JPH099587A - Flat air-core coil - Google Patents

Abstract

PURPOSE: To provide a flat air-core coil which has a high space factor and is inexpensive by cutting in a predetermined width a thin body formed of a wide conductive thin body and insulating thin bodies applied to both sides of the conductive thin body and making an insulator in an electrically conductive aqueous solution adhere to a cut surface. CONSTITUTION: A flat air-core coil 9 is made by the following method: A thin body formed of a wide conductive thin body 1 and insulating thin bodies 2 applied to both sides of the conductive thin body 1 is cut in a predetermined width to form a tape-like thin body 4. Next, an electric conductor cut part 5 which is the cut surface of the tape-like thin body 4 is immersed in an electrically conductive aqueous solution to which a voltage is being applied to make an insulator 7 in the electrically conductive aqueous solution adhere to the electric conductive cut part 5 and after that, an excessive insulator is removed and the tape-like thin body 4 is passed through a baking furnace, thereby being hardened, and it is wound on a take-up reel. As a result, a flat air-core coil which has a high space factor, is free from a layer short with respect to a ribbon-form wire made by rolling a round wire and has an arbitrary width can be made at low costs.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flat air core coil used as a driving coil of a motor, which is a coil for driving a plurality of trapezoidally wound coils in combination.

[0002]

2. Description of the Related Art Conventionally, a flat air core coil is most commonly formed by forming an insulating coating wire having a circular cross section in a winding frame of a required shape in a required number of turns coil.

[0003]

However, in the case of the insulating coated conductive wire having such a circular cross section, as shown in FIG. 5, since the conductor 11 cannot occupy a high occupancy in the cross sectional area, the number of turns is smaller than the required number of turns. There is a drawback that the cross-sectional area becomes large. That is, when the radius of the wire including the insulating layer is R1 and the radius of the conductor 11 in the wire is R2, the ratio of the cross-sectional areas of the conductors occupied by the wire in the cross-sectional area is 90. 7%, for example, a polyurethane copper wire that uses a copper wire with a diameter of 0.17 mm as the conductor 11 has a maximum coating diameter of 0.214 mm, so the space factor is 62% and it is necessary to reduce the size and thickness of the motor. There is a limit.

Further, in recent years, a coil has been proposed in which a conductive thin body and an insulating thin body are adhered, rolled up, and cut into a predetermined thickness. In this case, the space factor of the coil is smaller than that of a coil having a circular cross section. Although it is high, burrs of the conductive thin body are generated on the end face portion, which causes interlayer short-circuiting, and therefore chemical treatment such as etching must be performed, resulting in large scale manufacturing equipment, complicated manufacturing process, and cost. Is at a disadvantage.

Further, a ribbon-shaped coil in which a coil having a circular cross section is rolled and the insulating layer 12 is baked and coated as shown in FIG. 6 has been proposed in recent years. In this case, the insulating layer 12 becomes thin at the edge portion of the coil. It is easy to cause an interlayer short,
Further, there is a problem that rolling is limited and it is difficult to finish it to a predetermined size.

The present invention has been made in view of the problems of the conventional flat air-core coil, and provides a flat air-core coil which has a high space factor and is inexpensive.

[0007]

According to the present invention, a wide conductive thin body and a thin body in which an insulating thin body is adhered on both surfaces of the conductive thin body are cut into a predetermined width, and the cut surface of the thin body is cut. In addition, an insulator in an electrically conductive aqueous solution is applied to the thin body and the electrically conductive aqueous solution by applying an electric potential to the cut surface of the thin body, and adhered thereto.

[0008]

According to the present invention, the insulating thin body is adhered to both sides of the conductive thin body, cut into a predetermined width, the insulator is attached to the conductor cutting portion, and then the winding frame is wound a predetermined number of times. By producing a flat air-core coil by turning, a flat air-core coil with a high space factor and no interlayer short-circuit can be produced in comparison with a conventional coil wound with a round wire.

[0009]

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

In FIG. 1 (a), reference numeral 1 is a conductive thin body made of a metal such as copper, silver or aluminum. Reference numeral 2 denotes an insulating thin body, which is attached to both surfaces of the conductive thin body 1 to form a thin body 3 as a whole. The thin body 3 is wound around a take-up reel, which is not shown here. In FIG. 1B, 4 is a tape-shaped thin body obtained by cutting the thin body 3 into a predetermined size, and 5 is a conductor cutting portion. The tape-shaped thin body 4 is shown in FIG.
As shown in FIG. 4, the insulator 7 melted in the electroconductive aqueous solution 6 by being immersed in the electroconductive aqueous solution 6 for a certain period of time and applying a voltage between the electroconductive aqueous solution 6 and the tape-shaped thin body 4.
Adheres to the conductor cutting portion 5 of the tape-shaped thin body 4. The insulator 7 attached to the conductor cutting portion 5 of the tape-shaped thin body 4.
After the cleaning process, the excess insulation is removed, and the product is passed through a baking oven to cure and is wound up on a take-up reel.

The tape-shaped thin body 4 produced through the above-mentioned steps becomes a thin body having good insulation by being covered with the insulating thin body 2 and the insulating body 7 around the conductive thin body 1. FIG. 3A shows a flat air core coil 9 in which the tape-shaped thin body 4 is wound around a winding frame 8 by a predetermined number of turns, and FIG. 3B shows the flat air core coil 9
FIG. FIG. 4 is a detailed view of the AA cross section of the flat air core coil. Since the tape-shaped thin body 4 is a thin body which is covered with the insulating thin body 2 and the insulating body 7 and has a good insulating property, the flat air-core coil 9 is an excellent coil without interlayer short-circuit.

As described above, according to this embodiment, the wide conductive thin body 1 and the thin body 3 in which the insulating thin bodies 2 are attached to both surfaces of the conductive thin body 1 are cut into a predetermined width. A tape-shaped thin body 4 is formed, and the tape-shaped thin body 4 is dipped in a conductor cutting portion 5 which is a cut surface and an electrically conductive aqueous solution 6 while applying a voltage,
The insulator 7 in the electrically conductive aqueous solution 6 is replaced with the conductor cutting portion 5
Then, the flat air-core coil 9 is manufactured by winding a predetermined number of turns on the winding frame 8 to roll the round wire at a high space factor and with respect to the coil wound with the conventional round wire. It is possible to make a flat air-core coil having an arbitrary width with no interlayer short-circuit with respect to the formed ribbon-shaped wire.

In this embodiment, the tape-shaped thin body 4 was immersed in the electrically conductive aqueous solution 6 and then wound around the winding frame 8. However, the tape-shaped thin body 4 is wound around the winding frame 8 by a predetermined number of turns. The same effect can be obtained by winding the flat air-core coil 9 and immersing the flat air-core coil 9 in the electrically conductive aqueous solution 6 to attach the insulator 7 to the cut surface of the flat air-core coil 9.

[0014]

As described above, according to the present invention, a ribbon-shaped wire formed by rolling a round wire with a high space factor for a coil wound with a conventional round wire has no interlayer short circuit. A flat air core coil of any width can be made.

[Brief description of drawings]

FIG. 1A is a perspective view of a thin body according to an embodiment of the present invention. FIG. 1B is a perspective view of a cut tape-shaped thin body according to the embodiment.

FIG. 2 is a diagram showing a step of attaching an insulator to a cut surface of a tape-shaped thin body.

FIG. 3A is a perspective view of a flat air-core coil in the same embodiment. FIG. 3B is a sectional view taken along line AA ′ of the flat air-core coil in the same embodiment.

FIG. 4 is a detailed view of an AA ′ cross-sectional view of a flat air core coil.

FIG. 5 is a diagram for considering the space factor of a conventional round wire.

FIG. 6 is a sectional view of a conventional ribbon coil.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Conductive thin body 2 Insulating thin body 3 Thin body 4 Tape-like thin body 5 Conductor cutting part 6 Electrically conductive aqueous solution 7 Insulator 8 Reel frame 9 Flat air core coil 11 Conductor 12 Insulating layer

Claims (2)

[Claims] 1. A wide conductive thin body and a thin body in which an insulating thin body is attached to both surfaces of the conductive thin body are cut into a predetermined width, and the cut surface of the thin body is cut in an electrically conductive aqueous solution. A flat air-core coil characterized by being attached with the above-mentioned insulator. 2. A wide conductive thin body and a thin body in which an insulating thin body is adhered on both sides of the conductive thin body are cut into a predetermined width, and the thin body is wound by a predetermined number of turns to obtain electrical conductivity. A flat air core coil having an insulator in an aqueous solution attached thereto.