WO2023112510A1 - Method for manufacturing coil, coil, and coil material - Google Patents

Method for manufacturing coil, coil, and coil material Download PDF

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Publication number
WO2023112510A1
WO2023112510A1 PCT/JP2022/040222 JP2022040222W WO2023112510A1 WO 2023112510 A1 WO2023112510 A1 WO 2023112510A1 JP 2022040222 W JP2022040222 W JP 2022040222W WO 2023112510 A1 WO2023112510 A1 WO 2023112510A1
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Prior art keywords
coil
pieces
bent
horizontal
predetermined direction
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PCT/JP2022/040222
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French (fr)
Japanese (ja)
Inventor
司 齋藤
樹 金澤
憲道 大高
範子 小川
幸平 市川
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株式会社小松製作所
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Publication of WO2023112510A1 publication Critical patent/WO2023112510A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors

Definitions

  • the present invention relates to a coil manufacturing method, a coil, and a coil material.
  • Some of the coils that electric motors and generators have are made by spirally forming a coil material with a rectangular cross section.
  • a plurality of L-shaped plate pieces are punched out from a copper plate.
  • a plurality of L-shaped plate pieces are joined together by welding to form a spiral coil.
  • An object of the present invention is to reduce the cost of manufacturing a coil from a coil material having a rectangular cross section and to facilitate quality assurance.
  • a plurality of first coil pieces are arranged alternately in a predetermined direction, and the plurality of first coil pieces are integrally formed with each other.
  • a coil according to a second aspect of the present invention includes a plurality of first coil pieces, a plurality of second coil pieces, and a plurality of bent portions.
  • the plurality of first coil pieces have a rectangular cross section.
  • the plurality of second coil pieces have a rectangular cross section.
  • the plurality of second coil pieces are integrally connected to each of the plurality of first coil pieces.
  • the plurality of second coil pieces are spirally connected to each of the plurality of first coil pieces.
  • the plurality of bent portions are bent such that each of the plurality of second coil pieces is alternately folded on each of the plurality of first coil pieces.
  • a coil material according to a third aspect of the present invention is a coil material that is formed into a spiral coil by being folded, and includes a plurality of first coil pieces, a plurality of second coil pieces, and a plurality of folded coil pieces. and a part.
  • the plurality of first coil pieces have a rectangular cross section.
  • the plurality of second coil pieces are arranged alternately in a predetermined direction with respect to each of the plurality of first coil pieces.
  • the plurality of second coil pieces are integrally connected to each of the plurality of first coil pieces.
  • the plurality of bent portions are arranged such that the plurality of first coil pieces and the plurality of second coil pieces are alternately folded by being bent.
  • a spiral coil is formed from a coil material having a rectangular cross section by bending a plurality of bending portions. Therefore, the number of joints in the coil is reduced. As a result, the cost for manufacturing the coil can be reduced, and the quality can be easily ensured.
  • FIG. 1 is a perspective view of a coil according to an embodiment; FIG. It is a figure which shows a part of coil material. It is an enlarged view of a coil material.
  • FIG. 4 is an enlarged view of the coil material during bending;
  • FIG. 4 is an enlarged view of the coil material during bending;
  • FIG. 4 is an enlarged view of the coil material during bending;
  • FIG. 1 is a perspective view of a coil 1 according to an embodiment.
  • Coil 1 is used, for example, in an electric motor. Alternatively, coil 1 may be used in a generator.
  • a coil 1 is attached to a stator 2 .
  • Stator 2 includes teeth 3 .
  • Coil 1 is arranged around teeth 3 .
  • Coil 1 includes a first coil portion 11 , a second coil portion 12 , a first coil end 13 and a second coil end 14 .
  • the first coil portion 11 and the second coil portion 12 are arranged inside the stator 2 .
  • the first coil end 13 and the second coil end 14 are arranged outside the starter 2 .
  • FIG. 2 shows part of the coil material 20 .
  • the coil material 20 is folded in a zigzag shape to form a spiral coil.
  • the coil material 20 is formed by punching, for example, a copper plate by press working.
  • the coil material 20 may be obtained by cutting out a flat metal plate with a cutting means such as a laser.
  • the coil material 20 has a flat plate shape extending in the predetermined direction X1 and has a rectangular cross section.
  • the coil material 20 has a wave-like shape that is continuously bent.
  • the coil material 20 includes a plurality of first coil pieces 21A-21D, a plurality of second coil pieces 22A-22D, and a plurality of bent portions 23A-23D, 24A-24D.
  • the plurality of first coil pieces 21A-21D, the plurality of second coil pieces 22A-22D, and the plurality of bent portions 23A-23D and 24A-24D are integrally formed continuously.
  • the plurality of first coil pieces 21A-21D have an L-shaped bent shape.
  • the plurality of second coil pieces 22A-22D have an L-shaped bent shape.
  • the plurality of second coil pieces 22A-22D and the plurality of first coil pieces 21A-21D are alternately arranged in the predetermined direction X1.
  • FIG. 3 is an enlarged view of the coil material 20.
  • the first coil piece 21A includes a first vertical portion 25A and a first horizontal portion 26A.
  • the first vertical portion 25A extends in the predetermined direction X1.
  • the first horizontal portion 26A extends in the first horizontal direction Y1.
  • the first horizontal direction Y1 is a direction crossing the predetermined direction X1.
  • the first lateral portion 26A includes a first portion 27A and a second portion 28A.
  • the first portion 27A extends in the first horizontal direction Y1 from the first vertical portion 25A.
  • the second portion 28A extends in the first horizontal direction Y1.
  • the second portion 28A is arranged apart from the first portion 27A in the predetermined direction X1. That is, the second portion 28A is displaced from the first portion 27A in the predetermined direction X1.
  • the first bent portion 23A is provided on the first horizontal portion 26A.
  • the first bent portion 23A is arranged between the first portion 27A and the second portion 28A.
  • the first bent portion 23A extends in the predetermined direction X1.
  • the first bent portion 23A connects the first portion 27A and the second portion 28A.
  • the second coil piece 22A includes a second vertical portion 31A and a second horizontal portion 32A.
  • the second vertical portion 31A extends in the predetermined direction X1 from the first horizontal portion 26A.
  • the second horizontal portion 32A extends in the second horizontal direction Y2 from the second vertical portion 31A.
  • the second horizontal direction Y2 is a direction opposite to the first horizontal direction Y1.
  • the second lateral portion 32A includes a third portion 33A and a fourth portion 34A.
  • the third portion 33A extends from the second vertical portion 31A in the second horizontal direction Y2.
  • the fourth portion 34A extends in the second horizontal direction Y2.
  • the fourth portion 34A is arranged apart from the third portion 33A in the predetermined direction X1. That is, the fourth portion 34A is displaced from the third portion 33A in the predetermined direction X1.
  • the second bent portion 24A is provided on the second horizontal portion 32A.
  • the second bent portion 24A is arranged between the third portion 33A and the fourth portion 34A.
  • the second bent portion 24A extends in the predetermined direction X1.
  • the second bent portion 24A connects the third portion 33A and the fourth portion 34A.
  • the next first coil piece 21B has the same shape as the first coil piece 21A.
  • the first coil piece 21B includes a first vertical portion 25B and a first horizontal portion 26B.
  • the first vertical portion 25B and the first horizontal portion 26B have the same shapes as the first vertical portion 25A and the first horizontal portion 26A, respectively.
  • the first lateral portion 26B includes a first portion 27B and a second portion 28B.
  • the first portion 27B and the second portion 28B have the same shapes as the first portion 27A and the second portion 28A, respectively.
  • the next second coil piece 22B has the same shape as the second coil piece 22A.
  • the second coil piece 22B includes a second vertical portion 31B and a second horizontal portion 32B.
  • the second vertical portion 31B and the second horizontal portion 32B have the same shapes as the second vertical portion 31A and the second horizontal portion 32A, respectively.
  • the second lateral portion 32B includes a third portion 33B and a fourth portion 34B.
  • the third portion 33B and the fourth portion 34B have the same shape as the third portion 33A and the fourth portion 34A, respectively.
  • the next first bent portion 23B has the same shape as the first bent portion 23A described above.
  • the next second bent portion 24B has the same shape as the second bent portion 24A described above.
  • the coil material 20 is sequentially bent at a plurality of bending portions 23A-23D and 24A-24D.
  • the second bent portions 24A-24D are bent in the opposite direction to the first bent portions 23A-23D.
  • the first folding portions 23A-23D are folded in valley folds
  • the second folding portions 24A-24D are folded in mountain folds.
  • the first bent portions 23A-23D may be mountain-folded and the second bent portions 24A-24D may be valley-folded.
  • the procedure for bending the plurality of bending portions 23A-23D and 24A-24D will be described in detail below.
  • the coil material 20 is bent at the first bending portion 23A.
  • the first coil piece 21A and the second coil piece 22A are combined in a loop to form one loop coil.
  • the coil material 20 is bent at the second bending portion 24A.
  • the first coil piece 21B is overlaid on the first coil piece 21A.
  • the coil material 20 is bent at the first bending portion 23B.
  • the second coil piece 22B is overlaid on the second coil piece 22A.
  • the first coil piece 21B and the second coil piece 22B are combined in a loop to form the next one-loop coil.
  • first coil pieces 21A and 21B overlap each other.
  • the plurality of second coil pieces 22A, 22B overlap each other. However, some of the multiple first coil pieces 21A and 21B may be displaced from each other. A part of the plurality of second coil pieces 22A and 22B may be arranged to be shifted from each other.
  • the plurality of first coil pieces 21A-21D and the plurality of second coil pieces 22A-22D are alternately folded in a zigzag manner, The coil material 20 is bent in order. Thereby, a coil 1 is formed as shown in FIG.
  • the above-described first coil portion 11 is formed by the first vertical portions 25A, 25B, .
  • the second coil portion 12 described above is formed by the second vertical portions 31A, 31B, .
  • the first coil ends 13 described above are formed by the first horizontal portions 26A, 26B, .
  • the second coil ends 14 described above are formed by the second horizontal portions 32A, 32B, .
  • a spiral coil is formed from the coil material 20 having a rectangular cross section by bending the plurality of bending portions 23A-23D and 24A-24D. Therefore, the number of joints in the coil is reduced. As a result, the cost for manufacturing the coil can be reduced, and the quality can be easily ensured.
  • the coil 1 may be provided on the rotor instead of the stator.
  • the shape of the coil material 20 is not limited to that of the above embodiment, and may be changed.
  • the shapes of the first coil pieces 21A-21D and the second coil pieces 22A-22D may be different from each other.
  • the cost of manufacturing a coil from a coil material having a rectangular cross section is reduced, and the quality can be easily ensured.
  • Coil material 21A First coil piece 22A: Second coil piece 23A: First bent portion 24A: Second bent portion 25A: First vertical portion 26A: First horizontal portion 27A: First portion 28A: Second portion 31A: Second vertical portion 32A: Second horizontal portion 33A: Third portion 34A: Fourth portion X1: Predetermined direction Y1: First horizontal direction Y2: Second horizontal direction

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Windings For Motors And Generators (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

This method for manufacturing a coil comprises: preparing a coil material including a plurality of first coil pieces, a plurality of second coil pieces that are arranged alternately with the plurality of first coil pieces along a predetermined direction and are integrally connected to the plurality of first coil pieces, and a plurality of bend portions, the coil material having a rectangular cross-section; and forming a spiral coil by bending the coil material at the plurality of bend portions in such a way that the plurality of first coil pieces and the plurality of second coil pieces are alternately folded on one another.

Description

コイルの製造方法、コイル、及びコイル素材COIL MANUFACTURING METHOD, COIL, AND COIL MATERIAL
　本発明は、コイルの製造方法、コイル、及びコイル素材に関する。 The present invention relates to a coil manufacturing method, a coil, and a coil material.
　電動モータ、或いは発電機が備えるコイルには、矩形断面のコイル素材を、らせん状に形成したものがある。例えば、特許文献１では、銅板から複数のＬ字状の板片が打ち抜かれる。そして、複数のＬ字状の板片が溶接によって互いに接合されることで、らせん状のコイルが形成される。 Some of the coils that electric motors and generators have are made by spirally forming a coil material with a rectangular cross section. For example, in Patent Document 1, a plurality of L-shaped plate pieces are punched out from a copper plate. A plurality of L-shaped plate pieces are joined together by welding to form a spiral coil.
特開２００１－１７８０５２号Japanese Patent Application Laid-Open No. 2001-178052
　上述したコイルでは、製造時に多くの板片が接合される。そのため、製造コストが増大する。また、上述したコイルは、多くの接合部分を有している。接合部分が多いほど、品質を高く確保することは困難になる。本発明の目的は、矩形断面のコイル素材からコイルを製造する際のコストを低減すると共に、品質の確保を容易にすることにある。 In the coil described above, many plate pieces are joined during manufacturing. Therefore, manufacturing costs increase. Also, the coils described above have many joints. The more joints there are, the more difficult it is to ensure high quality. SUMMARY OF THE INVENTION An object of the present invention is to reduce the cost of manufacturing a coil from a coil material having a rectangular cross section and to facilitate quality assurance.
　本発明の第１態様に係るコイルの製造方法は、複数の第１コイル片と、複数の第１コイル片と所定方向に交互に並んで配置され、複数の第１コイル片と互いに一体的に接続された複数の第２コイル片と、複数の折り曲げ部とを含み、矩形断面を有するコイル素材を用意することと、複数の第１コイル片と複数の第２コイル片とのそれぞれが交互に折り重なるように、複数の折り曲げ部においてコイル素材を折り曲げることで、らせん状のコイルを形成すること、を備える。 In the coil manufacturing method according to the first aspect of the present invention, a plurality of first coil pieces are arranged alternately in a predetermined direction, and the plurality of first coil pieces are integrally formed with each other. preparing a coil material having a rectangular cross section including a plurality of connected second coil pieces and a plurality of bent portions; and alternately forming the plurality of first coil pieces and the plurality of second coil pieces. Folding the coil material at a plurality of folds to form a helical coil.
　本発明の第２態様に係るコイルは、複数の第１コイル片と、複数の第２コイル片と、複数の折り曲げ部とを備える。複数の第１コイル片は、矩形断面を有する。複数の第２コイル片は、矩形断面を有する。複数の第２コイル片は、複数の第１コイル片のそれぞれと互いに一体的に接続されている。複数の第２コイル片は、複数の第１コイル片のそれぞれに対して、らせん状に連なっている。複数の折り曲げ部は、複数の第２コイル片のそれぞれが、複数の第１コイル片のそれぞれに対して交互に折り重なるように、折り曲げられている。 A coil according to a second aspect of the present invention includes a plurality of first coil pieces, a plurality of second coil pieces, and a plurality of bent portions. The plurality of first coil pieces have a rectangular cross section. The plurality of second coil pieces have a rectangular cross section. The plurality of second coil pieces are integrally connected to each of the plurality of first coil pieces. The plurality of second coil pieces are spirally connected to each of the plurality of first coil pieces. The plurality of bent portions are bent such that each of the plurality of second coil pieces is alternately folded on each of the plurality of first coil pieces.
　本発明の第３の態様に係るコイル素材は、折り曲げられることでらせん状のコイルに形成されるコイル素材であって、複数の第１コイル片と、複数の第２コイル片と、複数の折り曲げ部とを備える。複数の第１コイル片は、矩形断面を有する。複数の第２コイル片は、複数の第１コイル片のそれぞれに対して、所定方向に交互に並んで配置される。複数の第２コイル片は、複数の第１コイル片のそれぞれと互いに一体的に接続される。複数の折り曲げ部は、折り曲げられることで、複数の第１コイル片と複数の第２コイル片とのそれぞれが交互に折り重なるように配置される。 A coil material according to a third aspect of the present invention is a coil material that is formed into a spiral coil by being folded, and includes a plurality of first coil pieces, a plurality of second coil pieces, and a plurality of folded coil pieces. and a part. The plurality of first coil pieces have a rectangular cross section. The plurality of second coil pieces are arranged alternately in a predetermined direction with respect to each of the plurality of first coil pieces. The plurality of second coil pieces are integrally connected to each of the plurality of first coil pieces. The plurality of bent portions are arranged such that the plurality of first coil pieces and the plurality of second coil pieces are alternately folded by being bent.
　本発明によれば、複数の折り曲げ部を折り曲げることで、矩形断面のコイル素材から、らせん状のコイルが形成される。従って、コイルにおける接合部分が少なくなる。それにより、コイルを製造する際のコストが低減すると共に、品質の確保が容易になる。 According to the present invention, a spiral coil is formed from a coil material having a rectangular cross section by bending a plurality of bending portions. Therefore, the number of joints in the coil is reduced. As a result, the cost for manufacturing the coil can be reduced, and the quality can be easily ensured.
実施形態に係るコイルの斜視図である。1 is a perspective view of a coil according to an embodiment; FIG. コイル素材の一部を示す図である。It is a figure which shows a part of coil material. コイル素材の拡大図である。It is an enlarged view of a coil material. 折り曲げ加工中のコイル素材の拡大図である。FIG. 4 is an enlarged view of the coil material during bending; 折り曲げ加工中のコイル素材の拡大図である。FIG. 4 is an enlarged view of the coil material during bending; 折り曲げ加工中のコイル素材の拡大図である。FIG. 4 is an enlarged view of the coil material during bending;
　以下、図面を参照して本実施形態に係るコイルについて説明する。図１は、実施形態に係るコイル１の斜視図である。コイル１は、例えば、電動モータに用いられる。或いは、コイル１は、発電機に用いられてもよい。コイル１は、ステータ２に取り付けられる。ステータ２は、ティース３を含む。コイル１は、ティース３の周囲に配置される。コイル１は、第１コイル部１１と、第２コイル部１２と、第１コイルエンド１３と、第２コイルエンド１４とを含む。第１コイル部１１と、第２コイル部１２とは、ステータ２内に配置される。第１コイルエンド１３と、第２コイルエンド１４とは、スタータ２外に配置される。 The coil according to this embodiment will be described below with reference to the drawings. FIG. 1 is a perspective view of a coil 1 according to an embodiment. Coil 1 is used, for example, in an electric motor. Alternatively, coil 1 may be used in a generator. A coil 1 is attached to a stator 2 . Stator 2 includes teeth 3 . Coil 1 is arranged around teeth 3 . Coil 1 includes a first coil portion 11 , a second coil portion 12 , a first coil end 13 and a second coil end 14 . The first coil portion 11 and the second coil portion 12 are arranged inside the stator 2 . The first coil end 13 and the second coil end 14 are arranged outside the starter 2 .
　以下、コイル１の製造方法について説明する。まず、図２に示すコイル素材２０が用意される。図２は、コイル素材２０の一部を示している。コイル素材２０は、ジグザグ状に折り畳まれることで、らせん状のコイルに形成される。コイル素材２０は、例えば銅板から、プレス加工により打ち抜かれることで形成される。或いは、コイル素材２０は、金属製の平板をレーザ等の切断手段によって切り出したものであってもよい。コイル素材２０は、所定方向Ｘ１に延びる平板状であり、矩形断面を有する。コイル素材２０は、連続的に屈曲した波状の形状を有している。 A method for manufacturing the coil 1 will be described below. First, the coil material 20 shown in FIG. 2 is prepared. FIG. 2 shows part of the coil material 20 . The coil material 20 is folded in a zigzag shape to form a spiral coil. The coil material 20 is formed by punching, for example, a copper plate by press working. Alternatively, the coil material 20 may be obtained by cutting out a flat metal plate with a cutting means such as a laser. The coil material 20 has a flat plate shape extending in the predetermined direction X1 and has a rectangular cross section. The coil material 20 has a wave-like shape that is continuously bent.
　コイル素材２０は、複数の第１コイル片２１Ａ－２１Ｄと、複数の第２コイル片２２Ａ－２２Ｄと、複数の折り曲げ部２３Ａ－２３Ｄ，２４Ａ－２４Ｄとを含む。複数の第１コイル片２１Ａ－２１Ｄと、複数の第２コイル片２２Ａ－２２Ｄと、複数の折り曲げ部２３Ａ－２３Ｄ，２４Ａ－２４Ｄとは、一体的に連続して形成されている。複数の第１コイル片２１Ａ－２１Ｄは、Ｌ字状に屈曲した形状を有している。複数の第２コイル片２２Ａ－２２Ｄは、Ｌ字状に屈曲した形状を有している。複数の第２コイル片２２Ａ－２２Ｄは、複数の第１コイル片２１Ａ－２１Ｄと、所定方向Ｘ１に交互に並んで配置されている。 The coil material 20 includes a plurality of first coil pieces 21A-21D, a plurality of second coil pieces 22A-22D, and a plurality of bent portions 23A-23D, 24A-24D. The plurality of first coil pieces 21A-21D, the plurality of second coil pieces 22A-22D, and the plurality of bent portions 23A-23D and 24A-24D are integrally formed continuously. The plurality of first coil pieces 21A-21D have an L-shaped bent shape. The plurality of second coil pieces 22A-22D have an L-shaped bent shape. The plurality of second coil pieces 22A-22D and the plurality of first coil pieces 21A-21D are alternately arranged in the predetermined direction X1.
　図３は、コイル素材２０の拡大図である。図３に示すように、第１コイル片２１Ａは、第１縦部２５Ａと第１横部２６Ａとを含む。第１縦部２５Ａは、所定方向Ｘ１に延びている。第１横部２６Ａは、第１横方向Ｙ１に延びている。第１横方向Ｙ１は、所定方向Ｘ１に交差する方向である。 FIG. 3 is an enlarged view of the coil material 20. FIG. As shown in FIG. 3, the first coil piece 21A includes a first vertical portion 25A and a first horizontal portion 26A. The first vertical portion 25A extends in the predetermined direction X1. The first horizontal portion 26A extends in the first horizontal direction Y1. The first horizontal direction Y1 is a direction crossing the predetermined direction X1.
　詳細には、第１横部２６Ａは、第１部分２７Ａと第２部分２８Ａとを含む。第１部分２７Ａは、第１縦部２５Ａから第１横方向Ｙ１に延びている。第２部分２８Ａは、第１横方向Ｙ１に延びている。第２部分２８Ａは、第１部分２７Ａから所定方向Ｘ１に離れて配置されている。すなわち、第２部分２８Ａは、第１部分２７Ａから所定方向Ｘ１に、ずれて配置されている。 Specifically, the first lateral portion 26A includes a first portion 27A and a second portion 28A. The first portion 27A extends in the first horizontal direction Y1 from the first vertical portion 25A. The second portion 28A extends in the first horizontal direction Y1. The second portion 28A is arranged apart from the first portion 27A in the predetermined direction X1. That is, the second portion 28A is displaced from the first portion 27A in the predetermined direction X1.
　第１折り曲げ部２３Ａは、第１横部２６Ａに設けられている。第１折り曲げ部２３Ａは、第１部分２７Ａと第２部分２８Ａとの間に配置されている。第１折り曲げ部２３Ａは、所定方向Ｘ１に延びている。第１折り曲げ部２３Ａは、第１部分２７Ａと第２部分２８Ａとを接続している。 The first bent portion 23A is provided on the first horizontal portion 26A. The first bent portion 23A is arranged between the first portion 27A and the second portion 28A. The first bent portion 23A extends in the predetermined direction X1. The first bent portion 23A connects the first portion 27A and the second portion 28A.
　第２コイル片２２Ａは、第２縦部３１Ａと第２横部３２Ａとを含む。第２縦部３１Ａは、第１横部２６Ａから所定方向Ｘ１に延びている。第２横部３２Ａは、第２縦部３１Ａから第２横方向Ｙ２に延びている。第２横方向Ｙ２は、第１横方向Ｙ１と反対の方向である。 The second coil piece 22A includes a second vertical portion 31A and a second horizontal portion 32A. The second vertical portion 31A extends in the predetermined direction X1 from the first horizontal portion 26A. The second horizontal portion 32A extends in the second horizontal direction Y2 from the second vertical portion 31A. The second horizontal direction Y2 is a direction opposite to the first horizontal direction Y1.
　詳細には、第２横部３２Ａは、第３部分３３Ａと第４部分３４Ａとを含む。第３部分３３Ａは、第２縦部３１Ａから第２横方向Ｙ２に延びている。第４部分３４Ａは、第２横方向Ｙ２に延びている。第４部分３４Ａは、第３部分３３Ａから所定方向Ｘ１に離れて配置されている。すなわち、第４部分３４Ａは、第３部分３３Ａから所定方向Ｘ１に、ずれて配置されている。 Specifically, the second lateral portion 32A includes a third portion 33A and a fourth portion 34A. The third portion 33A extends from the second vertical portion 31A in the second horizontal direction Y2. The fourth portion 34A extends in the second horizontal direction Y2. The fourth portion 34A is arranged apart from the third portion 33A in the predetermined direction X1. That is, the fourth portion 34A is displaced from the third portion 33A in the predetermined direction X1.
　第２折り曲げ部２４Ａは、第２横部３２Ａに設けられている。第２折り曲げ部２４Ａは、第３部分３３Ａと第４部分３４Ａとの間に配置されている。第２折り曲げ部２４Ａは、所定方向Ｘ１に延びている。第２折り曲げ部２４Ａは、第３部分３３Ａと第４部分３４Ａとを接続している。 The second bent portion 24A is provided on the second horizontal portion 32A. The second bent portion 24A is arranged between the third portion 33A and the fourth portion 34A. The second bent portion 24A extends in the predetermined direction X1. The second bent portion 24A connects the third portion 33A and the fourth portion 34A.
　次の第１コイル片２１Ｂは、第１コイル片２１Ａと同様の形状を有している。第１コイル片２１Ｂは、第１縦部２５Ｂと第１横部２６Ｂとを含む。第１縦部２５Ｂと、第１横部２６Ｂとは、上述した第１縦部２５Ａと第１横部２６Ａと、それぞれ同様の形状を有している。第１横部２６Ｂは、第１部分２７Ｂと第２部分２８Ｂとを含む。第１部分２７Ｂと第２部分２８Ｂとは、上述した第１部分２７Ａと第２部分２８Ａと、それぞれ同様の形状を有している。 The next first coil piece 21B has the same shape as the first coil piece 21A. The first coil piece 21B includes a first vertical portion 25B and a first horizontal portion 26B. The first vertical portion 25B and the first horizontal portion 26B have the same shapes as the first vertical portion 25A and the first horizontal portion 26A, respectively. The first lateral portion 26B includes a first portion 27B and a second portion 28B. The first portion 27B and the second portion 28B have the same shapes as the first portion 27A and the second portion 28A, respectively.
　次の第２コイル片２２Ｂは、第２コイル片２２Ａと同様の形状を有している。第２コイル片２２Ｂは、第２縦部３１Ｂと第２横部３２Ｂとを含む。第２縦部３１Ｂと、第２横部３２Ｂとは、上述した第２縦部３１Ａと第２横部３２Ａと、それぞれ同様の形状を有している。第２横部３２Ｂは、第３部分３３Ｂと第４部分３４Ｂとを含む。第３部分３３Ｂと第４部分３４Ｂとは、上述した第３部分３３Ａと第４部分３４Ａと、それぞれ同様の形状を有している。 The next second coil piece 22B has the same shape as the second coil piece 22A. The second coil piece 22B includes a second vertical portion 31B and a second horizontal portion 32B. The second vertical portion 31B and the second horizontal portion 32B have the same shapes as the second vertical portion 31A and the second horizontal portion 32A, respectively. The second lateral portion 32B includes a third portion 33B and a fourth portion 34B. The third portion 33B and the fourth portion 34B have the same shape as the third portion 33A and the fourth portion 34A, respectively.
　次の第１折り曲げ部２３Ｂは、上述した第１折り曲げ部２３Ａと同様の形状を有している。次の第２折り曲げ部２４Ｂは、上述した第２折り曲げ部２４Ａと同様の形状を有している。 The next first bent portion 23B has the same shape as the first bent portion 23A described above. The next second bent portion 24B has the same shape as the second bent portion 24A described above.
　次に、複数の折り曲げ部２３Ａ－２３Ｄ，２４Ａ－２４Ｄにおいて、順次、コイル素材２０が折り曲げられる。第２折り曲げ部２４Ａ－２４Ｄは、第１折り曲げ部２３Ａ－２３Ｄと逆方向に折り曲げられる。例えば、第１折り曲げ部２３Ａ－２３Ｄが谷折りで折り曲げられ、第２折り曲げ部２４Ａ－２４Ｄが山折りで折り曲げられる。或いは、第１折り曲げ部２３Ａ－２３Ｄが山折りで折り曲げられ、第２折り曲げ部２４Ａ－２４Ｄが谷折りで折り曲げられてもよい。 Next, the coil material 20 is sequentially bent at a plurality of bending portions 23A-23D and 24A-24D. The second bent portions 24A-24D are bent in the opposite direction to the first bent portions 23A-23D. For example, the first folding portions 23A-23D are folded in valley folds, and the second folding portions 24A-24D are folded in mountain folds. Alternatively, the first bent portions 23A-23D may be mountain-folded and the second bent portions 24A-24D may be valley-folded.
　以下、複数の折り曲げ部２３Ａ－２３Ｄ，２４Ａ－２４Ｄの折り曲げの手順について詳細に説明する。まず、図３に示すように、第１折り曲げ部２３Ａにおいて、コイル素材２０が折り曲げられる。それにより、図４に示すように、第１コイル片２１Ａと第２コイル片２２Ａとが、ループ状に組み合わされ、１ループのコイルが形成される。 The procedure for bending the plurality of bending portions 23A-23D and 24A-24D will be described in detail below. First, as shown in FIG. 3, the coil material 20 is bent at the first bending portion 23A. As a result, as shown in FIG. 4, the first coil piece 21A and the second coil piece 22A are combined in a loop to form one loop coil.
　次に、第２折り曲げ部２４Ａにおいて、コイル素材２０が折り曲げられる。それにより、図５に示すように、第１コイル片２１Ｂが、第１コイル片２１Ａ上に重ねられる。そして、第１折り曲げ部２３Ｂにおいて、コイル素材２０が折り曲げられる。それにより、図６に示すように、第２コイル片２２Ｂが、第２コイル片２２Ａに重ねられる。それにより、第１コイル片２１Ｂと第２コイル片２２Ｂとが、ループ状に組み合わされ、次の１ループのコイルが形成される。 Next, the coil material 20 is bent at the second bending portion 24A. Thereby, as shown in FIG. 5, the first coil piece 21B is overlaid on the first coil piece 21A. Then, the coil material 20 is bent at the first bending portion 23B. Thereby, as shown in FIG. 6, the second coil piece 22B is overlaid on the second coil piece 22A. As a result, the first coil piece 21B and the second coil piece 22B are combined in a loop to form the next one-loop coil.
　なお、複数の第１コイル片２１Ａ，２１Ｂは、互いに重なる。複数の第２コイル片２２Ａ，２２Ｂは、互いに重なる。ただし、複数の第１コイル片２１Ａ，２１Ｂの一部が、互いにずれて配置されてもよい。複数の第２コイル片２２Ａ，２２Ｂの一部が、互いにずれて配置されてもよい。 Note that the plurality of first coil pieces 21A and 21B overlap each other. The plurality of second coil pieces 22A, 22B overlap each other. However, some of the multiple first coil pieces 21A and 21B may be displaced from each other. A part of the plurality of second coil pieces 22A and 22B may be arranged to be shifted from each other.
　以上のように、複数の第１コイル片２１Ａ－２１Ｄと複数の第２コイル片２２Ａ－２２Ｄとのそれぞれがジグザグ状に交互に折り重なるように、複数の折り曲げ部２３Ａ－２３Ｄ，２４Ａ－２４Ｄにおいて、順にコイル素材２０が折り曲げられる。それにより、図１に示すように、コイル１が形成される。 As described above, at the plurality of bending portions 23A-23D and 24A-24D, the plurality of first coil pieces 21A-21D and the plurality of second coil pieces 22A-22D are alternately folded in a zigzag manner, The coil material 20 is bent in order. Thereby, a coil 1 is formed as shown in FIG.
　互いに積み重ねられた複数の第１コイル片２１Ａ－２１Ｄの第１縦部２５Ａ，２５Ｂ，・・・によって、上述した第１コイル部１１が形成される。互いに積み重ねられた複数の第２コイル片２２Ａ－２２Ｄの第２縦部３１Ａ，３１Ｂ，・・・によって、上述した第２コイル部１２が形成される。互いに積み重ねられた複数の第１コイル片２１Ａ－２１Ｄの第１横部２６Ａ，２６Ｂ，・・・によって、上述した第１コイルエンド１３が形成される。互いに積み重ねられた複数の第２コイル片２２Ａ－２２Ｄの第２横部３２Ａ，３２Ｂ，・・・によって、上述した第２コイルエンド１４が形成される。 The above-described first coil portion 11 is formed by the first vertical portions 25A, 25B, . The second coil portion 12 described above is formed by the second vertical portions 31A, 31B, . The first coil ends 13 described above are formed by the first horizontal portions 26A, 26B, . The second coil ends 14 described above are formed by the second horizontal portions 32A, 32B, .
　以上説明した本実施形態に係るコイルの製造方法によれば、複数の折り曲げ部２３Ａ－２３Ｄ，２４Ａ－２４Ｄを折り曲げることで、矩形断面のコイル素材２０から、らせん状のコイルが形成される。従って、コイルにおける接合部分が少なくなる。それにより、コイルを製造する際のコストが低減すると共に、品質の確保が容易になる。 According to the coil manufacturing method according to the present embodiment described above, a spiral coil is formed from the coil material 20 having a rectangular cross section by bending the plurality of bending portions 23A-23D and 24A-24D. Therefore, the number of joints in the coil is reduced. As a result, the cost for manufacturing the coil can be reduced, and the quality can be easily ensured.
　以上、本発明の一実施形態について説明したが、本発明は上記実施形態に限定されるものではなく、発明の要旨を逸脱しない範囲で種々の変更が可能である。 Although one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications are possible without departing from the gist of the invention.
　コイル１は、ステータではなく、ロータに設けられてもよい。コイル素材２０の形状は、上記の実施形態のものに限らず、変更されてもよい。例えば、第１コイル片２１Ａ－２１Ｄと第２コイル片２２Ａ－２２Ｄとの形状は互いに異なっていてもよい。 The coil 1 may be provided on the rotor instead of the stator. The shape of the coil material 20 is not limited to that of the above embodiment, and may be changed. For example, the shapes of the first coil pieces 21A-21D and the second coil pieces 22A-22D may be different from each other.
　本発明によれば、矩形断面のコイル素材からコイルを製造する際のコストが低減すると共に、品質の確保が容易になる。 According to the present invention, the cost of manufacturing a coil from a coil material having a rectangular cross section is reduced, and the quality can be easily ensured.
２０：コイル素材
２１Ａ：第１コイル片
２２Ａ：第２コイル片
２３Ａ：第１折り曲げ部
２４Ａ：第２折り曲げ部
２５Ａ：第１縦部
２６Ａ：第１横部
２７Ａ：第１部分
２８Ａ：第２部分
３１Ａ：第２縦部
３２Ａ：第２横部
３３Ａ：第３部分
３４Ａ：第４部分
Ｘ１：所定方向
Ｙ１：第１横方向
Ｙ２：第２横方向 20: Coil material 21A: First coil piece 22A: Second coil piece 23A: First bent portion 24A: Second bent portion 25A: First vertical portion 26A: First horizontal portion 27A: First portion 28A: Second portion 31A: Second vertical portion 32A: Second horizontal portion 33A: Third portion 34A: Fourth portion X1: Predetermined direction Y1: First horizontal direction Y2: Second horizontal direction

Claims (13)

  1. 　複数の第１コイル片と、前記複数の第１コイル片と所定方向に交互に並んで配置され、複数の第１コイル片と互いに一体的に接続された複数の第２コイル片と、複数の折り曲げ部とを含み、矩形断面を有するコイル素材を用意することと、
    　前記複数の第１コイル片と前記複数の第２コイル片とのそれぞれが交互に折り重なるように、前記複数の折り曲げ部において前記コイル素材を折り曲げることで、らせん状のコイルを形成すること、
    を備えるコイルの製造方法。     a plurality of first coil pieces; a plurality of second coil pieces arranged alternately in a predetermined direction with the plurality of first coil pieces and integrally connected to the plurality of first coil pieces; preparing a coil material having a rectangular cross section, including a bent portion;
    forming a spiral coil by bending the coil material at the plurality of bending portions so that the plurality of first coil pieces and the plurality of second coil pieces are alternately folded;
    A method of manufacturing a coil comprising:
  2. 　前記コイル素材は、平板状である、
    請求項１に記載のコイルの製造方法。     The coil material has a flat plate shape,
    A method of manufacturing the coil according to claim 1 .
  3. 　前記第１コイル片は、
    　　前記所定方向に延びる第１縦部と、
    　　前記第１縦部から前記所定方向に交差する第１横方向に延びる第１横部と、
    　を含み、
    　前記第２コイル片は、
    　　前記第１横部から前記所定方向に延びる第２縦部と、
    　　前記第２縦部から前記第１横方向と反対の第２横方向に延びる第２横部と、
    　を含む、
    請求項１又は２に記載のコイルの製造方法。     The first coil piece is
    a first vertical portion extending in the predetermined direction;
    a first horizontal portion extending from the first vertical portion in a first horizontal direction intersecting the predetermined direction;
    including
    The second coil piece is
    a second vertical portion extending in the predetermined direction from the first horizontal portion;
    a second horizontal portion extending from the second vertical portion in a second horizontal direction opposite to the first horizontal direction;
    including,
    A method for manufacturing the coil according to claim 1 or 2.
  4. 　前記複数の折り曲げ部は、前記第１横部に設けられる第１折り曲げ部を含み、
    　前記第１折り曲げ部において、前記コイル素材を折り曲げることをさらに備える、
    請求項３に記載のコイルの製造方法。     The plurality of bent portions includes a first bent portion provided on the first lateral portion,
    Further comprising bending the coil material at the first bending portion,
    A method for manufacturing the coil according to claim 3.
  5. 　前記複数の折り曲げ部は、前記第２横部に設けられる第２折り曲げ部を含み、
    　前記第２折り曲げ部において、前記コイル素材を折り曲げることをさらに備える、
    請求項４に記載のコイルの製造方法。     The plurality of bent portions includes a second bent portion provided on the second horizontal portion,
    Further comprising bending the coil material at the second bending portion,
    A method for manufacturing the coil according to claim 4.
  6. 　前記第１横部は、
    　　前記第１縦部から前記第１横方向に延びる第１部分と、
    　　前記第１横方向に延び、前記第１部分から前記所定方向に離れて配置された第２部分と、
    　を含み、
    　前記第１折り曲げ部は、前記所定方向に延び、前記第１部分と前記第２部分とを接続している、
    請求項４又は５に記載のコイルの製造方法。     The first horizontal portion is
    a first portion extending in the first lateral direction from the first vertical portion;
    a second portion extending in the first lateral direction and spaced apart from the first portion in the predetermined direction;
    including
    The first bent portion extends in the predetermined direction and connects the first portion and the second portion,
    A method for manufacturing the coil according to claim 4 or 5.
  7. 　前記第２横部は、
    　　前記第２縦部から前記第２横方向に延びる第３部分と、
    　　前記第２横方向に延び、前記第３部分から前記所定方向に離れて配置された第４部分と、
    　を含み、
    　前記第２折り曲げ部は、前記所定方向に延び、前記第３部分と前記第４部分とを接続している、
    請求項６に記載のコイルの製造方法。     The second horizontal portion is
    a third portion extending in the second lateral direction from the second vertical portion;
    a fourth portion extending in the second lateral direction and spaced apart from the third portion in the predetermined direction;
    including
    The second bent portion extends in the predetermined direction and connects the third portion and the fourth portion,
    A method of manufacturing the coil according to claim 6 .
  8. 　矩形断面を有する複数の第１コイル片と、
    　矩形断面を有し、前記複数の第１コイル片のそれぞれと互いに一体的に接続されており、前記複数の第１コイル片のそれぞれに対して、らせん状に連なる複数の第２コイル片と、
    　前記複数の第２コイル片のそれぞれが、前記複数の第１コイル片のそれぞれに対して交互に折り重なるように、折り曲げられた複数の折り曲げ部と、
    を備えるコイル。     a plurality of first coil pieces having a rectangular cross section;
    a plurality of second coil pieces having a rectangular cross section, integrally connected to each of the plurality of first coil pieces, and spirally connected to each of the plurality of first coil pieces;
    a plurality of bending portions that are bent such that each of the plurality of second coil pieces is alternately folded on each of the plurality of first coil pieces;
    A coil with a
  9. 　前記第１コイル片と前記第２コイル片とは、平板状である、
    請求項８に記載のコイル。     The first coil piece and the second coil piece are flat plate-shaped,
    A coil according to claim 8.
  10. 　折り曲げられることで、らせん状のコイルに形成されるコイル素材であって、
    　矩形断面を有する複数の第１コイル片と、
    　矩形断面を有し、前記複数の第１コイル片のそれぞれに対して、所定方向に交互に並んで配置され、前記複数の第１コイル片のそれぞれと互いに一体的に接続された複数の第２コイル片と、
    　折り曲げられることで、前記複数の第１コイル片と前記複数の第２コイル片とのそれぞれが交互に折り重なるように配置される複数の折り曲げ部と、
    を備えるコイル素材。     A coil material that is formed into a helical coil by being folded,
    a plurality of first coil pieces having a rectangular cross section;
    A plurality of second coil pieces having a rectangular cross section, arranged alternately in a predetermined direction with respect to each of the plurality of first coil pieces, and integrally connected to each of the plurality of first coil pieces. a coil piece;
    a plurality of bent portions arranged so that the plurality of first coil pieces and the plurality of second coil pieces are alternately folded by being bent;
    Coil material with
  11. 　前記第１コイル片は、
    　　前記所定方向に延びる第１縦部と、
    　　前記第１縦部から前記所定方向に交差する第１横方向に延びる第１横部と、
    　を含み、
    　前記第２コイル片は、
    　　前記第１横部から前記所定方向に延びる第２縦部と、
    　　前記第２縦部から前記第１横方向と反対の第２横方向に延びる第２横部と、
    　を含む、
    請求項１０に記載のコイル素材。     The first coil piece is
    a first vertical portion extending in the predetermined direction;
    a first horizontal portion extending from the first vertical portion in a first horizontal direction intersecting the predetermined direction;
    including
    The second coil piece is
    a second vertical portion extending in the predetermined direction from the first horizontal portion;
    a second horizontal portion extending from the second vertical portion in a second horizontal direction opposite to the first horizontal direction;
    including,
    The coil material according to claim 10.
  12. 　前記第１横部は、
    　　前記第１縦部から前記第１横方向に延びる第１部分と、
    　　前記第１横方向に延び、前記第１部分から前記所定方向に離れて配置された第２部分と、
    　を含み、
    　前記複数の折り曲げ部は、前記所定方向に延び、前記第１部分と前記第２部分とを接続する第１折り曲げ部を含む、
    請求項１１に記載のコイル素材。     The first horizontal portion is
    a first portion extending in the first lateral direction from the first vertical portion;
    a second portion extending in the first lateral direction and spaced apart from the first portion in the predetermined direction;
    including
    The plurality of bent portions include a first bent portion extending in the predetermined direction and connecting the first portion and the second portion,
    The coil material according to claim 11.
  13. 　前記第２横部は、
    　　前記第２縦部から前記第２横方向に延びる第３部分と、
    　　前記第２横方向に延び、前記第３部分から前記所定方向に離れて配置された第４部分と、
    　を含み、
    　前記複数の折り曲げ部は、前記所定方向に延び、前記第３部分と前記第４部分とを接続する第２折り曲げ部をさらに含む、
    請求項１２に記載のコイル素材。     The second horizontal portion is
    a third portion extending in the second lateral direction from the second vertical portion;
    a fourth portion extending in the second lateral direction and spaced apart from the third portion in the predetermined direction;
    including
    The plurality of bent portions further includes a second bent portion extending in the predetermined direction and connecting the third portion and the fourth portion,
    The coil material according to claim 12.
PCT/JP2022/040222 2021-12-16 2022-10-27 Method for manufacturing coil, coil, and coil material WO2023112510A1 (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5923510A (en) * 1982-07-30 1984-02-07 Hitachi Ltd Manufacture of coil for electric machine and apparatus
JP2014120762A (en) * 2012-12-14 2014-06-30 Ghing-Hsin Dien Coil and method of manufacturing the same
JP2018198237A (en) * 2017-05-23 2018-12-13 Tdk株式会社 Coil component

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5923510A (en) * 1982-07-30 1984-02-07 Hitachi Ltd Manufacture of coil for electric machine and apparatus
JP2014120762A (en) * 2012-12-14 2014-06-30 Ghing-Hsin Dien Coil and method of manufacturing the same
JP2018198237A (en) * 2017-05-23 2018-12-13 Tdk株式会社 Coil component

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