JPS611241A - Manufacture of flat air core coil - Google Patents

Abstract

PURPOSE:To enhance the efficiency and the quality by forming an insulating layer and an adhesive layer on a thin conductive strip, then cutting it in the prescribed width, and winding it in the prescribed shape in the prescribed number of turns, thereby eliminating the collapse and unnecessary space. CONSTITUTION:A copper coil from a supply reel 5 is coated with an insulator layer 7 on one surface and an insulating layer by a coating roller 6 in the prescribed thickness, the coated insulating layer is solidified by a heater 8, and wound on a winding reel 9. Then, the foil is passed through the coating roller 6 in an adhesive tank 10, the adhesive layer is coated in the prescribed thickness, heated by the heater 8, and wound on the winding reel 11. Then, the foil is passed through a slitter roll 12, cut in the prescribed width, wound on the winding reel 13, the insulating layer and the adhesive layer are formed, and the foil cut in the prescribed width is wound on a frame 17. Further, the wound end is insulated at the end.

Description

[Detailed Description of the Invention] [Technical Field of the Invention] The present invention relates to a method of manufacturing a flat air-core coil, such as a drive coil for a motor, which is a drive coil made by combining several self-shaped coils wound five times. It is something.

[Technical background of the invention and its problems] This type of conventional flat air-core coil is made by winding an insulated cotton wool with a circular cross section around a core of a desired shape and the required number of turns L7. was most commonly used.

However, as shown in Fig. 4, even if the conductor 1 can be turned with the least amount of voids, the occupancy rate of the conductor 1 in the cross-sectional area cannot be kept high compared to the required number of turns. However, it had the disadvantage that the cross-sectional area became too crowded.

That is, in FIG. 4, the radius of the cotton phase including the insulating layer 2 is R.
+, the radius of the conductor in the wire is R2, 7, the ratio of the cross-sectional area occupied by the wire to the cross-sectional area is = 9 CL 6994, but 1, this is an ideal value, and in reality it is Since the space is governed by 11■, the value will be lower than this.

7.The space factor of the conductor 2 in the wire is the wire used +
Although it differs slightly depending on i, for example, if the conductor is 2 and 7 is 0.
When a copper wire with a diameter of 17 IIm is used, the maximum dimension 1-diameter of the polyurethane-coated IIφ copper wire is 0.214IN+1, so the space factor is 69%.

Therefore, the space factor occupied by the conductor 2 in the cross section of the coil is:
Even in the ideal case, it is 90, Fi 9% x 69% #62%, and in reality it is usually around 50%, and at best it is only 60%, which is the area of the coil used in cassette record players etc. The percentage is also 60% culm.

Therefore, as shown in FIG. 5, a method has also been proposed in which a copper wire with a circular cross section is flattened using a II-ru machine or the like and then wound into an ML-A shape.

- In case 2), since the 4A material of the wire is an insulating coated copper wire, the space factor of the wires 4 itself does not change (additionally, the space factor of the conductor in the coil, l, 17 is 70 In addition, since the insulating layer is rolled with rolls, etc., the cross section becomes thinner. , you can't make it too flat, -, and the flattening ratio is 1.7, 0, + 7.
In the cotton phase of the fin diameter, the insulation thickness is 0.022 mmP degree, which is not preferable because the thickness of the conductor becomes smaller than the thickness including the insulation layer, resulting in a decrease in the 1ζ space factor.

Furthermore, if the diameter of the conductor varies, the variation will be magnified in the crushed wire, so that the width of the entire turned coil (7) may no longer be within the specified [1], In the case of a coil used as part of a magnetic circuit, the gap between the coil and the magnet increases in some areas, resulting in a decrease in magnetic efficiency.

Also, recently, we have been applying thin insulation sheet I-Miko metal thin film.
A predetermined pattern is printed on this thin film, or photoresist (
・It has been proposed to use a printed coil that has been processed by punching and cutting to leave a metal thin film in a predetermined coil shape, by stacking a predetermined number of such insulating sheets.

However, this coil is formed as described above), since the metal thin film 1113 that becomes the coil requires a large dimension as shown in Figure 6 compared to the thickness of the thin film, an insulating sheet is used. It could not be used for coils that required a large number of turns due to the stacking of coils.

Also, when considering collateral production, it is difficult to make the 1v height of the insulating sheet 4 less than 001 mm, so the direction of the space factor is
There are still some drawbacks that cannot be desired.

The present applicant intends to improve the above-mentioned drawbacks.
Nos. t-249126 to 249131 and 1.7 were filed.

This application is wide! Turn the lil foil into the core and insulate between the copper foils with an insulating layer and adhesive G.
Tashiko Said': 1 Remove A, So, ; After or Cor? What do you want with 6, 2 cuts and 4? ″／＋、ru.

By the way, if you remove the 2l A from the above ``(Ka, l・suzImonin+(+-・teLSl), there is a possibility that the cuff 1 o'clock G, 2-shaped collapse--therefore, Cζ1-shape It (, 1-, therefore It saves the time and effort of solidifying 7, and also strengthens the core! 1- IQ: 1. The drawback is that it cannot be used and the cost of materials (parts) increases. or J).

[Purpose of the invention]

In order to eliminate the drawbacks of the conventional O11 mentioned above, the present invention provides an insulating layer and an adhesive layer on a four-conductor ribbon to insulate and bond the ribbon, thereby eliminating unnecessary space in the coil. With the aim of increasing the space factor of the conductor, we fixed its external shape and increased the number of turns to create a high-efficiency, high-quality flat air-core coil (X
The primary purpose is to provide

Then, after providing an insulating layer and an adhesive layer on an 11-wide conductive thin strip, it is cut into a predetermined shape I#r+, and then either deburring or winding is performed first to give a predetermined shape. The cutting is t
A second object of the present invention is to eliminate interlayer short circuits due to burrs on the cut end surface, which would occur after cutting, and to allow burr removal to be performed relatively easily.

[Embodiments of the invention]

An embodiment of the present invention will be described below with reference to FIGS. 1 to 3.

Copper foil a rolled to a thickness of io~2011 and having a thickness of about 50~2001 Im is supplied as shown in Fig. 1 (△) at a speed of 1 g.
H-7')Xllt,XノJi,.

One side of the 1X output V, f, 711...19Fia contains a soft (IF bonding) agent that will not be damaged by etching. The coating roller 11 in the tank 7 is in contact with the coating roller 7, and the coating roller fi L,'l L; An insulating layer is applied to one side of a) to a constant thickness.

The applied insulating layer is heated by a heater 8 to volatilize the solvent and solidify the insulating agent, and then is wound up into a roll 11V and a reel 9.

Next 4.1 As shown in Figure 11 (13), the take-up reel 9 of:
20 to 50 times per minute again with the copper foil a as the top surface.
8. The second copper foil a, which is sent toward the adhesive tank 10 at a speed of Ir1, is coated with fJ urethane epoxy, which has a softening point lower than that of the insulating material, on the lower surface and the opposite surface of the insulating layer. The coating roll [i] in the adhesive tank 10 containing the resin is in contact with the coating roll 6, and the coating roll 6 is moved by the guide in contact with it.
, the excess adhesive is removed, and an adhesive layer C of a constant thickness is applied to the lower surface of the copper foil a.

Coating - Seat 41 - The adhesive layer C is heated by the heater 8 to volatilize the solvent and solidify the adhesive, and then the adhesive layer C is wound onto the take-up reel 11 .

In this way, the insulating layer and the adhesive layer (7) are formed, and the copper 211a having a thickness of 50 to 200, which is wound on the take-up reel 11, is rolled onto the slick roll 12 as shown in FIG. 1(C).
6. It is introduced from the take-up reel 11 to a slitter roll 12 to be cut into two pieces.

The slick roll 12 is composed of two rolls in which large diameter discs and small diameter discs are arranged alternately in the middle, and the other large diameter disc is inserted into the small diameter disc part of one roll.
The copper 7Aa inserted between these two rolls is cut at the pitch of the disc.

In this way, the same team that was analyzed over a certain period of time? f5 d
are respectively wound onto separate take-up reels 13.

An adhesive layer C is formed on this insulating layer, and a copper foil (1) cut into a predetermined length is wound around a winding frame 18 as shown in FIG. 1 (one piece).

Immediately J. Copper foil numbers d and l sent out from the planning reel 13
, iji guide roller 15 having sublin η゛14
, illiZ, please"l:・Therefore, a constant tension is applied, and the heating heat 1 (1 degree) causes the adhesive 1st pressure C to soften slightly, and a contact force of 71 is applied, it:,'7'l', after being heated to a low temperature, winding frame 17G, turn 4 of two places
The evening turns.

By winding the winding frame 17-, the adhesive C becomes copper '9.
i'i (1 each 11!! Shrine 14 +1, l- glued 7, Makikawa 已: retain the shape'・l-?'+, I) number,
Two.

After that, after waiting for the adhesive layer [5] to solidify, apply 1 fV from the winding frame 17.
, S1107 Hanging jig 1 as shown in Figure 1 ([L])
BG, double washed and immersed in pN197, lI5
There are 5 people in front of me.
fk (F e Ce (),
An etching bath containing an etching solution such as IINO+ is used to remove burrs and burrs from the above-mentioned cutting process. Subsequently, the culm produces a culm;
5] was melted and the cut end face of the copper foil d was etched to eliminate short circuits between the winding layers. After that, I went to the cleaning tank 19 again and washed it again for 7 hours.
Value 'fi-(1-ru.

When the cleaning was completed, the cleaning solution was placed in the drying oven 21 and then dried. The foil (with an insulating layer 1 also on the end faces of the coil 1, ie on the side end faces of the coil) is then dried in a drying oven 23.

Since the softening point of the insulating layer and the adhesive layer C is lower than the softening temperature of half 1]1,
: 1 can be attached directly to the outer I foil (I).In other words, without peeling off the insulating layer or adhesive layer, you can directly attach the 1ζ wire, etc. to the copper foil d. It is possible.

1゛1゛The cleaning, machining, and machining steps of the above example were repeated in the second step.
As shown in the figure, wind the spade 1 foil d onto the winding frame 176 (in front of Reno, roll 1
fV, even if it is wound around the reel 13, there will probably be no problems whatsoever.J1゛Embodiment 1.Flat air-core coil for motor'! ', 'J j forward tjs l: 2 6 examples,
Tep + ``l Ka, book Q 'Jl &f Cノ and other G1r
Speaker 9 coils, laser disc playback 8-noji-ri - also used in the method of manufacturing the 1-il of the i' knob part-
(It's black.

[91+ Results of the Invention] As described above, the LSI of the present invention forms an adhesive layer on an insulating layer on a wide conductive thin strip G, and cuts it into a predetermined shape on the back.
This is wound into the required shape and the required number of turns. After winding the conventional wide conductor, G;
) 6 = IA = There is no deformation at all, and the wire rod with a circular cross section is wound. .14 winding layers 6,!゛Glue-c'18 High-performance Lee Mi 1, Haku 1 Blue, I, , 7! r□)-Rail J's Seven. I can do two things],.

So 1 H' One of the thin strips in 1 Iji 1 forms a thread-colored layer, 1t 1 1 A, l ha ζ l;7. : η Ki 1 (edge layer, adhesion j (・1) J (
11116,'1['111/7\4-jru's γ, part 1i1. 'Efficiency is 111<Etsuno, d+l' 7
790) i'ill 'IHQ is 3z,.

vinegar! 6. 2.λ9. lji Station G: Two shots η coil 4-ru Bali etc. G,! , Removal of burrs from 1, culm (completely removed by 6.1) (turned (turn l each time) q large) (1
111 and 4 insulating layers 71, so there is no interlayer short circuit or contact with other conductors! I trust that there is no risk of this happening.

[Brief explanation of the drawing]

Fig. 1 is a process diagram of one embodiment of the present invention, Fig. 2 is a process diagram showing another embodiment, Fig. 3 is a cross-sectional view of cut copper foil, and Fig. 4 is a conventional process diagram. Figure 5 is an explanatory diagram of the space factor of a coil using a wire rod with a circular cross section. Figure 5 is an explanatory diagram of the first fold plane when a wire rod with a circular cross section is flattened. Figure 6 is an explanatory cross-sectional diagram of a printed coil. be. a... Wide button j foil, h... Insulating layer, C... Contact@
Layer, d...Cut copper foil, 7...Insulating material 4111
7.10... Adhesive tank 12... Slitter raw ham 17... Winding frame, 20... Etching tank, 22...
・Insulating agent tank. Patent applicant Pioneer Corporation Figure 1 (A) (B) (C) (D) (E) (F) Old

Claims (1)

[Claims] A wide three-layer thin strip, which has an insulating layer that insulates each wound layer of the conductive thin strip and an adhesive layer that bonds the insulating layer and the thin strip, is cut into a predetermined size using a cutting machine such as a slitter machine. After cutting to width,
Deburring the cut end surface by etching, etc., and winding the cut three-layer ribbon into a predetermined shape, followed by an end surface treatment step of insulating the wound side end surface. A manufacturing method for a characteristic flat air-core coil.