JPH0677043A - Coil element and electrical equipment using this - Google Patents

Abstract

PURPOSE:To contrive generation of a strong magnetic field at the small amount of winding by a method wherein insulating layers are respectively attached to both side surfaces of a coil obtained by winding an insulating electrical wire in a flat plate form in an air-core winding to compress side plates consisting of a magnetic material and at the same time, an intermediate insulating layer is provided in almost the center in the direction of winding of the CONSTITUTION:A coil 2 is one having the number of winding columns of two columns, obtained by winding an insulating electrical wire 6 covered with an insulating film in an alignment winding on a conductor of 95% or higher of a conductivity and an intermediate insulating layer 3 is arranged in the middle between two pieces of these winding columns 7 and 7. The winding ends of these winding columns 7 and 7 are connected with leads. Moreover, two sheets of side surface insulating layers 4 and 4 are respectively provided on both side surfaces of such the coil 2. Two sheets of side plates 5 and 5 consisting of a magnetic material are respectively clamped and mounted on both sides of the layers 4 and 4. Thereby, the winding columns 7 and 7 of the coil 2 approach nearer the side plates 5 and 5, a magnetic flux generated in the coil 2 is efficiently transmitted to the side plates 5 and 5, the intensity of a strong magnetic field can be obtained and moreover, the magnetic vibration of the coil and the like can be also prevented front being generated.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention allows a magnetic field generated in a coil to be concentrated in the central portion of the coil without leaking to the outside.
The present invention relates to a coil element capable of obtaining a high magnetic field with a small number of windings, and an electric device such as a transformer, a motor or a generator using the coil element.

[0002]

2. Description of the Related Art Most conventional coils used in transformers, motors, etc. have a structure in which an insulated wire (magnet wire) is simply and densely wound around a winding core. In such a coil, the strength of the magnetic field generated is proportional to the number of turns and the current, so the required coil characteristics are determined under this condition, especially when the current and voltage are limited. The number determines the strength of the magnetic field.

Therefore, in order to obtain a strong magnetic field, the number of turns is increased. However, when the number of turns is increased, the conductor is inevitably wound at a position away from the center winding core, and the insulated wire is insulated. However, there is a drawback that a strong magnetic field cannot be obtained at the center of the winding core, which is the core. That is, most of the magnetic force generated in the winding wire located away from the winding core leaks to the outside and does not contribute to the central portion of the winding core.

[0004]

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to efficiently concentrate the magnetic force generated in the winding on the central portion of the winding core and to generate a strong magnetic field with a small winding amount. It is to obtain a coil element that can obtain strength.

[0005]

SUMMARY OF THE INVENTION The problem is that a coil is formed by winding an air-core wound insulated wire having a conductor having a conductivity of 95% or more in a flat plate shape, and is made of a magnetic material via insulating layers on both sides. This can be solved by compressing the side plates and providing a coil element having a structure in which an intermediate insulating layer is provided substantially at the center of the coil in the winding width direction.

[0006]

In the coil element having such a structure, the side plate made of a magnetic material constitutes a kind of magnetic circuit, and most of the magnetic flux generated in the coil is concentrated in the central portion of the coil element.
In particular, the magnetic flux generated on the outer peripheral side of the coil is also guided to the side plate and concentrated on the central portion without leaking to the outside, and a high magnetic flux is generated at the central portion which is the core portion. Therefore, this coil element produces a high magnetic field with a small amount of winding.

[0007]

1 to 3 show an example of a coil element of the present invention. The coil element 1 includes a coil 2, an intermediate insulating layer 3 and two side surface insulating layers 4 as shown in FIG. , 4
And two side plates 5 and 5. FIG. 2 shows the internal structure of the coil element 1 with the side plates 5 and 5 and one side surface insulating layer 4 removed.
Shows the appearance of the coil element 1.

The coil 2 has two windings obtained by winding one insulated wire 6 in an aligned winding, and an intermediate insulating layer 3 is provided between the two windings 7, 7. It is distributed. These winding rows 7 and 7 are wound in opposite directions with the same number of windings, and the beginning of each winding is at the innermost circumference,
The winding ends are at the outermost circumferences, and the leads 8 extend from these winding ends. Also, each winding 7,
One insulated wire 6 is continuous at the beginning of winding 7.

The outer diameter of the coil 2 is 25 to 300 m.
m, the inner diameter is 10 to 100 mm, the ratio of (outer diameter) to (inner diameter) is preferably about 3 to 1, the number of winding layers is preferably about 20 to 750, and the number of windings depends on the heat generation amount and the generated magnetism. Determined by strength, usually 40-5000
It is a range of turns.

As the insulated wire 6, a conductor coated with an insulating coating is used. The conductor here is selected to have a conductivity of 95% or more (IACS). A conductor having an electric conductivity of less than 95% is not preferable because the magnetic field and heat are simultaneously generated and the strength of the magnetic field is reduced. As the conductor, copper, copper alloy, aluminum, aluminum alloy, gold, gold alloy, platinum, silver, silver alloy, carbon fiber, etc. are used, and the conductor diameter is preferably about 0.05 to 10 mm, but outside this range. It may be. Further, not only a round wire, but also a conductor having an irregular cross section such as a rectangular wire may be used.

The insulating coating is not particularly limited, and those widely used in this field can be widely used. For example, polyester, polyurethane, polyimide, polyamide, polyester imide, polyester amide, polyimide amide, polyhydantoin, nylon, polybutyral, epoxy, phenoxy, amino resin modified epoxy, amino resin modified phenoxy and the like. The thickness of this insulating coating is usually in the range of 1 to 100 μm, but it may be out of this range.

The intermediate insulating layer 3 is made of a material having electrical insulation and a certain degree of flexibility, for example, a plate-like thickness of 0.1 to 0.1.
1 mm of mica, glass cloth, glass mat, ceramic paper (sheet) or the like coated with an adhesive such as an epoxy adhesive is used. As shown in FIG. 3, the intermediate insulating layer 3 has a square outer shape, and has a circular hole corresponding to the hollow portion of the coil 2 at the center thereof. Insulated wire 6
A notch 9 for locating the inner peripheral side is formed toward the hole. The coil 2 is in a state where the windings 7, 7 are fixed to the intermediate insulating layer 3 with an adhesive on the surface of the intermediate insulating layer 3. In addition, as the intermediate insulating layer 3, a plate material made of a magnetic material such as an iron plate, a steel plate, a silicon steel plate, and a ferrite plate is laminated with the above-described insulating material such as mica, glass cloth, glass mat, and ceramic paper, and the insulating material It is also possible to use one having an epoxy adhesive applied on the surface. This is advantageous when a coil having a large number of windings or an insulated electric wire having a small diameter is used, and like the side plate 5 described later, the magnetic material in the central portion forms a magnetic circuit, and the magnetic force is effectively generated in the central portion. You can concentrate on

Further, two side surface insulating layers 4 and 4 are provided on both side surfaces of such a coil 2. As the side surface insulating layer 4, the same one as the intermediate insulating layer 3 described above is used, but no cut is required. These side surface insulating layers 4 and 4 are also firmly fixed to the windings 7 and 7 by the adhesive on the surface thereof.

Then, two side plates 5 and 5 made of a magnetic material are press-fitted and attached to both sides of the side surface insulating layers 4 and 4 to form a coil element 1 of this example as shown in FIG. Has been done. In the side plate of this example, one side plate 5 is
A shallow dish-shaped accommodating portion 5a having the thickness of the coil element 1 and a bent portion is formed, the other side plate 5 is a flat plate-like lid portion 5b, and the coil 2 and the intermediate insulating layer 3 and the side surface are formed in the accommodating portion 5a. The insulating layers 4 and 4 are housed together, the lid 5b is covered, and then pressure is applied by a pressing device, and the bent portion 5c is bent and integrated as shown in FIGS. 1 and 3. . The side plates 5 and 5 may be clamped by bolts and nuts other than the above-mentioned press working. It goes without saying that the side plates 5 and 5 are naturally provided with circular holes corresponding to the hollow portions of the coil 2.

As the side plate 5, a metal plate made of a magnetic material such as soft iron, steel or silicon steel is used. Usually, a stainless steel plate (excluding 18-8 steel is excluded) from the viewpoint of durability and rust resistance. ), Galvanized, tin-plated, or other rustproof iron plate is used. The thickness of the side plate 5 is about 0.02 to 5
mm is preferable, and the surface area is 20 to 3000 per sheet
It is preferably 1.5 times or more of the coil surface area in cm ² . Further, a large number of ribs protruding outward can be formed on the side plate 5 in terms of heat dissipation, strength, and prevention of magnetic vibration.

If a non-magnetic material such as aluminum is used for the side plate 5, the strength of the magnetic field is reduced, which is not preferable. However, if a laminated plate of an iron plate and an aluminum plate is used, the reduction of the magnetic field can be prevented.

Further, in this coil element 1, the side plates 5, 5 are
It is important to clamp the central coil 2 at. That is, by tightening the side plates 5 and 5, each winding 7 of the coil 2
7 approaches the side plates 5 and 5, and the magnetic flux generated in the coil 2 is efficiently transmitted to the side plates 5 and 5. Also, magnetic vibrations and humming of the coil 2 can be prevented by this clamping, and damage to the insulating film can be greatly reduced.

In the coil element 1 having such a structure, since the side plate 5 is made of a magnetic material, the side plate 5
Constitutes a kind of magnetic circuit, and most of the magnetic flux generated in the coil 2 is concentrated in the central cavity portion 9 of the coil element 1, and particularly the magnetic flux generated in the outer peripheral side of the coil 2 is concentrated in the central cavity portion. A high magnetic flux is generated in the cavity. As a result, the coil element 1 has a strong generated magnetic field.
The strength of the generated magnetic field can be set within a wide range by appropriately changing the number of winding rows, the number of winding layers, and the number of windings of the coil 2.

In particular, each of the winding rows 7 and 7 is wound in the state of one row of aligned winding, and the state is fixed by the intermediate insulating layer 3 and the side surface insulating layers 4 and 4, so that each winding is wound. The magnetic fluxes generated in 1 do not cancel each other out, and all of them are concentrated and propagated to the magnetic circuit composed of the side plates 5 and 5, whereby the magnetic flux is concentrated very efficiently. Therefore, when the current flowing through the coil 2 is constant, it is possible to obtain the same magnetic flux density with 50% or less of the number of turns compared to the conventional coil, and if the number of turns is the same, the current value is 5%.
It is less than 0%.

4 and 5 each show another example of the coil element according to the present invention, which is similar to FIG.
In order to show the winding state of each winding train 7,
5 and one side insulating layer 4 are removed and drawn.
Both of these examples are large ones in which the amount of generated magnetic flux is large, and the same components as those in FIG. 2 are designated by the same reference numerals.
In these devices, the coil 2 is wound in a horizontal direction, and the side plates 5, 5 and the intermediate and side insulating layers 3,
This is different from the previous example in that the planar shapes of 4 and 4 are also horizontally long. The two or more holes formed in the coil element 1 are for passing a core rod required for winding the insulated wire 6 without slack, and one of these holes is a coil block described later. The hollow core of is inserted.

Further, in the present invention, the number of windings of the respective windings 7, 7 is not limited to one as the coil constituting the coil element, but two or more windings may be used. It is good if it is wound in a line. However, if the number of windings is too large, the efficiency of concentration of the magnetic field from the windings in the middle deteriorates, so it is preferable to keep the number of windings to 20 or less in each winding.

Next, the coil block will be described. Figure 6
Shows an example of the coil block of the present invention. The coil block 10 comprises a plurality of coil elements 1 ... As shown in FIG. As the hollow winding core 11, a metal pipe or the like whose insulation is cut off by mica or the like can be used.

The coil block 10 is composed of a plurality of coil blocks 10, usually about 2 to 5, in consideration of durability etc., because the strength of the magnetic field is limited in the coil element 1 alone. The connections between the leads 8 between the coil elements 1 ... May be connected in series or in parallel, and can be determined in consideration of the strength of the magnetic field. In addition, as shown in FIG. 6, a space of 1 to 10 mm is provided between the coil elements 1 ...
When the area of each coil element is widened, the coil elements 1 may be brought close to each other. Further, as the coil element 1 used in the coil block 10, the elements shown in FIGS. 4 and 5 can be used as a matter of course.

FIG. 7 shows an example of the motor of the present invention. In this motor 12, the above-mentioned coil block 10 is used for the field coil winding of the stator of a bear motor, which is a kind of induction motor. It is a thing. That is, the hollow core 11 of the coil block 10 has a structure in which the stator core 13 of the shading motor is inserted. Therefore, in the motor 12 having this structure, the stator field coil winding itself of the coil block 10 functions as a primary winding that generates a rotating magnetic field.

Further, the coil element of the present invention is not limited to the above-mentioned shunting motor, but may be any type of DC motor such as a series winding motor, a shunt winding motor, a compound winding motor, an AC motor such as an induction motor or a cycle motor. It can be used as a rotor or stator winding of a motor.

Further, the coil element of the present invention is a field winding of a direct-current generator such as a series-wound generator, a shunt-wound generator, a compound-winding generator or an alternating-current generator such as a synchronous generator or an induction generator. Or as an armature winding.

FIG. 8 shows an example of the transformer of the present invention. This transformer 15 includes a frame-shaped iron core 16 and a primary winding 1
7 and secondary winding 18 each have three coil elements 1 ... As the iron core 16, a normal hot-rolled silicon steel plate or a cold-rolled silicon steel plate laminated with interlayer insulation is used. The number of coil elements 1 attached is arbitrary on both the primary side and the secondary side, and can be appropriately changed according to the application.

In the example of FIG. 8, the coil elements 1 ... Are attached to the iron core 16 as they are, but the invention is not limited to this.
The coil core 10 of the coil block 10 shown in FIG.
It may be attached by passing it through.

Further, the coil element of the present invention can be widely used in place of a coil for generating a magnetic field such as a magnetic amplifier, and it is possible to obtain an effect such as a reduction in the winding amount or a power consumption, saving resources, It greatly contributes to energy saving.

Examples will be shown below. (Example 1) An insulated wire obtained by coating an anodized copper wire having a conductor diameter of 0.1 mm with an insulating coating (thickness: 50 μm) made of polyesterimide was used, and an outer diameter of about 60 mm, an inner diameter of 22 mm, and a winding length of 15
Insert the intermediate insulating layer of mica in the center by aligning winding with m,
The number of windings was two. Next, after fixing the side insulating layer of mica on both sides of this, 0.2 mm thick and 5 mm wide on both sides.
A side plate made of a stainless steel plate in which a center hole having a diameter of 20 mm and a length of 0 mm and a length of 50 mm was formed was press-fitted and attached to obtain a coil element as shown in FIG. When an alternating current (60 Hz) of 10 V was applied to this coil element, a current of 3.4 A flowed and the strength of the alternating magnetic field in the hollow portion of the coil element was about 150 gauss.

Comparative Example 1 A coil element was obtained in the same manner as in Example 1 except that an aluminum alloy plate having a thickness of 1 mm was used as the side plate. AC 10V to this coil element
Was applied, a current of 3.7 A flowed, and the strength of the AC magnetic field in the hollow portion was about 75 gauss.

(Comparative Example 2) A coil element was obtained in the same manner as in Example 1 except that the side plate was not used. When an alternating current (60 Hz) of 10 V was applied to this product, a current of 3.6 A flowed, and the strength of the alternating magnetic field in the hollow portion was about 70 gauss.

Example 2 A coil element was obtained in the same manner as in Example 1 except that the total number of windings was 4 and the winding length was 30 m. Alternating current (60Hz) to this coil element
When 10 V was applied, a current of 1.7 A flowed, and the strength of the AC magnetic field in the hollow portion was about 140 gauss.

(Example 3) Four coil elements obtained in Example 1 were connected to a hollow core and attached to form a coil block. As the hollow core, a steel pipe having an outer diameter of 21 mm, an inner diameter of 19 mm, and a length of 40 mm and having a thickness of 0.3 mm and having mica insulation was used. The leads were connected in series between the coil elements. Then, AC coil 50V
Was applied, a current of 3.8 A flowed, and the strength of the alternating magnetic field in the hollow portion of the coil block was about 160 gauss.

(Embodiment 4) The coil block obtained in Embodiment 3 is used as a stator field coil of a bear motor. This bear-rolling motor originally uses, as a stator field coil, a coil formed by tightly winding an insulated electric wire having a conductor diameter of 0.3 mm and a winding length of 200 m. An alternating current (60H) is applied to a bear motor equipped with the coil block of the present invention.
z) was applied and the applied voltage was gradually increased, it started to rotate at about 20V, and when it was set to 40V,
It rotated at full speed. Further, during the operation, no magnetic vibration or beat was generated in the coil block. On the other hand, in the conventional shading motor, the rotation was started only when the applied voltage was 40 V, and finally it was rotated at full speed at 70 V.

[0036]

As described above, according to the coil element of the present invention, the magnetic flux generated in the coil is efficiently concentrated at the center thereof by the action of the side plate made of the magnetic plate, and a high magnetic flux density can be obtained. . Therefore, high magnetic force is generated with a small number of windings, and high magnetic force can be generated with low current. Therefore, electric equipment such as motors, transformers, and generators that use this coil element can function as before with a small winding amount or current, which can contribute to resource and energy savings. .

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a coil element of the present invention.

FIG. 2 is an exploded cross-sectional view showing the content structure of the coil element of the present invention.

FIG. 3 is a perspective view showing an example of a coil element of the present invention.

FIG. 4 is a plan view showing another example of the coil element of the present invention.

FIG. 5 is a plan view of another example of the coil element of the present invention.

FIG. 6 is a sectional view showing an example of a coil block of the present invention.

FIG. 7 is a perspective view showing an example of a motor of the present invention.

FIG. 8 is a perspective view showing an example of the transformer of the present invention.

[Explanation of symbols]

 1 Coil Element 2 Coil 3 Intermediate Insulating Layer 4 Side Insulating Layer 5 Heat Sink 6 Heat Insulating Plate 6 Insulated Wire 7 Winding Row 10 Coil Block 11 Hollow Winding Core 12 Heating Motor 13 Stator Core 14 Rotating Shaft 15 Transformer 16 Iron Core

Claims (10)

[Claims] 1. A side plate made of a magnetic material is clamped through insulating layers on both side surfaces of a coil in which an insulated electric wire having a conductor having a conductivity of 95% or more is wound in a flat plate shape by air core winding, and the coil A coil element in which an intermediate insulating layer is provided approximately at the center of the winding width direction. 2. The coil element according to claim 1, wherein the coil has two winding rows, and an intermediate insulating layer is provided in the middle thereof. 3. The winding directions of the respective windings of the coil are opposite to each other, each winding start is at the innermost circumference, and each winding end is at the outermost circumference, and two windings are formed by one insulated wire. The coil element according to claim 2, wherein the coil element is continuously wound. 4. The coil element according to claim 1, wherein the insulating layer is mica having an adhesive applied on its surface. 5. The coil element according to claim 1, wherein the magnetic material is an iron plate, a stainless steel plate, or a silicon steel plate. 6. A coil block in which one or more coil elements according to claim 1 are connected to and attached to a hollow winding core. 7. An electric motor using the coil element according to claim 1. Description: 8. A generator using the coil element according to claim 1. 9. A transformer using the coil element according to claim 1. Description: 10. An electric device using the coil element according to claim 1.