JPH0750218A - Manufacture of coil - Google Patents

Abstract

PURPOSE:To improve the space factor of a coil as well as to prevent a winding jig and the like from being contaminated. CONSTITUTION:A method of manufacturing a coil has a winding process for winding a flat type wire 1 by a winding jig 6, an alignment process, wherein while a vibration is applied to this jig 6 for aligning a winding wound by this winding process, this jig 6 is made narrow to the wire width of this flat type wire 1 to make the winding align, and a current conduction heating process, wherein after the winding is aligned by this alignment process, a coil wound with this wire 1 is heated by current conduction, a welded layer provided on this wire 1 is melted and this coil is secured.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a flat coil wound with a rectangular wire used in, for example, a stator coil or a transformer coil of a flat motor.

[0002]

2. Description of the Related Art As a stator coil of a conventional flat motor, for example, as shown in FIG. 2, the thickness is 0.060 mm and the width is 0.39.
A flat coil in which a 6 mm flat wire 1 is wound, for example, 264.5 turns is used.

As the rectangular wire 1, as shown in FIG. 3, an insulating layer 3 is provided on the outer periphery of a rectangular copper wire 2 and a fusion-bonding layer 4 made of, for example, an epoxy resin is provided on the outer periphery thereof. In FIG. 2, 1a and 1b are an inner terminal portion and an outer terminal portion, respectively, from which the insulating layer 3 and the fusion bonding layer 4 of the rectangular wire 1 are peeled off, and the coil shown in FIG. 2 is called a so-called tapless coil.

Conventionally, when manufacturing a flat coil as shown in FIG. 2, the flat wire 1 is set on a bobbin base as shown in FIG. 4, that is, the flat wire 1 is passed through a tensioning device 5 to wind the wire. It is set on the winding jig 6. In this case, as shown in FIG. 5, the tip end of the rectangular wire 1 is fixed to the mandrel forming the winding core 7, and the gap w between the fixed side disk 6a and the moving side disk 6b of the winding jig 6 is set to the rectangular wire. Width of 1 0.396
The width is slightly wider than 0.45 mm.

Thereafter, the outer surface of the rectangular wire 1 is coated with ethyl alcohol in the ethyl alcohol coating section 8 to melt the fusion layer 3 on the outer periphery of the rectangular wire 1 while the winding jig 6 is turned to 264.5 turns. To wind. In this case, the winding lines of the rectangular wire 1 are fixed by the fusion layer 3. After the winding operation is stopped, the lead wire at the end of the winding is cut into a designated length.

After that, the coil is removed from the winding jig, and the coil is hot-pressed for a predetermined time so that the ethyl alcohol is dried.

[0007]

However, the winding jig 6
The spacing w between the fixed side circular plate 6a and the movable side circular plate 6b is set to 0.3 in order to facilitate winding of the rectangular wire 1.
Since it is wider than 96 mm, for example, 0.45 mm,
This rectangular wire 1 meanders while being wound, and there is a disadvantage that the space factor decreases.

Further, in the conventional example, since the ethyl alcohol is applied when the rectangular wire 1 is wound, there is a disadvantage that the winding jig 6 and the winding core (mandrel) 7 are contaminated, and the amount of the applied ethyl alcohol is controlled. There was a difficult inconvenience.

In view of the above point, the present invention aims to improve the space factor of the coil and prevent the winding jig and the like from becoming dirty.

[0010]

The method of manufacturing a coil according to the present invention comprises a winding step of winding a rectangular wire 1 by a winding jig 6 as shown in FIG. 1, and a winding wound by this winding step. In order to arrange the winding jig 6, the winding jig 6 is aligned while being narrowed to the line width of the rectangular wire 1 while vibrating, and the rectangular wire 1 is aligned after the alignment step. The winding coil is electrically heated to melt the fusion layer 4 provided on the rectangular wire 1, and the coil is fixed by an electrically heating process.

[0011]

According to the present invention, after the wound windings are aligned, the coil on which the rectangular wire 1 is wound is electrically heated to melt the fusion layer 4 provided on the rectangular wire 1. Since the wires of the coil are fixed to each other, the space factor of the coil can be improved and ethyl alcohol is not used to melt the fusion layer 4 of the rectangular wire 1. It is possible to reduce dirt on the tool 6, the core 7, and the like.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the coil manufacturing method of the present invention will be described below with reference to FIG. In FIG. 1, FIG.
The same reference numerals are given to the parts corresponding to those in FIG. 5, and the detailed description thereof will be omitted. Also in this example, an example of manufacturing a flat coil used as a stator coil of a flat motor as shown in FIG. 2 will be described. The flat wire 1 used for this flat coil has a thickness of 0.060 mm and a width of 0.396 mm.
As shown in FIG. 3, the structure is such that the insulating layer 3 is provided on the outer periphery of the rectangular copper wire 2 and the fusion layer 4 made of, for example, an epoxy resin is provided on the outer periphery thereof.

In this example, first, as shown in FIG.
Set this rectangular wire 1 on the bobbin stand, that is, this rectangular wire 1
Through the tension device 5 and set on the winding jig 6 of the winding machine. In this case, in this example, as shown in FIG. 1A, the tip portion 1c of the rectangular wire 1 is passed through a mandrel constituting the winding core 7, and further through a through hole 13 formed in the fixed side disk 6a of the winding jig 6, The fixed side disk 6a is fixed so as to project from the outer peripheral surface.

Further, the fixed side disk 6a and the moving side disk 6
The interval w of b is set to 0.45 mm, which is slightly wider than the width 0.396 mm of the rectangular wire 1. Winding speed 132r in this state
This winding jig 6 is rotated about the winding core 7 at pm
Wind for 4.5 turns. The back tension at this time is 370 g, and the winding is performed at room temperature.

After the winding operation is stopped, in this embodiment, the moving side disk 6a of the winding jig 6 is applied with a vibration of 10 to 20 Hz by a vibration device 9 provided on the moving side disk 6a.
It moves in the direction of narrowing indicated by the arrow, and moves until the distance w between the fixed side disk 6a and the moving side disk becomes approximately equal to the width 0.396 of the rectangular wire 1.

In this case, since alcohol is not used at the time of winding the rectangular wire 1 and the operation is performed at room temperature, the fusion layer 4 is not melted, and the meandering of the rectangular wire 1 at the time of winding can be satisfactorily adjusted. it can.

After the wound coils are aligned, the winding jig 6 is left as it is, and the winding start portion 1c of the coil is maintained.
And the insulating layer 3 and the fusion bonding layer 4 of the rectangular wire 1 of the winding end portion 1d are peeled off by a cutter or the like, and the peeled winding start portion 1c is formed.
1A, the electrode 10a connected to the positive electrode of the DC power supply 12 is connected via the connection switch 11, and the electrode 10b connected to the negative electrode of the DC power supply 12 is connected to the winding end portion 1d. For example, a voltage of 70 V is applied to the rotated coil so that a current of 2 A is flown to heat the coil.

In this case, the fixed side disc 6a and the moving side disc 6b of the winding jig 6 are kept stationary.

By this electric heating, the fusion layer 4 of the rectangular wire 1 between the wires of the coil is melted, and then cooled and taken out from this winding jig to fuse the space between the wires of the coil, It is possible to obtain a flat coil in which the wires are fixed to each other.

In the above-mentioned example, the winding start portion 1c and the winding end portion 1d can be used as terminals, respectively. However, when the tapless coil as shown in FIG. 2 is used, a luter, a cutter or the like is used after forming the coil and the rectangular wire is used. If the insulating layer 3 and the fusion bonding layer 4 of No. 1 are peeled off to form the inner terminal 1a and the outer terminal 1b, the positional accuracy of the terminals 1a and 1b can be improved.

As described above, according to the present embodiment, the wound windings are aligned and the meandering of the windings is adjusted, and then the flat wire 1 is electrically heated to the wound coil. Since the fusing layer 4 provided in the coil is melted and the wires of the coil are fixed to each other, the space factor of the coil can be improved and the fusing layer 4 of the rectangular wire 1 can be formed. Since ethyl alcohol is not used for melting, winding jig 6,
There is an advantage that the contamination of the winding core 7 and the like can be reduced.

The present invention is not limited to the above-mentioned embodiments, and it goes without saying that various other configurations can be adopted without departing from the gist of the present invention.

[0023]

According to the present invention, there is an advantage that the space factor of the coil can be improved and the winding jig and the like can be prevented from getting dirty.

[Brief description of drawings]

FIG. 1 is a configuration diagram for explaining an embodiment of a coil manufacturing method of the present invention.

FIG. 2 is a perspective view showing an example of a flat coil.

FIG. 3 is a cross-sectional view showing an example of a rectangular wire.

FIG. 4 is a configuration diagram for explaining an example of a conventional coil manufacturing method.

FIG. 5 is a cutaway front view showing an example of a winding jig.

[Explanation of symbols]

 1 rectangular wire 4 fusion layer 6 winding jig 6a fixed side disk 6b moving side disk 7 winding core 9 vibration device 12 DC power supply

Claims (1)

[Claims] 1. A winding step of winding a rectangular wire with a winding jig, and the winding jig is applied while vibrating the winding jig in order to arrange the winding wound by the winding step. An aligning step of narrowing and aligning the wire width of the rectangular wire, and after aligning by the aligning step, the coil around which the rectangular wire is wound is electrically heated to melt the fusion layer provided on the rectangular wire. A method for manufacturing a coil, comprising an electric heating step for fixing the coil.