JPS6118330A - Winding method of pancake coil - Google Patents

Abstract

PURPOSE:To enable winding start sections and winding finish sections to be led outside the circumference of coils, by a method wherein self-fusion conduction wires are used and most coils are wound with the wires except mid-winding start sections the wires of which are previously left unwound, and after that, the unwound wires are wound up so that the ends may be positioned outside the circumference of the coils. CONSTITUTION:Pancake coils having winding-start sections S inside are formed by winding up self-fusion conduction wires in a multilayer solenoid form in a narrow space A between winding jigs 5. In this process, wires 4 enough for winding separate sections of coils are left unwound at the winding-start sections S. After most L1 of coils 1 are wound up, the space between the winding jigs is slightly expanded and the wires 4 left unwound at mid-winding start sections S are wound in the expanded space so that the pre-wound coils and polarity may be arranged in the direction of easy flow. In short, another units L2 of the coils are wound up in addition to the L1 so that they may be arranged to be wound up in the opposite direction of the former coils.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of winding a flat coil used, for example, in a coil for a brushless motor.

Traditionally, this type of motor coil, etc., wound thinly using self-fused conductor wire, has been widely used, but since the winding start of the coil is normally located inside the coil, When leading the lead wires to the outside, an extra space is required with a thickness corresponding to the diameter of the lead wires.

This is a loss that cannot be ignored in coils for small motors, etc., where the thickness of the coil is required to be as thin as possible.

Of course, soldering is sometimes done inside the coil without leading the lead wire at the beginning of the coil to the outside, but as coils become ultra-miniaturized, soldering is done inside the coil. It has become extremely difficult to carry out this process due to space limitations, and it has become necessary to derive the outside.

The purpose of the present invention is to improve such problems.

To provide a winding method in which a winding start part of a flat coil can be pulled out from the outer circumferential side of the coil in the same way as a winding end part.

The present invention uses a self-bonding conductor wire, winds most of the coil by leaving an excess wire at the beginning of the winding, and then (the excess wire is placed in the same polarity as the already wound coil). The coil is wound in the same direction as the coil, and the end thereof is located on the outer circumferential side of the coil.

Hereinafter, five embodiments of the present invention will be described with reference to the drawings.

FIG. 1 is a plan view of two brushless motor coils wound by the method of the present invention, and FIG. 2 is a side view thereof.

This is the same as the conventional one in that it is wound flat into a fan shape using self-fused conductor wire, but the winding start part 2 of coil It is different from the conventional one in that it is drawn out.

The method of winding the wire is shown in FIG.

That is, if a self-welding conductive wire is wound in a multilayer solenoid shape between the winding jigs 5 separated by a narrow interval A, a normal flat coil having a winding start portion S on the inside, as shown in FIG. is formed.

However, in the present invention, at this stage there is enough extra wire 4 left to wind the remainder of the coil around the winding start portion S.

Therefore, the winding start part S at this stage is a temporary winding start part (hereinafter referred to as the mid-winding start part) that will eventually become partway through the coil.
It is.

After winding most part LL of coil 1 in this way.

As shown in Figure 5, the interval between the first winding jigs is slightly expanded,
The remaining portion L2 of the coil is added to the expanded space by winding it in the midway winding start direction.

In this way, the end of the winding of the part L2, which was added later by scraping the excess wire 4, becomes the real winding start part 2 in FIG. 1, which is pulled out from the outer circumferential side of the coil 1. .

In the coil 1 wound in this way, the winding direction of the coil 1 is opposite to the winding direction of the winding machine, but the polarity is the same. The overall result is the same as a coil made by winding a single wire in the same direction.

According to the method of the present invention, as described above, there is an effect that the winding start part 2 of the flat coil can be pulled out from the outer circumferential side of the coil l in the same way as the winding end part 3, and the lead wire of the conventional coil can be pulled out from the inside to the outside. It is possible to eliminate wasted space that occurs when the coil is pulled out, and it can greatly contribute to the miniaturization of motor coils and the like.

Further, advantages such as easier coil terminal processing and connection work are brought about.

[Brief explanation of drawings]

Fig. 1 is a plan view of a flat coil wound by the method of the present invention, Fig. 2 is a side view thereof, Fig. 3 is a sectional view showing an intermediate process of the method of the present invention, and Fig. 4 is a diagram showing the process at that stage. FIG. 3 is a plan view showing an example of the shape of a formed coil. FIG. 5 is a sectional view showing the final process. 1 is the coil, 2 is the beginning of winding, and 3 is the end of winding. S is the middle winding start, 4 is the middle winding start (the extra wire left behind, and Lt is the bulk of the coil that is wound first).

Claims (1)

[Claims] 1. Using a self-bonding conductor, wind most of the coil by leaving an extra wire at the beginning of the winding, and then the extra wire has the same polarity as the already wound coil. A method of winding a flat coil, which is characterized by winding the coil in such a manner that the end thereof is located on the outer circumferential side of the coil.