JPH11102831A - Manufacture of coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a coil in which a planar wire is wound into a spiral shape. SOLUTION: When placing a part 3 of a wire to be pulled out across a spiral portion 1A, the part 3 is placed in a groove 16 formed on a flange 1, and a remainder 2 of the wire is then pulled up from inside groove onto the flange, and starts to be wound around a winding core 10 from a starting point 10A of winding where the remainder 2 is pulled up. In this case, the radius of the winding core 10 is increased gradually along a direction, in which the wire is wound such that a radius immediately in front 10B of the starting point 10A of a winding is of a wire larger than the radius the starting point 10A of the winding.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a coil for an electric circuit formed by winding a conductive wire.

[0002]

2. Description of the Related Art As shown in FIG. 10, a flat wire having a conductor coated with an insulating coating is spirally wound, and the end of a wire 3 inside a spiral portion 1A is drawn out across the spiral portion. A coil 1 without a core is disclosed in, for example, Japanese Patent Application Laid-Open No. 6-151.
No. 207. This coil has a different cross-sectional area than a conventional coil obtained by repeating the operation of sequentially winding the wire-shaped thin wire around the core remaining in the coil in the axial direction of the core. It has a great feature in that a large flat wire is spirally wound in the plane direction.

[0003]

In the manufacture of this coil, it is a matter that a person skilled in the art can easily conceive of using a winding core and employing means for spirally winding a wire around the winding core. . FIG. 14 shows an example of this, in which the wire 40 is wound around a winding core 45 having a circular cross section from a winding start point 43 while leaving a wire portion 41 to be drawn out across a spiral portion. Is shown. However, in this case,
At a point 42 where the wound wire meets the wire portion 41 to be drawn out across the spiral portion, the wire portion 41 must be overcome, and therefore a pair of wires 45 sandwiching the wire 40 on both sides of the winding core 45 By providing the flanges on both sides, a problem arises in that the movement of the wire 40 in a direction other than the plane direction (diameter direction of the winding core) cannot be restricted. Further, unlike the prior art coil using a thin wire which does not need to be conscious of the thickness of the wire, in this coil having a flat wire having a large cross-sectional area, as shown in FIG. In this case, there is a problem in that a step in the radial direction is generated between the spirally wound portion and the spirally wound portion, and the wound coil has a distorted shape.

[0004]

DISCLOSURE OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and comprises a method of winding a flat wire into a spiral shape, and winding the end of the wire inside the spiral portion. In manufacturing a coil drawn out across the part using a core provided with a pair of flanges on both sides for sandwiching the wire, a part 3 of the wire to be drawn out across the spiral part 1A is wound. At this time, after being recessed in the groove 16 provided in one of the flanges 14, the remaining portion 2 is pulled up from the inside of the groove onto the flange 14, and winding around the winding core 10 is started as a winding start point 10A with the raised portion, In this case, the radius of the winding core 10 is 10B immediately before the winding start point 10A, and the winding start point 10B is equal to the wire width.
A characteristic is that the radius of the winding core 10 is gradually increased along the winding direction of the wire so as to increase from the radius at A.

In the present application, a portion of a wire to be drawn out across a spiral portion of a coil manufactured by the above method is formed by using a winding core having a pair of flanges provided on both sides for sandwiching the wire. Furthermore, a method of manufacturing a double-wound coil by winding in a spiral shape is also a second method.
It is disclosed as an invention, and after winding the coil 1 manufactured by the above-described method in a recess 36 provided in one flange 34 at the time of winding, the coil 1 is drawn out across the spiral portion 1A of the coil. The portion 3 of the wire to be wound is pulled up from the recess 36 onto the flange 34, and the winding point is started around the winding core 30 as the winding start point 30A. In this case, the radius of the winding core 30 is immediately before the winding start point. 3
0B, the radius of the winding core 30 is gradually increased along the winding direction of the wire so as to increase from the radius at the winding start point 30A by the width of the wire.

[0006]

Embodiments of the present invention will be described below with reference to the accompanying drawings. In carrying out the coil manufacturing method of the present invention, a jig shown in FIGS. 1 to 4 is used. This jig is a rotary roll having a winding core for winding a flat wire as a coil material and forming it into a spiral shape. In this case, a combination of a receiving part B1 and a holding part A1 which are divided and used. To serve. Receiving part B1
Has a cylindrical shape, one end face of which functions as one flange portion 14 of the winding core, and the other side is rotatably connected to a power mechanism (not shown) as appropriate. The holding portion A1 is formed in a columnar shape, and one end surface of the holding portion A1 functions as the other flange portion 13 of the winding core. 12 is inserted into the concave portion 14 provided on one side of the receiving portion B1 while leaving the core 10 at the root,
By fixing with the screw C, it is united with the receiving part B1.

A groove 16 is formed in the flange portion 14 of the receiving portion B1 so that a wire rod can be recessed in a tangential direction at a position where the winding core 10 is located at the time of joining. or,
The radius of the winding core 10 of the pressing portion A1 is not uniform, and the enlarged diameter portion 11 whose radius gradually increases as the winding core advances in the half-rotation direction is provided. The details of the operation of the groove 16 and the enlarged diameter portion 11 will be described later.
When the pressing portion A1 is combined with the pressing portion A1, the end of the groove 16 is set to be located at a position retracted in the rotation direction of the winding core with a gap slightly larger than the end of the groove 16 than the thickness of the wire.

FIGS. 5 to 9 are views showing steps of manufacturing the coil 1 shown in FIG. 9 from a wire using the above jig.
Here, a flat-plate conductor having a rectangular cross section is shown as the wire, and this conductor is coated with an insulating material. In this wire, after the coil is completed, the part 3 to be drawn out across the spiral part 1A is first recessed into the groove 16 provided on one flange 14 at the time of winding, and the remaining part 2 is removed from the groove. Pull up on the flange 14 (see FIG. 5).

Next, the holding portion A1 is attached to the receiving portion B1 of the jig.
Are combined, the remaining portion 2 of the wire is formed in a plane direction (diameter direction of the winding core) by the two flange portions 14 and 13.
By rotating the winding core 10 (rotating roll) (in this case, rotating in the counterclockwise direction on the paper surface), the raised portion is wound at a position 1
As 0A, winding around the winding core 10 is started (see FIGS. 6 and 7).

In this case, as described above, the winding core 10 is provided with the enlarged diameter portion 11 whose radius gradually increases as it advances in the half-rotation direction. Since the wire is located at a position retracted in the rotation direction of the winding core while leaving a gap slightly larger than the thickness of the wire from the end, as a result, the remaining portion 2 of the wire is pulled up onto the flange 14 from the gap and The radius of 10 is gently increased along the winding direction of the wire so as to be larger than the radius at the winding start location 10A by the width of the wire just before the winding start location 10A of the wire. Therefore, at the winding start point of the wire rod, there is no step in the radial direction between the spiral part wound outward and the spiral part is prevented from being distorted. (See FIG. 8).

Next, after winding the wire around the core 10 by rotating the core 10 a desired number of times (see FIG. 9), the pressing portion A1 is removed from the receiving portion B1 of the jig and the completed coil 1 is wound. Take out from 10 (see FIG. 10). Note that the other end 4 of the coil 1 is left as a straight line.

Next, a portion of the wire to be drawn out across the spiral portion of the coil manufactured by the above method is further spirally wound by using a core having a pair of flanges provided on both sides for sandwiching the wire. A specific embodiment of the second invention in which a double-wound coil is manufactured by winding in a shape will be described with reference to the accompanying drawings. In carrying out the coil manufacturing method of the present invention, a jig shown in FIG. 11 is used. This jig is a rotary roll having a winding core similar to that of the first invention, and has a receiving portion B2 and a holding portion A.
Combine the two parts for use. The receiving portion B2 is formed in a cylindrical shape, and one end surface of the receiving portion B2 functions as one flange portion 34 of the winding core, and the other side is rotatably connected to a power mechanism (not shown) as appropriate. . The holding portion A2 is formed in a columnar shape, and one end surface of the holding portion A2 acts as the other flange portion 33 of the winding core.
The pillar 32 is inserted into the concave portion 35 provided on one side of the receiving portion B2 while leaving the core 30 at the root thereof, and is fixed with a screw (not shown), thereby forming the receiving portion B2. Merged.

The flange 34 of the receiving portion B2 is provided with a groove 36 in which the coil 1 of the first invention can be recessed. Further, the radius of the winding core 30 of the pressing portion A2 is not uniform, and the enlarged diameter portion 31 whose radius gradually increases as the winding core advances in a half rotation direction is provided as in the case of the first invention. is there. The enlarged diameter portion 31 is formed when the receiving portion B2 and the pressing portion A2 are united, and the end of the expanded portion 31 crosses the spiral portion of the coil 1 which is recessed in the groove 36 and the winding start portion of the wire portion 3 to be drawn outward. It is set to be located at a position slightly retracted in the rotation direction of the winding core from 30.

FIG. 12 is a view showing a process of manufacturing the coil 1W shown in FIG. 13 from the coil 1 of the first invention using the above jig. First, in the coil 1 of the first invention, the part 3 to be drawn out across the spiral part 1A is set to a length that allows double winding. And the first
After winding the coil 1 of the invention in the groove 16 provided on one of the flanges 34 at the time of winding, the above-mentioned portion 3 is pulled up onto the flange 34 from inside the groove.

Next, the holding portion A2 is attached to the receiving portion B2 of the jig.
By winding the core 30 (rotary roll), the flange portion 34, 33 sandwiches the wire portion 3 of the coil 1 so as not to move in a direction other than the plane direction (diameter direction of the core). (Here, it rotates in the counterclockwise direction on the paper surface), and winding around the winding core 30 is started with the raised portion as a winding start portion 30A.

In this case, as described above, since the winding core 30 is provided with the enlarged diameter portion 31 whose radius gradually increases as the winding core 30 advances in the half rotation direction, the radius of the winding core 30 is set at the winding start point 30A of the wire. Immediately before 30B, the width is gradually increased along the winding direction of the wire so as to increase from the radius at the winding start point 30A by the width of the wire. Therefore, as in the case of the first invention, a step in the radial direction does not occur between the winding portion of the wire and the portion of the spiral wound further outward, and the wound coil has a distorted shape. Will be prevented.

Next, after winding the wire around the core 30 by rotating the core 30 by a desired number of times, the holding part A2 is removed from the receiving part B2 of the jig, and the completed coil 1W is taken out from the core 30 (FIG. 13). In addition, coil 1
The other end 35 of W is left as a straight line.

[0018]

According to the manufacturing method of the present invention having the above structure, the flat wire is spirally wound, and the end of the wire inside the spiral portion is drawn out across the spiral portion. It is possible to accurately and quickly manufacture a coil having no wire and a double-wound coil using a jig without distortion.

[Brief description of the drawings]

FIG. 1 is a partially omitted exploded perspective view of a jig used in a manufacturing method according to a first invention.

FIG. 2 is a partially cutaway sectional view of the same.

FIG. 3 is a partially cutaway perspective view of a jig used in the manufacturing method of the first invention.

FIG. 4 is a side view of a jig used in the manufacturing method of the first invention.

FIG. 5 is a partially cutaway side view showing the steps of the manufacturing method of the first invention.

FIG. 6 is a side view, partially cut away, of the above.

FIG. 7 is a perspective view, partially cut away, of the above.

FIG. 8 is a plan view of the same.

FIG. 9 is a partially cutaway perspective view of the same.

FIG. 10 is a perspective view of a coil obtained by the manufacturing method of the first invention.

FIG. 11 is a partially cutaway perspective view of a jig used in the manufacturing method of the second invention.

FIG. 12 is a partially cutaway perspective view showing the steps of the manufacturing method according to the second invention.

FIG. 13 is a perspective view of a coil obtained by the manufacturing method according to the second invention.

FIG. 14 is a plan view of a conventional technique.

[Explanation of symbols]

 Reference Signs List 1 coil 1A spiral part (of coil) 2 wire part (of coil) 10 core 13 flange part 14 flange part

Claims (2)

[Claims] 1. A coil in which a flat wire is spirally wound, and an end of the wire inside the spiral portion is drawn out across the spiral portion, and a pair of flanges for sandwiching the wire are provided on both sides. In the manufacture using the core, one of the flanges (14) is used to wind the part (3) of the wire to be drawn out across the spiral part (1A).
After the concave portion is formed in the groove (16) provided in the above, the remaining portion (2) is pulled up from the inside of the groove onto the flange (14), and the raised portion is used as a winding start portion (10A) as a winding core (10).
In this case, the radius of the winding core (10) is increased immediately before the winding start point (10A) (10B) by the width of the wire so as to be larger than the radius at the winding start point (10A). A method for manufacturing a coil, characterized in that the radius of the winding core (10) is gradually increased along the winding direction of the wire. 2. A coil (1) manufactured according to the method of claim 1, wherein a portion (3) of the wire to be drawn out across the spiral portion (1A) is provided on both sides with a pair of flanges sandwiching the wire. When the coil is further spirally wound using the provided winding core to manufacture a double-wound coil, the coil (1) manufactured by the method according to claim 1 is wound with one flange (1). 34), the coil is wound into a spiral portion (1).
A portion (3) of the wire to be drawn out across A) is pulled up from the recess (36) onto the flange (34), and the raised portion is used as a winding start point (30A) to be wound on the winding core (30). Winding is started, and in this case, the winding core (30) is set so that the radius of the winding core (30) is larger than the radius at the winding start position (30A) by the width of the wire just before the winding start position (30B). Characterized in that the radius of the coil is gradually increased along the winding direction of the wire.