JPS6392241A - Manufacture of coil for electrical machinery - Google Patents

Abstract

PURPOSE:To enable compact and high-performance coils for electrical machinery to be easily manufactured with improved workability, by folding the film-formed coil material of conductor foils laminated on an insulating sheet, and by punch- processing the coil material. CONSTITUTION:The film-formed coil material 1 of conductor foils laminated on an insulating sheet is divided into a plurality of sections with bending lines A, B and C, and slit slots 2 are punched at the specified positions of the respective divided sections. Then, after the film-formed material 1 is bent with the bending lines A, B and C and the respective divided sections are put together, the combined unit of closed loop patterns having the partial notched slit slots 2 and sections connected to those of the adjacent divided sections is punched to be formed. A coilformed circuit is formed with the partial notched conductor closed-loops of the respective divided sections.

Description

[Detailed Description of the Invention] <Industrial Application Field> The present invention uses a film-like coil material consisting of simply laminating a conductive foil on the surface of an insulating sheet, and is capable of producing coils for electrical equipment extremely efficiently and quickly. It is related to the method of manufacturing.

<Background Art> Conventionally, for armatures of small electric motors such as transistor motors, a single coil is manufactured by winding one or two self-welding wires using a winding machine, and multiple coils are wound in the radial direction. They were generally manufactured by arranging them and joining them with adhesive, or by molding and fixing them in a resin mold.

However, multi-layer coils manufactured by winding machines suffer from the jump phenomenon of the conductive wire due to fluctuations in the conductive wire payout position in the center diameter direction of the cotton wire, uneven winding tension, etc., and the conductive wire used is Because of this, hollow parts often occur between the winding layers, and for example, when used in electric motors, it is difficult to balance the generated torque of rotating electrical machines, and when arranging and positioning coils in the radial direction. However, when used as a small electric motor, there is a limit to efficiency improvement due to the low occupancy rate of the conductor per unit space.
It has also been pointed out that the process of connecting conductors at the terminals of each coil to be incorporated during armature manufacture is numerous, which inevitably leads to higher costs.

For this reason, as a high-efficiency coil to replace the coil produced by a winding machine as described above, recently, a wire conductor obtained by etching a bonded conductor foil, vapor deposition or plating of a conductor is used to coat the surface of an insulating sheet. It is formed by forming coil poles.
"Sheet coil" was proposed (Japanese Patent Application Laid-Open No. 57-186940)
Furthermore, the terminal treatment is such that the coil poles of the corresponding pattern are formed in each section of the insulating sheet and are simply folded and overlapped to form the armature coil. A film-like coil unit with a simplified process was also proposed (Japanese Patent Laid-Open No. 59-191444).
issue).

<Problems to be Solved by the Invention> However, when manufacturing a small armature using a film-like coil unit as described above, it is necessary to form a complicated linear pattern on an insulating film by means such as vacuum evaporation. It is necessary to form a linear conductor with a complex pattern by vapor deposition or etching the conductor foil laminated on the surface of the insulating sheet, and these processes require a great deal of effort and careful attention. For this reason, although it was certainly more advantageous than producing coils using a winding machine, it was still a major obstacle in terms of mass production.

<Means for Solving the Problems> From the above-mentioned viewpoint, the present invention provides a highly efficient and compact coil product for electrical equipment without requiring troublesome processes such as vacuum deposition and etching. It was completed through research by the present inventors who had lost a means for efficient production, and it is made by dividing a film-like coil material made by laminating conductive foil onto an insulating sheet into a plurality of sections, and slit holes at predetermined locations in each section. by punching out a closed loop pattern having a portion cut out by the slit hole, and having a connecting portion with that of an adjacent compartment, by punching out a closed loop pattern from the superimposed body, and subsequently stacking each of the sections, By forming a coiled circuit between the closed loops of partially cut-out conductors in each of the sections, a compact and high-performance coil for electrical equipment can be manufactured easily and with good workability. It is.

Note that "dividing the above film-like coil material into multiple sections" refers to the case of simply "imagining the divisions" in addition to actually dividing the film-like coil material into a plurality of sections with marks etc. so that they can be seen visually. It will be easily understood from the following explanation that this also includes the following. In addition to the method of folding the film-like coil material into a bellows shape, the sections may be overlapped by a method of winding the film-like coil material into a spiral shape.

The method of the present invention can be fully applied not only to the production of versatile air-core coils but also to the production of planar opposed armature coils, and the main parts of the process are vacuum deposition and etching. Since a press punching method with extremely high workability is used instead of processing, it becomes possible to manufacture coils for various small electrical equipment much more efficiently and stably than in the past.

EXAMPLES Hereinafter, the present invention will be explained in more detail with reference to Examples, but the present invention is not limited in any way by the Examples. Furthermore, in the plans shown in the embodiments, parts having the same functions have been described with the same symbols.

<Example> FIG. 1 is a schematic diagram illustrating the manufacturing process of a coil for electrical equipment according to the present invention, taking as an example the manufacturing of an air-core coil suitable as a voice coil.

That is, when a film-like coil material in which conductive foil such as copper foil or aluminum foil is laminated on an insulating sheet is prepared, as shown in FIG. A predetermined slit hole 2 is formed in each of a plurality of sections with borders A, B, and C (this folding line is a target in the next folding process and is not necessarily indicated by a visible mark). is punched out. Note that this slit hole 2 will be
A closed loop pattern formed by "punching the film-like coil material 1 folded and stacked at the bending lines A, B, and C" (FIG. 1 (indicated by the dashed line in al.)
It is provided so that a part of it is cut out.

Next, this film-like coil material 1 is produced as shown in FIG. 1(b).
As shown in the figure, each section is folded into a bellows shape along the bending line, and the sections are overlapped and pressed.

In this case, it goes without saying that insulation measures, such as inserting an insulating sheet, are taken on the surfaces where the conductor foils overlap.

Following the superposition of each section, the first
A closed loop pattern as shown in Figure (C) is punched out. This closed loop pattern has a connecting portion 3 that connects closed loop patterns formed in adjacent sections, as shown in FIG. 1(C) and FIG. 2 which is a developed view thereof. In addition, a part of the closed loop on each section is cut out in a staggered manner with the connecting portion 3 in between by the slit holes previously formed in each section, and the flow of current to that side is blocked.

Therefore, it will be easily understood that the punched and formed stack (as shown in FIG. 1C) is a conductive member itself having a coiled circuit.

In this way, according to the method of the present invention, air-core coils that are compact and have stable performance can be mass-produced extremely efficiently.

Here, we have shown an example of manufacturing an air-core coil having terminals at both ends in the thickness direction, but for example, by punching slit holes 2 as shown in FIG. Next, by folding this into a bellows shape and punching it out as shown in FIG. 3(b), it is possible to easily manufacture an air-core coil in which the connection terminal is drawn out from only one side in the thickness direction. In addition, FIG. 4 is a developed view of the punched-formed coil shown in FIG. 3 (bl).

Furthermore, FIGS. 5 to 7 and 9 show still other examples of armature coil production.

That is, FIG. 5 shows a slit in the manufacturing process of a cylindrical coil as shown in FIG. 6 (FIG. 6 is a front view thereof) or a linear motor coil as shown in FIG. 7 (FIG. 7 is a plan view thereof). The film-like coil material 1 is shown after the hole 2 punching process has been completed.

This film-like coil material 1 is then wound into a spiral shape and overlapped, and then punched into a closed loop pattern as shown in FIG. 6 to form a cylindrical coil, or folded into a bellows shape to form a cylindrical coil as shown in FIG. It is punched in a closed loop pattern to form a coil for a linear motor. In addition,
FIG. 8 is a developed view of the coil shown in FIG. 6 or 7 above.

On the other hand, FIG. 9 also shows a film-like coil material 1 that has completed the punching process of slit holes 2 in the manufacturing process of a cylindrical coil as shown in FIG. 6 or a linear motor coil as shown in FIG. This case is an example of means in a different format from that shown in FIG.

That is, a film-like coil material 1 with slit holes 2 punched therein as shown in FIG. 9 was first folded along the bending line, and then rolled into a spiral shape and stacked one on top of the other in the same manner as in FIG. This is an example of a coil for a linear motor being punched out into a closed loop pattern as shown in FIG. 6 to form a cylindrical coil, or folded into a predetermined bellows shape and punched out into a closed loop pattern as shown in FIG. 7. The developed view of the coil in this case is as shown in FIG. 10.

<Effects of the Invention> As described above, according to the present invention, it is possible to manufacture a compact coil for electrical equipment with extremely simple operations without using vacuum evaporation or etching methods that are troublesome and require long processing times. Not only is this possible, but in the manufacturing process, a predetermined closed loop pattern is punched out after overlapping the film-like coil materials, so there is no overlap error in the closed loop patterns, and the resulting coil for electrical equipment has extremely high and stable performance. This brings about extremely useful industrial effects, such as the ability to secure

[Brief explanation of the drawing]

FIG. 1 is a schematic diagram illustrating the manufacturing process of an air-core coil according to the present invention, and FIG.
Figure (b) is a schematic diagram illustrating the folding of a film-like coil material with slit holes punched out, and Figure 1 (C) is an air-core coil obtained by punching a closed-loop pattern from a film-like coil folded body. FIG. FIG. 2 is a developed view of the air-core coil shown in FIG. 1(C). FIG. 3 is a partial process diagram illustrating an example of manufacturing another type of air-core coil, and FIG. ) is a plan view of an air-core coil obtained by punching a closed loop pattern from a folded film-like coil. FIG. 4 is a developed view of the air-core coil shown in FIG. FIG. 5 shows a plan view of a film-like coil material with slit holes punched out in another example of the manufacturing process of the armature coil according to the present invention. FIG. 6 is a front view of an air-core coil obtained by winding the slitted film-like coil material shown in FIG. 5 or FIG. 9, which will be described later, into a cylinder and punching out a closed loop pattern. FIG. 7 is a plan view of a near motor coil obtained by folding the slitted film-like coil material shown in FIG. 5 or FIG. 9, which will be described later, and punching out a closed loop pattern. FIG. 8 is a developed view of an armature coil obtained from the slit-hole punched film-like coil material shown in FIG. FIG. 9 shows a plan view of a film-like coil material with slit holes punched out in still another example of the manufacturing process of the armature coil according to the present invention. FIG. 10 is a developed view of an armature coil obtained from the slit-hole punched film-like coil material shown in FIG. In the drawings, 1... Insulating sheet, 2... Slit hole, 3...
...Connection part.

Claims (1)

[Claims] A film-like coil material made by laminating conductive foil on an insulating sheet is divided into a plurality of sections, slits are punched at predetermined locations in each section, and then each section is overlapped, and then,
By punching out a closed loop pattern from the stacked body, which is partially cut out by the slit hole and has a connecting portion with that of an adjacent section, a coiled circuit is formed between the partially cut conductor closed loops of each section. A method for manufacturing a coil for electrical equipment, characterized by forming a coil for electrical equipment.