JP2010010176A - Multiple coil composed of planospirally wound rectangular wire - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a compact and readily producible multiple coil composed of planospirally wound rectangular wires, and to provide a manufacturing method thereof. <P>SOLUTION: The multiple coil is formed in such a way that two or more close plies of single layer coils of rectangular insulated wires are planospirally wound in alignment along the axis of a core, in which the rectangular insulated wires have the same turning direction, the rectangular insulated wires have different sectional conductor areas and/or numbers of turns, and leads at both ends of plies of single layer coils having the same number of turns are connected together in parallel. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a rectangular wire flat wound multiple coil and a method for manufacturing the same.

  In recent years, digitalization and switching technology of electrical equipment has been progressing rapidly. Since it has been digitized, there is a need for a coil that is a small, large current, low loss inductor for removing noise generated from a circuit and smoothing a voltage.

  Some of these coils are directly mounted on a printed circuit board depending on the purpose. In this case, especially a coil used for a power supply circuit or the like needs to reduce a inductance and flow a large current in a narrow space, and a vertical winding (edgewise) coil using a rectangular electric wire as shown in FIG. 9 is used. It was often done.

  However, the longitudinally wound coil using a rectangular electric wire does not have an ideal coil cross-sectional shape as shown in FIG. 10, but has a cross-sectional shape as shown in FIG.

  As a result, there were the following problems specifically. (1) The outer periphery of the flat insulated wire receives a large strain force. (2) On the coil outer diameter side of the flat insulated wire, the metal structure is collapsed excessively, the rectangular cross-section wire is deformed into a triangle or trapezoid, and the cross-sectional area is also reduced. (3) A gap is generated between the wires on the coil outer diameter side. (4) The wire drawn forcibly causes metal work hardening and metal lattice defects, and the electrical conductivity decreases.

  In this way, the density of the conductor that fills the volume taken by the coil decreases, so that the electrical conductivity of the wire decreases and the coil resistance increases.

  In addition, there were the following problems in work. (5) The wire rod collapses during winding, and the variation in electrical characteristics such as the coil shape, capacitance, and electrical resistance value increases. (6) When the flat insulated wire is stretched, the insulating film is also stretched and thinned, and the insulating performance may be deteriorated or the insulating film may be damaged.

  In addition, the design flexibility is extremely small, such as being inapplicable to a coil having a small coil inner diameter, and the aspect ratio of the flat insulated wire cannot be increased. There were also problems such as.

In the prior art, there has been proposed one having a large number of windings in which a rectangular wire is a vertically wound electromagnetic coil and vertically wound coils having different winding directions are assembled in a laminated form (see Patent Document 1, etc.).
JP 2007-188988 A

  SUMMARY OF THE INVENTION An object of the present invention is to solve the above-described problems and to provide a compact and highly productive rectangular wire flat wound multiplex coil and a method for manufacturing the same.

  The present inventors have found that it is useful to connect flat winding insulated wires in the axial direction of the winding core and connect the winding start wires to each other and the winding end wires to complete the following invention.

  (1) A multi-coil in which two or more single-layer coils in which flat insulated wires are aligned and wound in the axial direction of the core are in close contact with each other.

  In the multiple coil according to the invention of (1), two or more single-layer coils in which flat insulated wires are aligned and wound in the axial direction of the core are closely stacked. Here, flat winding refers to winding a rectangular insulated wire in such a way that the longer side of a rectangle whose flat cross section forms is aligned with the axial direction of the core. The so-called vertical winding is a method of winding a rectangular insulated wire by setting a rectangular insulated wire at a 90 ° angle while winding a rectangular insulated wire so that the longitudinal direction of the rectangular wire (rectangle) is perpendicular to the winding core. is there. Alignment means winding closely so as not to overlap in one layer.

  By adopting such a configuration, the above-mentioned “(1) The outer periphery of the rectangular insulated wire is subjected to a large distortion force, which has been a problem in the conventional vertical coil. (2) The coil outer diameter side of the rectangular insulated wire. Then, the metal structure collapses excessively and the specific resistance value of the portion increases, and the rectangular cross-sectional wire deforms into a triangular or trapezoidal shape, reducing the cross-sectional area. (3) On the coil outer diameter side There is a gap between the wires. (4) The wire that has been forcibly stretched causes work hardening of the metal and metal lattice defects, resulting in decreased electrical conductivity. (5) The wire rod collapses during winding. In addition, problems such as variation in electrical characteristics such as coil shape, capacitance, and electrical resistance value can be solved.

  (2) The single-layer coil at each stage of the multiple coil of (1) is a multiple coil having the same turning direction of the flat insulated wire.

  In the multiple coil according to the invention of (2), the single layer coil of each stage has the same turning direction of the flat insulated wire. Since the turning directions are the same, the direction of magnetic flux generation by each single-layer coil is the same, and by adopting such a configuration, it is possible to solve the problems described above and provide a coil with a large current capacity. I can do it.

  (3) The multiple coil according to (1) or (2), wherein the conductor cross-sectional area and / or the number of turns of the flat insulated wire of the single-layer coil at each stage is different.

  (4) The multi-coil according to any one of (1) to (3), wherein leads at both ends of the single-layer coils having the same number of turns in each stage are connected in parallel.

  (5) The multi-coil according to any one of (1) to (4), wherein the flat insulated wire is a self-bonding wire and is fixed.

  The multiple coils according to the inventions of (3) to (5) are characterized in that the leads at both ends of the single-layer coil are connected in parallel using wires having different conductor cross-sectional areas of the flat insulated wires of the single-layer coils of each stage. And Multiple coils with a large current capacity can be made by connecting them in parallel. However, the inner circumference layer and the outer circumference layer have different round lengths. Therefore, when the same rectangular insulated wires are connected in parallel, the inner circumference has a smaller resistance and the outer circumference is larger. As a result, even if they are connected in parallel, the current of the multiple coils is that the current flows through the innermost coil. Moreover, since it is the innermost periphery, heat radiation is poor and the temperature rises. Therefore, the performance of the multiple coil depends on the performance of some layers.

  In order to solve this problem, it is desirable to set the conductor cross-sectional area of the single-layer coil in the inner stage to be equal to or larger than the conductor cross-sectional area of the single-layer coil in the outer stage. Further, depending on the application, it is desirable to refer to the resistance value, inductance value, and heat dissipation coefficient, and to select an appropriate combination in consideration of the cost of the rectangular insulated wire.

  (6) Repeating the steps (1) to (5), in which the single-layer coil in which the flat insulated wires are aligned and wound in the axial direction of the core is used as the core, and the single-layer coil is wound in the axial direction. A method for producing a multiple coil according to any one of the above.

  (7) The multi-coil manufacturing according to any one of (1) to (5), wherein two or more of the rectangular insulated wires are simultaneously aligned and flatly wound in the axial direction of the core to form two or more single-layer coils simultaneously. Method.

  The inventions of (6) and (7) are inventions relating to the method for manufacturing a multi-coil of the present invention, and a multi-coil having a large current capacity can be manufactured well.

  (8) An electromagnetic coil using the multiple coil according to any one of (1) to (5).

  (9) A transformer using the multiple coil according to any one of (1) to (5).

  (10) An armature using the multiple coil described in (1) to (5).

  According to the present invention, a compact multiple coil having a large current capacity, excellent durability, good electrical safety, and compactness can be provided. In addition, it is possible to provide an electromagnetic coil, a transformer, and an armature that use a compact multiple coil that has a large current capacity, excellent durability, good electrical safety, and compactness.

  Hereinafter, the best mode for carrying out the present invention will be described with reference to the drawings. This is merely an example, and the technical scope of the present invention is not limited to this.

[First embodiment]
The first embodiment is a multiple coil connected in parallel. FIG. 1 is a front view of multiple coils connected in parallel according to an embodiment of the present invention. FIG. 2 is a front view (a) and a sectional view (b) of a multiple coil according to an embodiment of the present invention. FIG. 3 is a three-side view of a rectangular wire flat wound multi-coil winding frame according to an embodiment of the present invention. FIG. 4 is a conceptual diagram showing a method of manufacturing a rectangular wire flat wound multiplex coil according to an embodiment of the present invention.

  As shown in FIG. 1, the multiple coils 1 connected in parallel according to the present invention have windings in which a single-layer coil in which flat insulated wires 10 are aligned and wound in the axial direction of the core is in close contact and overlapped. Is a multi-coil including two or more winding layers, and each layer has a lead wire 8, 12, 14, 16... And another coil end lead 11, 13, 15,. 17 are derived. As shown in FIG. 1, the wires derived from the end portions of the coils for each layer are connected in parallel at both ends (30, 40), and are connected to the terminals 50 and 60.

  The multiple coils 1 connected in parallel can be manufactured by winding the rectangular insulated wire 10 having a circular cross section on the flat wire flat coil core 70 shown in FIG. The rectangular wire flat-winding multi-coil winding frame 70 has a notch 81 through which the flat insulated wire 10 can be passed through one side wall, a notch 82, and a protrusion that can invert the flat insulated wire 10 therebetween. 80 is provided. Similarly, on the opposite side wall, as shown in FIG. 2, a notch 91 through which the flat insulated wire 10 can be passed, a notch 92, and a protrusion 90 that can invert the flat insulated wire 10 therebetween. Provided. The rectangular wire flat wound coil 70 is preferably made of an insulator when used as a product after winding. When not used as a product after winding, it may be made of metal instead of an insulator, and after winding, it may be detached from the flat wire flat wound multiple coil.

  As described above, the flat insulated wire 10 is wound on the winding 70 for the flat wire flat wound multi-coil in the aligned winding. A specific method of winding will be described with reference to FIG. The flat wire multi-coil manufacturing apparatus includes a drive unit that can rotate the spindle 210, a control unit, and a guide unit 220 (not shown above) that supplies the flat insulated wire 10.

  4 is set in the state shown in (1) of FIG. 4 so that the rectangular wire flat wound coil frame 70 is set on the spindle 210, and the rectangular insulated wire 10 to be used can be supplied to the guide portion 220 according to the rotation of the spindle 210. set. Further, the flat insulated wire 10 is hooked and fixed to the notch 91 of the flat wire flat wound multi-coil winding frame 70.

  In this state, as shown in FIGS. 4 (2) and (3), the spindle 210 is rotated in one direction, and the guide unit 220 is moved in parallel at a speed that results in aligned flat winding in conjunction with the rotation. Wind the first layer. When the winding to the side wall of the flat wire flat coil core 70 is finished in this way, the rotation of the drive unit is temporarily stopped as shown in FIG. It is led out to the outside through a notch 82 on the side wall, and the wire rod is folded back by the protrusion 80.

    In the state of (5) of FIG. 4, the guide part 220 is returned to the original position as shown in the figure. After returning, the flat insulated wire 10 is hooked and fixed to the notch 91 of the flat wire flat wound coil frame 70. Then, as shown in FIGS. 4 (6) and (7), the spindle 210 is rotated in one direction, and the guide portion 220 is moved in parallel at a speed that results in aligned flat winding in conjunction with the rotation. Wind the layers. When the winding to the side wall of the rectangular wire flat winding multi-coil frame 70 is completed in this way, the rotation of the drive unit is temporarily stopped as shown in FIG. It leads to the outside through a notch 82 in the side wall.

By repeating this operation, the third layer is wound (see FIG. 4 (9)), and then the necessary number of layers are wound.
After winding, the adjacent portions of the flat insulated wire 10 are fixed, and then the rectangular wire flat wound multi-coil winding frame is removed. It is desirable to use a self-bonding flat insulated wire as the flat insulated wire 10. After the reel is removed, the insulation of the wires crossing between the layers is removed and connected in parallel as shown in FIG. Specifically, parallel connection lines 30 and 40 are provided and connected to the terminal 50 and the terminal 60, respectively.

  The flat-wire flat-winding multi-coil having the above-described configuration has been a problem with conventional vertical-winding coils. “(1) The outer periphery of a flat-shaped insulated wire is subjected to a large distortion force. On the outer diameter side, the metal structure is collapsed excessively and the specific resistance value of the portion is increased, and the rectangular cross-sectional wire is deformed into a triangular or trapezoidal shape, and the cross-sectional area is reduced (3) Coil outer diameter. (4) The wire that has been stretched forcibly causes metal work hardening and metal lattice defects, resulting in a decrease in electrical conductivity, and (5) collapse of the wire during winding. This causes problems such as the occurrence of dents and large variations in electrical characteristics such as coil shape, capacitance, and electrical resistance. "

  In addition, since the windings are aligned, the voltage applied to each adjacent winding of one layer is a voltage obtained by dividing the voltage applied between the coils connected in parallel by the number of turns of one layer. In addition, the voltage applied to each adjacent winding is almost zero. This is because these layers are connected in parallel.

  In this way, using a rectangular insulated wire, the current coil has a large current capacity and excellent insulation, and provides a compact flat wire wrap coil. An armature can be provided.

  In addition, as shown in FIGS. 5 and 6, the rectangular wire flat wound multiplex coil of the present invention can also be manufactured by aligning and flatly winding two or more rectangular insulated wires in the axial direction of the core. Further, as shown in FIG. 6, the multiple coils can be pulled out on both sides.

[Second Embodiment]
The multi-coil 100 of the second embodiment differs in the conductor cross-sectional area of the flat insulated wire of the single-layer coil at each stage. As shown in FIG. 7, the thicknesses are d1 and dn on the inner side and the outer side of the multiple coil 100, which are different. This is because the length of the outer single-layer coil is longer, and the resistance value becomes larger. For this reason, when connected in parallel, the resistance value differs between the inner periphery and the outer periphery, so that a large amount of current flows through the inner periphery with a small resistance value. Furthermore, heat is trapped inside because the heat radiation at the inner circumference is poor.

FIG. 7 shows an example in which the conductor cross-sectional area of the wire wound outside is increased in order to correct this phenomenon. As in the example of FIG. 7, it is desirable from the viewpoint of workability that the length direction of the flat-wrapped rectangles is the same and only the thickness is changed to adjust the cross-sectional area. However, it is not limited to this.

  Thus, by comprising, the multiple coil which prevented overheating locally can be provided.

[Third embodiment]
The multi-coil 200 of the third embodiment is different in the conductor cross-sectional area and the number of turns of the flat insulated wire of the single-layer coil at each stage. As shown in FIG. 8, the lengths of the inner and outer sides of the multiple coil 200 are 11 and ln, which are different, so that the conductor cross-sectional areas are also different. Further, the number of turns is different as shown in FIG.

  Further, as shown in FIG. 8, leads having the same number of turns at both ends of the single-layer coil in each stage are connected in parallel. That is, the coils having a large number of turns are connected in parallel and connected to the terminals 250 and 260. In addition, coils having a small number of turns are connected in parallel and connected to terminals 270 and 280.

  With this configuration, it can be used with a transformer having a large current capacity.

  As mentioned above, although demonstrated using embodiment of this invention, the technical scope of this invention is not limited to the range as described in the said embodiment. Various modifications or improvements can be added to the above embodiment. It is apparent from the scope of the claims that the embodiments added with such changes or improvements can be included in the technical scope of the present invention.

It is a front view of the flat wire flat wound multiplex coil connected in parallel concerning one embodiment of the present invention. It is the front view and sectional drawing of the parallel wire flat winding multiple coil which are connected in parallel which concern on one Embodiment of this invention. It is a 3rd page figure of the frame for flat wire flat winding multicoils concerning one embodiment of the present invention. It is a conceptual diagram which shows operation | movement of the rectangular wire flat winding multicoil manufacturing method which concerns on one Embodiment of this invention. It is a conceptual diagram which shows the rectangular wire flat winding multiple coil manufacturing method which concerns on one Embodiment of this invention. It is a perspective view of the flat wire flat wound multiplex coil connected in parallel concerning one embodiment of the present invention. It is the front view and sectional drawing of the rectangular wire flat wound multiplex coil connected in parallel which concerns on another one Embodiment of this invention. It is the front view and connection diagram of the parallel wire flat winding multiplex coil which concern on another one Embodiment of this invention. It is a perspective view of the conventional vertical winding coil. It is sectional drawing of an ideal vertical winding coil. It is sectional drawing of an actual vertical winding coil.

Explanation of symbols

10 Flat insulated wire 50 terminals 60 terminals

Claims (10)

  A multi-coil in which single-layer coils in which flat insulated wires are aligned and wound in the axial direction of the core are in close contact and overlapped.   The single-layer coil of each stage of the multiple coil according to claim 1 is the multiple coil having the same turning direction of the flat rectangular insulated wire.   The multiple coil according to claim 1 or 2, wherein the conductor cross-sectional area and / or the number of turns of the flat insulated wire of the single-layer coil of each stage are different.   The multi-coil according to any one of claims 1 to 3, wherein leads at both ends of the single-layer coils having the same number of turns in each stage are connected in parallel.   The multiplex coil according to any one of claims 1 to 4, wherein the flat insulated electric wire is a self-bonding electric wire and is fixed.   6. The method according to claim 1, wherein a single-layer coil in which the flat insulated wires are aligned and wound in the axial direction of the winding core is used as a winding core, and the single-layer coil is repeatedly wound in an aligned flat winding in the axial direction. Multiple coil manufacturing method.   The multi-coil manufacturing method according to any one of claims 1 to 5, wherein two or more flat insulated wires are simultaneously aligned and flatly wound in the axial direction of the core to form two or more single-layer coils simultaneously.   An electromagnetic coil using the multiple coil according to claim 1.   A transformer using the multiple coil according to claim 1.   An armature using the multiple coil according to claim 1.

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