201013716 六、發明說明： 【發明所屬之技術領域】 本發明係有關一種導電線圈製造方法，尤指一種以非圓柱狀 線材纏繞形成導電線圈製造方法。 【先前技術】 感應線圈係為一種载流元件，當通以電流可產生磁場，常應 用於電感或變壓器等電子元件上。一般的感應線圈係由圓柱形線 狀的金屬導體纏繞呈螺旋結構所形成，並於金屬導體表面附有一 _ 層絕緣漆。理想的環境下，通過金屬導體内的電子應該均勻分布 於截面積上；然而，實際上，特別是高頻的狀態，金屬導體内的 電子集t於表面的位置，使得中央區域空泛化，亦減少金屬導體 所能運送電子的面積，大幅減低電子傳送的效率，稱為集膚效應 (Skin Effect)。尤其是目前電子產品對於功率的需求曰益增加，亦 增添了感應線圈的負擔，若僅使用較大截面積的圓柱狀金屬導線 來克服問題，無疑是限制了電子產品微型化的可能。 為能夠解決上述圓柱狀金屬導線的問題，業界發展出扁平導 線。相較於圓柱狀金屬導線，扁平導線具有較大的表面積，縱使 © 在高頻的狀態下，也能提供較佳的電流運送量。除此之外，扁平 導線亦可避免在纏繞堆疊成線圈狀態時所產生多於的空隙，可以 減少線圈的體積，符合電子產品微型化的需求。一般扁平導線在 製作的過程，首先將金屬（如銅金屬等)壓力加工，使金屬強行通過 模具，而得到所預先設定截面積尺寸的圓柱狀裸線1，如『圖1-1』 所示。再者，如『圖^2』所示，將該圓柱狀裸線丨再一次經過外 力擠壓形變成扁平狀裸線la。為能對外部具有絕緣的能力，該扁 平狀裸線la利用浸塗等方式將絕緣漆附著在該扁平狀裸線u的 表面上，並經過烘烤工序使該扁平狀裸線la的表面形成一絕緣層 2 ’而成為扁平導線3，如『圖1-3』所示。最後，將爲平導線3 3 201013716 纏繞成螺旋線圈，以作為其他電子元件組裝使用，如 不。另-縣平線上龄式，則祕麟線 ·1』所 平狀裸線la後，以靜電塗裝或喷霧塗 、壓形呈扁 扁平狀裸線U上即形成絕緣層2。然而:二=漆附著於 f法，位於該扁平狀裸線】a四個角落的絕緣漆由於咐漆 、’在製造扁平導線3的過程中以及將扁平導線又較 圏的工序尹，衮层田在巨 考奸為螺旋線 落或破裂，尤其是位;^彎折端點2a ^拉伸或擠觀變表面積而Γ 效果。如此’=會造成短電層2的絕緣 【發明内容】 ^子轉的正常工作。 本發明之主要目的，在於使扁平線 以獲得較佳的絕緣能力。為達上述目的，本;明== 電線圈製造方法，包括步驟有： 八種導 1. ==:_導電線材具有至少二通過載面中 2. =::r:編導電線材為-輪數-適* 3. 的步驟：覆蓋熱固性液體於纏繞完成的該線圈 1 緣層的步驟：加熱烘烤附有該熱固性液體的線圈， 使該熱固性液體於該導電線材表面形成―的2圈 該絕緣層得以完整包覆 、、 藉此， 的絕緣效果。 “道圈外部，使該線圈獲得較佳 於本發明中，該_性_可為聚錢 酿亞胺或聚四氟乙烯之其—或其組合。 s聚酿胺、聚 其中為此使絕緣漆均勻分布於該導電線材的表面，於覆蓋 201013716 驟與形成絕緣層的步驟之間，更具有—去除多餘熱固性 外加風該去除多餘熱固性液體的步驟，係使職轉離心、 覆蓋结、真空抽乾等方式；而為能加魏緣的效果，重複進行 步驟以及形航緣層的步㈣增加魏緣層的數目， 為1至15層°於覆蓋線圈的步驟中，係利用浸泡 式，該熱固性液體覆蓋於該線圈上；浸泡於該熱固性液體的 、糸’丨於1與5秒之間。而敎該熱固性紐固定於該線圈的201013716 VI. Description of the Invention: [Technical Field] The present invention relates to a method of manufacturing a conductive coil, and more particularly to a method of manufacturing a conductive coil by winding a non-cylindrical wire. [Prior Art] The induction coil is a current-carrying element. When a current is generated by a current, it is often applied to an electronic component such as an inductor or a transformer. A general induction coil is formed by winding a cylindrical wire-shaped metal conductor in a spiral structure, and a _ layer of insulating varnish is attached to the surface of the metal conductor. In an ideal environment, the electrons passing through the metal conductor should be evenly distributed over the cross-sectional area; however, in fact, especially in the high-frequency state, the position of the electrons in the metal conductor on the surface makes the central region empty. Reducing the area of electrons that can be transported by metal conductors greatly reduces the efficiency of electron transport, known as the Skin Effect. In particular, the current demand for power of electronic products has increased, and the burden on the induction coil has been increased. If only a cylindrical metal wire with a large cross-sectional area is used to overcome the problem, the possibility of miniaturization of the electronic product is undoubtedly limited. In order to solve the above problem of the cylindrical metal wire, the industry has developed a flat wire. Compared to cylindrical metal wires, flat wires have a large surface area, and even at high frequencies, they provide better current carrying capacity. In addition, the flat conductors can also avoid more voids when wound into a coiled state, which can reduce the volume of the coil and meet the miniaturization requirements of electronic products. Generally, in the process of manufacturing a flat wire, a metal (such as copper metal) is first processed under pressure to force the metal through the mold to obtain a cylindrical bare wire 1 having a predetermined cross-sectional area, as shown in FIG. 1-1. . Further, as shown in Fig. 2, the cylindrical bare wire is once again pressed into a flat bare line la by external force. In order to be able to insulate the outside, the flat bare wire la is attached to the surface of the flat bare wire u by dip coating or the like, and the surface of the flat bare wire la is formed by a baking process. An insulating layer 2' becomes a flat wire 3 as shown in Fig. 1-3. Finally, the flat wire 3 3 201013716 will be wound into a spiral coil for assembly as other electronic components, if not. In addition, the county-level line-aged type, the Mirin line ·1』 is a flat-shaped bare line la, which is formed by electrostatic coating or spray coating, and is formed into a flat flat bare wire U. However: two = paint attached to the f method, located in the flat bare wire] a four corners of the insulating paint due to enamel paint, 'in the process of manufacturing the flat wire 3 and the flat wire is more ambiguous process Yin, 衮 layer Tian Zao's investigation is a spiral drop or rupture, especially in the position; ^ bending the end point 2a ^ stretching or squeezing the variable surface area and Γ effect. Thus, the insulation of the short electric layer 2 is caused. [Invention] The normal operation of the sub-rotation. The main object of the present invention is to provide a flat wire for better insulation. In order to achieve the above purpose, the method of manufacturing the electric coil comprises the following steps: Eight kinds of conductors 1. ==: _ Conductive wire has at least two passes through the carrier surface 2. =::r: braided conductive wire is - wheel The step of number-appropriate 3. 3. covering the edge layer of the coil 1 of the thermosetting liquid: heating and baking the coil with the thermosetting liquid, so that the thermosetting liquid forms "two turns" on the surface of the conductive wire The insulation layer is completely covered, and thereby, the insulation effect. "External to the coil, such that the coil is preferably obtained in the present invention, and the _ _ can be a polyanisole or a polytetrafluoroethylene - or a combination thereof. s polyamine, poly, which is insulated for this purpose The paint is evenly distributed on the surface of the conductive wire, and between the steps of covering 201013716 and forming the insulating layer, the step of removing excess thermosetting and adding wind to remove excess thermosetting liquid is to perform centrifugation, covering, vacuum pumping. Drying, etc.; and for the effect of adding the Wei edge, repeating the steps and the step of forming the voyage layer (4) increasing the number of the Wei edge layer, from 1 to 15 layers. In the step of covering the coil, the immersion type is used. a thermosetting liquid covering the coil; immersing in the thermosetting liquid between 1 and 5 seconds, and the thermosetting core is fixed to the coil
=共烤時間係、介於3與6G秒之，且其溫度係介於赋與戰 <間。 本發明導電線圈製造方法中，導電線材係於纏繞為線圈型賤 谈’再將熱固性液體附著於導電線材的表面，並加熱烘烤形成絕 緣層。S1此可㈣免傳統製造扁平線圈，當進行加壓成形以及曾 ^成線晴’因為扁平賴端角崎層較薄，錢邊緣的絕緣層 谷易脫^或破裂的現象。除此之外，本發明可以將絕緣層均句形 成於導電線圈的表面，使導電線圈獲得完整的絕緣保護。 【實施方式】 有關本發明之詳細說明及技術内容，現就配合圖式說明如下. 請參閱『圖2』所示，係本發明一較佳實施例之步驟方境示 意圖，如圖所示：本發明係為一種導電線圈製造方法，包括步驄 有： 1 1. 提供導電線材的步驟(S10):該導電線材具有至少二通過 截面中心不同長度的軸線； 2. 纏繞成形的步驟(S20):纏繞該導電線材為一適當匝數以 及適當型態的線圈； 3. 覆蓋線圈的步驟(S30):覆蓋熱固性液體於纏繞完成的兮 線圈上；以及 ~ 4. 201013716 ^絕緣拍㈣_):加祕烤财該_性液體的 藉圈，使該熱固性液體於該導電線材表面形成一絕緣層， 槔I，該絕緣層得以完整包覆於該線圈外部，使該線圈獲 得較佳的絕緣效果。 非圓柱形線材巾該導電線材可為騎線、矩形線、^規則線等 請參聞『_ 圖，如圖Μ -.,』所不’係本發㈣—實施例之步驟方塊示意 線圈的步驟I·為能使該絕緣層均勻包覆於該線圈外部，於覆蓋 餘熱固 ==)牛與形成絕緣層的步驟(S4Q)之間，更具有一去除多 風壓或真1 /驟(S31)。於此步驟中，可利職轉離心、外加 絕緣的效i =方式來除去多餘熱固性液體。此外，為能加強 驟(娜以増加該圈的步驟(S30)以及形成絕緣層的步 請參閱『圖4-1 „ $z ^ 之牛_ 』至圖44』所不，係本發明一較佳實施例 之步驟^程示意圖，並參考『 該導電線材10係以层平始L 』於本實施例中， ^ 、 千線為例。首先，進行提供導電線材的步驟 魯 ()，取得一由導體金屬壓力加工後形成的導電線材1〇，該導電 、10通過截面中心具有不同長度的第一軸線U以及第二轴線 1 士圖4-1』所不。再者，進行纏繞成形的步驟(s2〇)，將所取 '寻的導，線材1G根據需求纏繞成—適當阻數以及適當型態的線圈 0如®I 4-2』所tf ’該線圈2〇的㈣以及型態可依據所欲組 裝的電子元件如電感H或變M||f而調整。完躲圈如後，進行 覆蓋線_步驟卿)，將_性㈣3()覆蓋於纏繞完成的該線圈 20上。於本實施例中’係利用浸泡的方式使該熱固性液體3〇覆蓋 於該線圈20上’如『圖4-3』所示，而浸泡於該熱固性液體3〇的 時間係介於1與5秒之間。該熱固性液體可為聚氨酯 6 201013716 (Polyurethane)、聚酯（Polyester)、聚醯胺(Polyamide)、聚醯亞胺 (Polyimide)及聚四氟乙烯(polytetrafluoroethylene，PTFE)之其一或 其組合。由於浸泡方式成本低、方便操作且得以完整覆蓋於該線 圈20表面，有利於大量工業生產。完成覆蓋線圈的步驟(83〇)後， 則進行去除多餘熱固性液體的步驟(S31)，係利用旋轉離心的方 式’如『圖4-4』’附著於線圈20表面多餘的熱固性液體30因為 離心力的牵引而脫離線圈20’使覆著於線圈20表面的熱固性液體 30得以均勻分布。最後，進行形成絕緣層的步驟(S4〇):將附有該 φ 熱固性液體30的線圈20加熱烘烤，使該熱固性液體3〇於該導電 線材10表面形成一絕緣層3卜如『圖3-4』所示。於本實施例中， 加熱烘烤的溫度係介於200°C與500°C之間，而加熱烘烤的時間係 介於3與60秒之間。若欲加強絕緣的效果，可重複進行覆蓋線圈 的步驟(S30)以及形成絕緣層的步驟(S40)以增加該絕緣層31的數 目’如『圖5』所示，該絕緣層31的數目為1至15層。 綜上所述，本發明導電線圈製造方法係於導電線材纏繞形成 線圈後，才進行絕緣層的形成，相較於傳統先上漆後再行壓塑以 及纏繞的方式，本發明有效降低絕緣層破裂或脫離的可能，提高 β 產品良率’並避免通電時發生短路的危險。除此之外，本發明相 較於傳統靜電塗裝或噴霧塗裝等方式，具有低成本以及方便加工 的特徵’對於工業製造上而言具有較佳的優勢。因此本發明極具 進步性及符合申請發明專利之要件，爰依法提出申請，祈鈞局 早曰賜准專利，實感德便。 ° 以上已將本發明做一詳細說明，惟以上所述者，僅爲本發明 之—較佳實施例而已，當不能限定本發明實施之範圍。即凡依本 發明申請範麟作之均㈣化與修飾等’皆應仍屬本發明之 涵蓋範圍内。 7 201013716 【圖式簡單說明】 圖1-1至圖1-4，係習知製造扁平線圈之步驟流程示意圖 圖2,係本發明導電線圈製造方法一較佳實施例之步驟方塊示意圖 圖3，係本發明導電線圈製造方法另一實施例之步驟方塊示意圖 圖4-1至圖4-6，係本發明導電線圈製造方法一較佳實施例之步驟 流程示意圖 【主要元件符號說明】 1 .............圓柱狀裸線= total roasting time, between 3 and 6G seconds, and its temperature is between the match and the battle. In the method for producing a conductive coil of the present invention, the conductive wire is wound into a coil type, and the thermosetting liquid is attached to the surface of the conductive wire, and baked by heating to form an insulating layer. S1 can (4) avoid the traditional manufacture of flat coils, when performing pressure forming and splicing, because the flat layer is thinner, the edge of the insulating layer of the money is easy to break off or rupture. In addition, the present invention can form an insulating layer on the surface of the conductive coil to provide complete insulation protection for the conductive coil. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The detailed description and technical contents of the present invention will now be described with reference to the drawings. Please refer to FIG. 2, which is a schematic diagram of the steps of a preferred embodiment of the present invention, as shown in the figure: The invention is a method for manufacturing a conductive coil, comprising the steps of: 1 1. providing a conductive wire (S10): the conductive wire has at least two axes of different lengths passing through the center of the section; 2. a step of winding forming (S20) : winding the conductive wire into a suitable number of turns and a suitable type of coil; 3. covering the coil (S30): covering the thermosetting liquid on the wound twisted coil; and ~ 4. 201013716 ^Insulation shot (four)_): plus The thermosetting liquid forms an insulating layer on the surface of the conductive wire, and the insulating layer is completely covered on the outside of the coil, so that the coil obtains a better insulating effect. Non-cylindrical wire towel The conductive wire can be riding line, rectangular line, ^ rule line, etc. Please refer to "_ figure, as shown in Figure Μ -.," is not the same as the hair (four) - the step block of the embodiment shows the coil Step I· is to enable the insulating layer to be uniformly coated on the outside of the coil, and between the step of covering the residual heat and the formation of the insulating layer (S4Q), there is more to remove the wind pressure or the true 1 / ( S31). In this step, the excess thermosetting liquid can be removed by the effect of centrifugation and external insulation. In addition, in order to strengthen the step (the step of adding the ring (S30) and the step of forming the insulating layer, please refer to "Fig. 4-1 „ $z ^牛_ _" to Fig. 44), which is a comparison of the present invention. The schematic diagram of the steps of the preferred embodiment, and referring to "the conductive wire 10 is layered at the beginning L" in this embodiment, ^, thousand lines as an example. First, the step of providing a conductive wire Lu (), obtain a The conductive wire 1 形成 formed by press working of the conductor metal, the conductive 10 passing through the first axis U having different lengths in the center of the section and the second axis 1 4-1 are not included. Step (s2〇), taking the 'seek guide', the wire 1G is wound according to the demand—the appropriate resistance and the appropriate type of coil 0 such as ®I 4-2』tf 'the coil 2〇(4) and the type It can be adjusted according to the electronic component to be assembled, such as the inductance H or the change M||f. After the completion of the circle, the cover line is stepped, and the _ (4) 3 () is overlaid on the wound coil 20. In the present embodiment, the thermosetting liquid 3〇 is covered on the coil 20 by means of immersion as shown in Fig. 4-3. As shown, the time for immersing in the thermosetting liquid is between 1 and 5 seconds. The thermosetting liquid may be polyurethane 6 201013716 (Polyurethane), polyester (Polyester), polyamide (Polyamide), polyfluorene. One or a combination of polyimide and polytetrafluoroethylene (PTFE), which is advantageous for mass industrial production due to low cost, convenient operation and complete coverage on the surface of the coil 20. After the step (83〇), the step of removing the excess thermosetting liquid (S31) is performed by means of rotary centrifugation 'as shown in Fig. 4-4'. The excess thermosetting liquid 30 attached to the surface of the coil 20 is disengaged by the pulling of the centrifugal force. The coil 20' uniformly distributes the thermosetting liquid 30 coated on the surface of the coil 20. Finally, a step of forming an insulating layer (S4〇) is performed: the coil 20 to which the φ thermosetting liquid 30 is attached is heated and baked to make the thermosetting liquid 3, an insulating layer 3 is formed on the surface of the conductive wire 10 as shown in FIG. 3-4. In this embodiment, the temperature of the heating and baking is between 200 ° C and 500 ° C, and The baking time is between 3 and 60 seconds. If the effect of the insulation is to be reinforced, the step of covering the coil (S30) and the step of forming the insulating layer (S40) may be repeated to increase the number of the insulating layer 31. As shown in Fig. 5, the number of the insulating layers 31 is 1 to 15. In summary, the manufacturing method of the conductive coil of the present invention is performed after the conductive wires are wound to form a coil, and the insulating layer is formed. The invention firstly reduces the possibility of cracking or detachment of the insulating layer, improves the yield of the β product, and avoids the risk of short circuit during energization. In addition, the present invention has a superior advantage in industrial manufacturing as compared with the conventional electrostatic coating or spray coating. Therefore, the present invention is highly progressive and conforms to the requirements of the invention patent application, and the application is made according to the law, and the prayer bureau gives the patent as early as possible. The present invention has been described in detail above, but the foregoing is only the preferred embodiment of the present invention, and is not intended to limit the scope of the invention. That is, the average (four) and modification of the application of the invention according to the present invention should remain within the scope of the present invention. 7 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 。 FIG. 4-1 to FIG. 4-6 are schematic diagrams showing the steps of a preferred embodiment of the method for manufacturing a conductive coil of the present invention. ........... cylindrical bare wire
la · · ...........扁平狀裸線 2 .............絕緣層 2a.............彎折端點 3 .............扁平導線 10 .............導電線材 11 .............第一軸線 12 .............第二軸線 20.............線圈 30 .............熱固性液體 31 .............絕緣層 8La · · ...........flat bare wire 2..................Insulation layer 2a.............Bend End point 3 .............flat wire 10 .............conductive wire 11 .............first Axis 12 .............second axis 20 . . . coil 30 ........ thermosetting liquid 31 .............Insulation 8