

[Action]

 If a bobbin having a substantially C-shaped cross section is used as a winding core and a coil is provided with an electrode portion having a conductor layer exposed in the opening of the bobbin, an electrode is provided at the opening of the C-shaped bobbin. Since it can be provided, it is possible to cut into a ring shape without removing the winding core from the winding body. Further, it is not necessary to remove the conventional winding core, and damage or deformation of the inner peripheral portion of the coil can be prevented. In addition, the process of extracting the core can be omitted, and the extracting machine is not necessary, which reduces the manufacturing cost.

[0009]

【Example】

 An embodiment of a thin coil according to the present invention will be described below with reference to the drawings. FIG. 1 shows a thin coil according to the present invention. A bobbin 1 having a substantially C-shaped cross section is used as a winding core, an opening 1a is formed in the bobbin 1, and a metal foil 2 is insulated in the opening 1a. The electrode portion 5 having the conductor layer 4 exposed by peeling off the layer 3 is arranged correspondingly, and the metal foil 2 is wound from this state to obtain a wound body 6, which is cut to a predetermined thickness. This forms the thin coil 7.

That is, as shown in FIG. 2, the metal foil 2 includes a wide conductor layer 4 made of a copper foil or an aluminum foil and, for example, a polyamide amide laminated on both surfaces of the conductor layer 4. The insulating layer 3 is made of resin, epoxy resin, ceramic composite polymer, or the like. Then, the insulating layer 3 near the end portion of the one surface is peeled off by scraping off a predetermined size with a paper file or dissolved by a solvent, and the electrode 8 on the inner peripheral side is formed.

As shown in FIG. 2, the metal foil 2 thus formed is wound with the electrode portion 5 arranged in the opening 1a of the bobbin 1 having a substantially C-shaped cross section. In other words, the bobbin 1 is made of synthetic resin having electrical insulation and relatively good machinability, and is formed like a triangular C-shaped groove as shown in FIG. Has an opening 1a.

Then, when the metal foil 2 is wound a predetermined number of times with the bobbin 1 as a winding core, a wound body 6 as shown in FIG. 1A is obtained. By cutting this wound body 6 together with the bobbin 1 as a winding core to a predetermined thickness, a thin coil 7 shown in FIG. 1B is obtained. As a result, the inner peripheral electrode portion 5 is formed in the opening 1a of the bobbin 1 of the thin coil 7. Further, the electrode portion 6 is formed on the outer peripheral side of the thin coil 7 in the same manner as in the above-mentioned example.

4 (b) and 4 (c) show a modified example of the bobbin 1 serving as a winding core, and FIG. 4 (b) has a substantially circular cross section. Further, FIG. 4 (c) has a quadrangular cross section, and an opening 1a is formed in a part thereof. These bobbins 1 are appropriately changed, for example, according to the shape of the thin coil set by the specifications of the stator of the brushless motor, and can be changed to any shape.

It should be noted that the above-described embodiment is merely an example, and the metal foil for obtaining the thin coil may be one in which an insulating layer is laminated on one surface side of the conductor layer. In this case, the surface where the conductor layer is exposed is brought into contact with the opening of the bobbin and wound. Further, the bobbin may be formed of a metal plate whose surface is insulated, in addition to resin. Further, in order to maintain the size of the opening of the bobbin during winding, a reinforcing rod may be inserted inside the bobbin and only the rod may be pulled out before cutting. Various changes can be made without departing from the above.

[0015]

[Effect of device]

 As is clear from the above description, according to the thin coil according to the present invention, the bobbin having a substantially C-shaped cross section is used as the winding core, and the coil is provided with the electrode portion in which the conductor layer is exposed in the opening of the bobbin. Since the electrodes are arranged in the opening of the bobbin because of the arrangement, it is not necessary to remove the winding core from the winding body. As a result, it is possible to prevent damage or deformation of the inner circumference of the coil that occurs when the winding core is removed. In addition, it is possible to omit the step of extracting the winding core and eliminate the need for an extracting machine or the like, which is advantageous in that the manufacturing cost can be reduced.

[0016]

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of a thin coil according to the present invention.

FIG. 2 is a cross-sectional view showing a metal foil for obtaining the same thin coil.

FIG. 3 is a cross-sectional view showing a bobbin portion of the same thin coil.

FIG. 4 is a plan view showing a modified example of the bobbin of the same thin coil.

FIG. 5 is an explanatory view showing a forming process of a conventional thin coil.

[Explanation of symbols]

 1 bobbin 1a opening 2 metal foil 3 insulating layer 4 conductor layer 5 electrode part 6 winding body 7 thin coil

Front page continuation (72) Inventor Taiji Matsuyama 14-888 Ako, Komagane-shi, Nagano Sankyo Seiki Co., Ltd. Komagane factory

Claims (1)

[Scope of utility model registration request] 1. A coil formed by winding a metal foil having an insulating layer coated on the surface of a conductor layer and cutting the metal foil to a predetermined thickness, wherein the core has a cross section. A thin coil comprising a bobbin formed in a substantially C-shape, and an electrode portion exposing a conductor layer of the coil is arranged in an opening of the bobbin.