JP2022041690A - Electromagnetic coil - Google Patents

Abstract

To provide an electromagnetic coil which can reduce eddy current, miniaturize a coil end, and dissolve processing process problems of disconnection and wire diameter distortion due to forming of a conducting wire for a coil.SOLUTION: An electromagnetic coil 1 constituted by winding a conductive member so as to surround an air core area 101 has a trapezoidal shape, and comprises: an effective coil part 102; a first coil end part 103; and a second coil end part 104. An upper base part 121 having the trapezoidal shape is arranged on a first surface, and a lower base part 122 is arranged on a second surface different from the first surface. The effective coil part 102 is constituted of a conducting wire 110 for the coil constituted by bundling a plurality of conductive base materials, the first coil end part 103 is constituted of a first end member 130 constituted of an individual conductive material, and the second coil end part 104 is constituted of a second end member 140 constituted of an individual conductive material.SELECTED DRAWING: Figure 2

Description

The present invention relates to an air-core electromagnetic coil.

Electromagnetic coils used in coreless electromechanical devices are known (see, for example, Patent Document 1). FIG. 13 is a diagram shown for explaining the electromagnetic coil 9 described in Patent Document 1. 13 (a) is a perspective view showing the appearance of the electromagnetic coil 9, and FIG. 13 (b) is a plan view of the electromagnetic coil 9.

As shown in FIG. 13, the electromagnetic coil 9 described in Patent Document 1 is wound so that a coil lead wire surrounds an air core region 901. When the entire electromagnetic coil 9 is viewed in a plan view, the electromagnetic coil 9 has a substantially "trapezoidal shape", and includes an upper bottom portion 921, a lower bottom portion 922 facing the upper bottom portion 921, and an upper bottom portion 921 and a lower bottom portion 922. It has a leg portion 923, 924 to be connected and an air core region 901 surrounded by an upper bottom portion 921, a lower bottom portion 922, and a leg portion 923, 924. The legs 923 and 924 are formed so that the angles θ1 and θ2 formed with the lower bottom portion 922 are less than 90 degrees.

When a plurality of electromagnetic coils 9 are assembled to form a coil assembly (see FIG. 3 of Patent Document 1), when each electromagnetic coil 9 is viewed along the y direction, the upper bottom portion 921 and the lower bottom portion 922 are electromechanical devices. It is arranged on two circumferences having different distances from the central axis of the above << see FIG. 13 (a) >>. The legs 923 and 924 are provided with steps 923a and 924a for connecting the upper bottom portion 921 and the lower bottom portion 922 arranged on different circumferences.

Since the electromagnetic coil 9 described in Patent Document 1 has a trapezoidal shape as described above and the upper bottom portion 921 and the lower bottom portion 922 are arranged on two different circumferences, a plurality of electromagnetic coils 9 are provided. When they are overlapped with each other (see also FIGS. 4A to 4C of Patent Document 1), the upper bottom portion 921 and the lower bottom portion 922 of the adjacent electromagnetic coils 9 can be combined without interfering with each other in the radial direction of the electromechanical device. The coil assembly can be easily formed.

International Publication No. 2018/139246

On the other hand, looking at the electromagnetic coil 9 from another viewpoint, the electromagnetic coil 9 has an effective coil portion 902, a first coil end portion 903 located on one side in the longitudinal direction of the effective coil portion 902, and the longitudinal length of the effective coil portion. It has a second coil end portion 904 located on the other side of the direction. A circuit connection terminal 905 is provided at the second coil end portion 904.

The electromagnetic coil 9 (conventional electromagnetic coil) described in Patent Document 1 is formed by using a braided wire or the like formed by bundling a plurality of conductive base materials as a coil lead wire and bending the coil lead wire. be. Therefore, the winding direction changing portion 934, 944 at the coil end portion has to have a curved shape having a large radius of curvature. Although the coil end portion is a portion that does not directly contribute to the energy conversion between the electrical energy and the mechanical energy, the lengths L903 and L904 occupied by the coil end portion are relatively large due to the above circumstances. It had to be big. When the lengths L903 and L904 occupied by the coil end portion increase, the resistance value of the electromagnetic coil 9 as a whole also increases, and as a result, the starting torque of the electromechanical device is greatly attenuated.

In addition, since the conventional electromagnetic coil is formed by bending a coil lead wire formed by bundling a plurality of conductive substrates, the winding direction changing portion 934,944, which is a bent portion in the processing process, is formed. The problem of wire breakage and wire diameter distortion is likely to occur (problem in the processing process of wire breakage and wire diameter distortion). Further, in the bent portion, variation (difference) in the elongation of the material is likely to occur between the conductive substrate located inside and the conductive substrate located outside, and the problem of impedance distortion due to this elongation variation also arises. easy. These problems are not limited to braided wires, but can also occur when, for example, litz wires are used.

On the other hand, it is desired from the market to suppress the mechanical resistance of the electromechanical device to suppress the mechanical vibration. From this point of view, it is also strongly expected to reduce the eddy current in the effective coil portion generated by the movement of the magnet of the electromechanical device.

Therefore, the present invention has been made in view of the above circumstances, and it is possible to make the coil end portion smaller than before while reducing the generation of eddy currents, and the wire is broken or broken due to the forming of the coil lead wire. It is an object of the present invention to provide an electromagnetic coil capable of solving a processing process problem of diameter distortion.

According to one aspect of the present invention, there is provided an electromagnetic coil in which a conductive member is wound so as to surround an air core region and is arranged along a moving direction of a magnet of an electromechanical device. When the entire electromagnetic coil is viewed in a plan view, the electromagnetic coil has a lower bottom portion facing the upper bottom portion and the upper bottom portion, and a leg portion connecting the upper bottom portion and the lower bottom portion, and the leg portion and the lower bottom portion. It is formed so that the angle between them is less than 90 degrees. Further, the upper bottom portion, the lower bottom portion and the leg portion are arranged so as to surround the air core region. The upper bottom portion is arranged on a predetermined first surface, and the lower bottom portion is arranged on a second surface different from the first surface. The upper bottom portion and the lower bottom portion include an effective coil portion.
Further, this electromagnetic coil includes an effective coil portion, a first coil end portion located on one side in the longitudinal direction of the effective coil portion, and a second coil end portion located on the other side in the longitudinal direction of the effective coil portion. Has. The effective coil portion is composed of a coil lead wire formed by bundling a plurality of conductive substrates. The first coil end portion is composed of a first end member made of a solid conductive material. The first end member is connected to one end side of each of the one coil lead wire and the other coil lead wire constituting the effective coil portion, and is electrically connected between the one coil lead wire and the other coil lead wire. Is connected. The second coil end portion is composed of a second end member made of a solid conductive material. The second end member is connected to the other end side of the coil lead wire constituting the effective coil portion.

According to the coil of the present invention, the generation of eddy current can be reduced, the coil end portion can be made smaller than before, and the problem of the processing process of disconnection and wire diameter distortion due to forming of the coil lead wire can be solved. It becomes an electromagnetic coil that can be made.

It is a perspective view which shows for demonstrating the coil assembly 100 which was configured by combining the electromagnetic coil 1 which concerns on Embodiment 1 and a plurality of said electromagnetic coils 1. It is a figure which shows for demonstrating the electromagnetic coil 1 which concerns on Embodiment 1. FIG. It is a figure which shows for demonstrating the 1st end member 130. It is a figure which shows for demonstrating the 2nd end member 140. It is a flowchart which shows for demonstrating the manufacturing method of the electromagnetic coil 1 and the manufacturing method of a coil assembly 100 which concerns on Embodiment 1. It is a figure which shows for demonstrating the preparation of the coil lead wire 110 (braided wire 20). It is a figure which shows for demonstrating the manufacturing process (a part) of the electromagnetic coil 1 which concerns on Embodiment 1. FIG. It is a schematic diagram which shows the experimental structure in an experimental example. It is a table which shows the experimental result in the experimental example. It is a figure which shows for demonstrating the electromagnetic coil 2 which concerns on Embodiment 2. It is a figure which shows for demonstrating the state of the electromagnetic coil 2'in the insulating layer forming process S180 of Embodiment 2. It is a figure which shows for demonstrating the manufacturing process (a part) of the electromagnetic coil 3 which concerns on Embodiment 3. It is a figure which shows for demonstrating the electromagnetic coil 9 described in the patent document 1. FIG.

Hereinafter, embodiments of the electromagnetic coil according to the present invention will be described with reference to the drawings. Each drawing is a schematic diagram showing an example and does not necessarily accurately reflect actual dimensions, ratios, etc.

[Embodiment 1]
1. 1. Configuration of electromagnetic coil 1 according to embodiment 1
(1) Outline of Electromagnetic Coil 1 and Coil Assembly 100 The electromagnetic coil 1 according to the first embodiment is an air-core electromagnetic coil arranged along the moving direction of a magnet of an electromechanical device.
The electromechanical device to which the electromagnetic coil 1 is applied may be any electromechanical device that uses an air-core coil. Coreless motors are one of the preferred applications.
FIG. 1A is an example of a coil assembly 100 of a centralized winding type electromagnetic coil used in a coreless motor. As shown in the figure, the coil assembly 100 has a plurality of electromagnetic coils 1 (subscript alphabet means Index) so as to be in contact with each other along the moving direction ROT of the permanent magnets (not shown) of the rotor. They are arranged in a row. As described above, the electromagnetic coil 1 can be suitably applied to a so-called coreless motor.

In the figure, the direction parallel to the rotation axis AX1 of the coreless motor is defined as "y direction", the direction perpendicular to the rotation axis AX1 is defined as "x direction", and the direction perpendicular to the x direction and y direction is defined as "z direction". And. Further, the direction perpendicular to the rotation axis AX1 with the rotation axis AX1 as the starting point is defined as the "diametrical direction", and the direction orthogonal to the radial direction and parallel to the rotation axis AX1 is defined as the "circumferential direction". In the following description, the same definition as the definition of the directional relationship is used for the electromagnetic coil 1 arranged according to the definitions of these directions.
FIG. 1 (b) will be described later.

FIG. 1C is a perspective view showing the appearance of the electromagnetic coil 1. FIG. 2 is a diagram for explaining the electromagnetic coil 1 according to the first embodiment. In FIG. 2A, the center view shows a plan view of the electromagnetic coil 1, the lower figure shows a front view, and the upper figure shows a rear view.

As shown in FIGS. 1 (c) and 2 (a), the electromagnetic coil 1 is wound so that a conductive member (details will be described later) surrounds the air core region 101. The "winding" here includes the case of winding so as to completely surround the air core region 101 over 360 degrees, and does not reach one round around the air core region 101 (at 360 degrees). It also includes a winding method that surrounds the air core region 101.
For reference, the electromagnetic coil 1 shown in the first embodiment can be traced counterclockwise from the circuit connection terminal 105 of the second coil end portion 104 (described later) on the right side in FIG. 1 (c) to show the effective coil portion 102. (Described later), the first coil end portion 103 (described later), and the effective coil portion 102 are formed in this order to reach the circuit connection terminal 105 of the second coil end portion 104 on the left side of the drawing, and the circumference of the air core region 101 is approximately 0. It is configured to "wind" around .75 laps.

(2) Trapezoidal shape When the entire electromagnetic coil 1 is viewed in a plan view << see the central figure of FIG. 2A >>, the electromagnetic coil 1 has a substantially "trapezoidal shape", and has an upper bottom portion 121 and an upper portion. It has a lower bottom portion 122 facing the bottom portion 121 and a leg portion 123 connecting the upper bottom portion 121 and the lower bottom portion 122, and an angle formed between the leg portion 123 and the lower bottom portion 122 << in FIG. 2A. θ1 >> is formed so as to be less than 90 degrees. Further, when viewed in a plan view, the upper bottom portion 121, the lower bottom portion 122, and the leg portion 123 are arranged so as to surround the air core region 101.

The upper bottom portion 121, the lower bottom portion 122, and the leg portion 123 all have a linear shape. The length of the upper bottom 121 is shorter than the length of the lower bottom 122. The upper bottom portion 121 and the lower bottom portion 122 are two parallel coil portions extending in a direction parallel to the rotation axis AX1 (y direction) when the electromagnetic coil 1 is assembled as a coil assembly, and are effective coil portions 102 (described later). ) Is included. The leg portion 123 extends in a direction inclined obliquely from the upper bottom portion 121 and the lower bottom portion 122.
The "trapezoidal shape" here is not limited to the one in which the legs 223 and 224 are provided on the two sides, respectively, as in the electromagnetic coil 2 according to the second embodiment (see FIG. 10, details will be described later). Unlike the electromagnetic coil 1 according to the first embodiment, the leg portion as an entity is provided only on one side (leg portion 123), and the leg portion as an entity is not provided on the other side and is open. The shape is also included in the concept of "trapezoidal shape". Further, the "trapezoidal shape" is not limited to a strict trapezoidal shape, and the connecting portion between the upper bottom portion and the lower bottom portion and the leg portion has a curved shape with a certain radius of curvature, or a protruding portion (for example, the figure). It may have a shape having the second end member 240 ₁ of the second embodiment shown in 10 (a).

(3) Positional relationship between upper bottom portion 121 and lower bottom portion 122 When a plurality of electromagnetic coils 1 are assembled to form a coil assembly (hereinafter referred to as "when the coil assembly is assembled"), each electromagnetic coil 1 is y. When viewed along the direction, the upper bottom portion 121 and the lower bottom portion 122 are arranged on two circumferences having different distances from the rotation axis AX1 of the electromechanical device << see the front view below FIG. 2A). 》. In other words, the upper bottom portion 121 is arranged on a predetermined first surface (side surface of a virtual first cylinder centered on the rotation axis AX1), and the lower bottom portion 122 is a second surface different from the first surface (a second surface (side surface of a virtual first cylinder centered on the rotation axis AX1). It is arranged on the side surface of a virtual second cylinder centered on the rotation axis AX1). In the first embodiment, the upper bottom portion 121 is arranged at a position farther from the rotation axis AX1 than the lower bottom portion 122. That is, the first surface has a positional relationship outside the second surface (far from the rotation axis AX1).
The connection positions of the upper bottom portion 121 and the lower bottom portion 122 with the leg portions 123 are arranged on the first surface where the upper bottom portion 121 is present at the end portion of the upper bottom portion 121, and the lower bottom portion is located at the end portion of the lower bottom portion 122. It is placed on the second surface that exists.

In the leg portion 123, a step 123d is provided to connect the upper bottom portion 121 and the lower bottom portion 122 arranged on different circumferences to each other. In the first embodiment, the step 123d of the leg portion 123 connects the first surface and the second surface at a position closer to the lower bottom portion 122 than the upper bottom portion 121. As a whole, the leg portion 123 has a shape bent in a substantially Z shape so as to connect the upper bottom portion 121 and the lower bottom portion 122.

(4) Combination of a plurality of electromagnetic coils 1 FIG. 1B is a diagram showing a state in which a plurality of electromagnetic coils 1a, 1b, and 1c are overlapped with each other. The lower figure in the figure is a plan view when viewed along the −z direction, and the upper figure is a front view when viewed along the y direction.
Here, if the upper bottom portion 121b of the electromagnetic coil 1b is fitted by sliding from the side of the lower bottom portion 122c of the electromagnetic coil 1c adjacent to the side of the upper bottom portion 121b to the side of the upper bottom portion 121c, the electromagnetic wave is fitted. The coil 1b can be superposed on the electromagnetic coil 1c and fitted. Similarly, the electromagnetic coil 1a can be superposed on the electromagnetic coil 1b and fitted to the electromagnetic coil 1b << see FIG. 1B >>. At this time, between the lower surface of the upper bottom portion 121c of the electromagnetic coil 1c and the upper surface of the lower bottom portion 122a of the electromagnetic coil 1a, and between the lower surface of the leg portion 123b of the electromagnetic coil 1b and the upper surface of the lower bottom portion 122a of the electromagnetic coil 1a. Adhesives may be placed in the coils to temporarily fix them to each other.
By performing the fitting operation as described above for, for example, 24 electromagnetic coils 1, the coil assembly 100 as shown in FIG. 1A can be configured. After assembling the coil assembly 100 to the state shown in FIG. 1A, the entire body (excluding the circuit connection terminal 105) may be solidified with a molding agent to fix the outer shape. In this way, it is possible to form a coil assembly 100 in which a plurality of electromagnetic coils 1 are arranged along a moving direction of a magnet (not shown) of an electromechanical device.

At this time, the electromagnetic coil 1 is configured such that the upper bottom portion of each electromagnetic coil is housed in the air core region of another electromagnetic coil adjacent to the upper bottom portion side of the electromagnetic coil. For example, as shown in the lower figure of FIG. 1 (b), the upper bottom portion 121b of the electromagnetic coil 1b is an air core region 101c of another electromagnetic coil 1c adjacent to the upper bottom portion 121b side of the electromagnetic coil 1b. It is configured to be housed in (not shown).

Further, when a plurality of electromagnetic coils are combined, the upper bottom and legs of each electromagnetic coil are the diameters of the upper bottom and legs of other electromagnetic coils adjacent to the lower bottom side of the electromagnetic coil and the electromechanical device. It is configured so that it can be arranged so as to be lined up in the circumferential direction (direction along the moving direction ROT of the magnet) without overlapping in the direction (first direction). For example, as shown in FIG. 1B, the upper bottom portion 121a and the leg portion 123a of the electromagnetic coil 1b are adjacent to the lower bottom portion 122b side of the electromagnetic coil 1b, and the upper bottom portion 121a and the leg portion 123a of the other electromagnetic coil 1a are adjacent to each other. And, it can be arranged so as to line up in the circumferential direction without overlapping in the radial direction.

When the electromagnetic coil 1 is cut along a plane perpendicular to the rotation axis AX1, the outer diameter of the electromagnetic coil 1 has a split ring shape obtained by dividing the annulus into N equal parts, and the split ring shape 2 has a split ring shape. It is preferable that the angle formed by the two sides is 360 ° / N or less. Regarding the structure, action, and effect of this point, the contents of Patent Document 1 previously invented by the inventor of the present application can be incorporated into the present specification. Further, other technical features such as a method for connecting the electromagnetic coil 1 can be appropriately incorporated into the present specification as long as it does not contradict the gist of the present invention.

(5) Effective coil portion 102, first coil end portion 103, and second coil end portion 104
Looking at the electromagnetic coil 1 from a viewpoint different from the viewpoint of "trapezoidal shape", the electromagnetic coil 1 has an effective coil portion 102 and a first coil end portion located on one side LD1 of the longitudinal LD of the effective coil portion 102. It has 103 and a second coil end portion 104 located on the other side LD2 of the longitudinal LD of the effective coil portion 102. A circuit connection terminal 105 is arranged at the second coil end portion 104 << see the central diagram of FIGS. 1 (c) and 2 (a) >>. In the present specification, the first coil end portion 103 and the second coil end portion 104 may be simply referred to as “coil end portions”.

The "effective coil portion" is a portion that effectively performs energy transformation between electrical energy and mechanical energy. Typically, it is a portion where the longitudinal LD is arranged in a positional relationship so as to be orthogonal to the moving direction of the magnet. It can also be said that the "first coil end portion 103" and the "second coil end portion 104" are portions that do not directly contribute to the energy transformation between the electrical energy and the mechanical energy. In each figure, a pattern similar to the braided line is drawn on the surface of the effective coil portion 102, but the braided line is not actually exposed, and the pattern in the figure follows the pattern of the braided line. The pattern of the insulating layer 106 (described later) formed in the above is drawn. The same applies to the display of the effective coil portion 102 in other drawings.

The first coil end portion 103 has a crossover portion 133. The crossover portion 133 is connected so as to pass between the effective coil portions 102 arranged on the left and right when the first coil end portion 103 is viewed from the front along the y direction (FIGS. 2 (a) and FIG. See 3 >>.

The first coil end portion 103 has a winding direction changing portion 134 which is a portion for changing the winding direction of the conductive member. When the electromagnetic coil 1 is viewed in a plan view, the shape of the conductive member changes from the longitudinal LD (direction along the y direction) of the effective coil portion 102 to the longitudinal LD of the effective coil portion in the winding direction changing portion 134. The direction of the conductive member is changed so as to be refracted in a direction having an angle with respect to the other.

(6) Coil lead wire 110
FIG. 2B is a cross-sectional view when the effective coil portion 102 of the electromagnetic coil 1 is cut by the virtual surface PL1 shown in FIG. 1C, and the cut surface is viewed along the arrow A.
As shown in FIG. 2B, the effective coil portion 102 is composed of a coil conducting wire 110 formed by bundling a plurality of conductive base materials 10. The "coil conductor 110 in which a plurality of conductive substrates 10 are bundled" can also be said to be a coil conductor 110 in which a plurality of conductive substrates 10 are twisted or / or woven.

As the "conductive base material 10", the bare conductor wire 11 is adopted here.
The "bare conductor wire 11" refers to a wire in which an insulating material is not coated around the bare conductor wire 11 and the conductor which is a conductive member is exposed. For example, in addition to solid "bare copper wire" made mainly of copper, "carbon wire" using carbon, "plated wire" made of bare copper wire plated with tin or nickel, etc. are "bare". It is included in the conductor wire 11 ”. In the example described here, a tin-plated wire is used as the "bare conductor wire 11".

The thickness of the conductive base material 10 can be appropriately selected according to the specifications of the electromechanical device. The wire used as the conductive base material 10 is a conductive wire containing copper, and the average radius of the conductive base material 10 is preferably 120 μm or less. Further, it is more preferable that the average radius of the conductive base material 10 is 100 μm or less. It is even more preferable that the average radius of the conductive substrate 10 is 50 μm or less. This is because the generation of eddy current can be reduced by adopting the conductive base material 10 having such a diameter << details will be described later in [Experimental Example] >>.

The coil lead wire 110 is a braided wire 20 in which a plurality of bare conductor wires 11 are braided. Specifically, for example, as shown in FIG. 2B, the coil conductor 110 uses a stranded wire 15 in which bare conductor wires 11 are twisted in units of 6 as an intermediate material, and three sets of the stranded wires 15 are knitted. It is made up of braided wires 20. By having the coil lead wire 110 having such a configuration, it is possible to reduce the generation of eddy currents << details will be described later in [Experimental Example] >>.

An insulating layer 106 is provided on at least the surface of the braided wire 20.
The insulating layer 106 may be made of any insulating member.
In the first embodiment, at least the insulating layer in the effective coil portion 102 is the insulating layer 107 in which the water-soluble material permeated around the conductive base material 10 is solidified. The insulating layer 107 is preferably an electrodeposition insulating coating film formed around the conductive base material 10. In other words, the insulating layer 107 here is an "electrodeposited insulating coating film" obtained by electrodeposition coating on the conductive base material 10. The electrodeposition insulating coating film as the insulating layer 107 coats the conductive base material 10, is made of an insulating material, and has an insulating function.

On the other hand, even if the insulating layer 106 in the effective coil portion 102 is an insulating coating film formed around the conductive base material 10, this is also preferable. This is because the insulating layer 106 can be constructed at a relatively low cost, and the electromagnetic coil 1 which is economically advantageous can be obtained. In addition, the insulating layer 106 here is, in other words, an “insulating coating film (excluding the electrodeposition insulating coating film)” obtained by applying an insulating coating material to the conductive base material 10. The insulating coating film as the insulating layer 106 coats the conductive base material 10, is made of an insulating material, and has an insulating function.

The coil lead wire 110 includes the braided wire 20 and the insulating layer 106 described above.

(7) First end member 130
FIG. 3 is a view (perspective view) shown for explaining the first end member 130.
The first coil end portion 103 is composed of a first end member 130 made of a solid conductive material (see FIG. 3).
The "solid conductive material" is one of the variations of the "conductive member", and refers to a conductive member that is not a bundle of wires (wires) but a single individual. For example, it may be made of a metal containing copper and cast or forged into a predetermined shape. A copper plate (rolled metal containing copper) may be pressed into a predetermined shape.

The first end member 130 is provided with an opening 131 so that, for example, one end side 111 of the coil conductors 110 ₁ and 110 ₂ can be received and fitted (see also FIG. 7).

The first end member 130 includes one coil lead wire 110 that constitutes the effective coil portion 102 << for example, the coil lead wire 110 ₁ on the right side of the plan view in the center of FIG. 2A >> and another coil lead wire 110 ( It is "connected" to one end side (LD1 side) of each coil lead wire 110 ₂ ) on the left side, and electrically connects between one coil lead wire 110 ₁ and another coil lead wire 110 ₂ . The "connection" here includes not only the case of being directly connected as in the first embodiment but also the case of being indirectly connected via the spacer 40 or the like as in the second embodiment (the case of being indirectly connected via the spacer 40 or the like). The second embodiment will be described later).

When the first end member 130 is incorporated as a part of the electromagnetic coil 1, it has the following structure. That is, assuming that the solid conductive material is made of metal, the first end member 130 is caulked and fixed to one end side of the coil conducting wire 110. Specifically, with the one end side 111 of the coil lead wire 110 fitted into the opening 131 of the first end member 130, the inner wall of the opening 131 of the first end member 130 is the coil lead wire 110. The first end member 130 is firmly fixed to the coil lead wire 110 by "caulking" the one end side 111 << see FIGS. 2 (a), 3 and 7 (b) described later >>. ..

The insertion allowance (margin) of the coil lead wire 110 into the opening 131 of the first end member 130 is the connecting portion 132 of the coil lead wire 110. Such a connecting portion 132 can also be referred to as an overlapping portion 132. In the assembled electromagnetic coil 1, the first end member 130 and the coil lead wire 110 are closely connected by the overlap portion 132 and electrically connected.

The first end member 130 has a winding direction changing portion 134. In the winding direction changing portion 134, the conductive member (solid conductive material) is not a curved shape having a large radius of curvature, but a shape bent so as to have a certain angle. In the first embodiment, in the first coil end portion 103, the direction is changed between the upper bottom portion 121 and the leg portion 123. FIG. 2 (a) The right winding direction changing portion 134, the leg portion 123, and the lower bottom portion 122. There are two winding direction changing portions 134 with the winding direction changing portion 134 on the left side of the figure which changes the direction between the two. In the winding direction changing portion 134 on the left side of the figure, the angle θ1 formed between the leg portion 123 and the lower bottom portion 122 is less than 90.

The first end member 130 has a crossover portion 133. Further, the first end member 130 has an obliquely formed side surface (see the figure below FIG. 2A).

(8) Second end member 140
FIG. 4 is a diagram shown for explaining the second end member 140. FIG. 4A shows a perspective view of the second end member 140, and FIG. 4B shows a plan view of the second end member 140.
As shown in FIG. 4, the second coil end portion 104 is composed of a second end member 140 made of a solid conductive material.

The second end member 140 has an opening 141 so that it can receive and fit the other end side (LD2 side) of the coil conductors 110 ₁ and 110 ₂ << see the plan view in the center of FIG. 2A >>. Is provided. Further, the circuit connection terminal 105 is arranged on the second end member 140.

The second end member 140 is "connected" to the other end of the coil conductors 110 ₁ and 110 ₂ constituting the effective coil portion 102 << see FIG. 2A >>. The "connection" here includes not only the case of being directly connected as in the first embodiment but also the case of being indirectly connected via the spacer 40 or the like as in the second embodiment (the case of being indirectly connected via the spacer 40 or the like). The second embodiment will be described later).

When the second end member 140 is incorporated as a part of the electromagnetic coil 1, it has the following structure. That is, assuming that the solid conductive material described above is made of metal, the second end member 140 is caulked and fixed to the other end side of the coil lead wire 110. Specifically, in a state where the other end side 112 of the coil lead wire 110 is fitted into the opening 141 of the second end member 140, the inner wall of the opening 141 of the second end member 140 is the coil lead wire 110. The second end member 140 is firmly fixed to the coil lead wire 110 by "caulking" the other end side 112 of the coil (see also FIG. 7B described later).

The insertion allowance (margin) of the coil lead wire 110 into the opening 141 of the second end member 140 is the connecting portion 142 of the coil lead wire 110. Such a connecting portion 142 can also be referred to as an overlapping portion 142. In the assembled electromagnetic coil 1, the second end member 140 and the coil lead wire 110 are closely connected by the overlap portion 142 and electrically connected.

One end side of the coil lead wire 110 is caulked and fixed by the overlap portion 132 of the first end member 130, and the other end side of the coil lead wire 110 is crimped and fixed by the overlap portion 142 of the second end member 140. However, for reference, the portion of the coil lead wire 110 other than the overlap portions 132 and 142 constitutes the effective coil portion 102. Further, the portion of the first end member 130 constitutes the first coil end portion 103, and the portion of the second end member 140 (excluding the portion of the circuit connection terminal 105) constitutes the second coil end portion 104. << Refer to the plan view in the center of FIG. 2A >>.

(9) Insulation layer 106
In the electromagnetic coil 1, the insulating layer 106 is provided on at least the surface of the entire area other than the circuit connection terminal 105. Specifically, the "whole area" here means the entire area of the first end member 130 of the electromagnetic coil 1, the coil lead wire 110, and the second end member 140 (excluding the portion of the circuit connection terminal 105). It can also be called the surface.
The insulating layer in the first end member 130 and the second end member 140 can have the same configuration as the insulating layer 106 provided in the coil conducting wire 110 (braided wire 20) described above. However, it does not prevent the insulating layer having a structure different from that of the insulating layer 106 provided on the coil conducting wire 110 (braided wire 20).

2. 2. 5 is a flowchart showing a method for manufacturing the electromagnetic coil 1 according to the first embodiment and a method for manufacturing the coil assembly 100 according to the first embodiment.
As shown in FIG. 5, the method for manufacturing the electromagnetic coil 1 according to the first embodiment roughly describes the first end member setup step S110, the second end member setup step S120, and the coil lead wire setup step S130. The first end member insertion step S140 and the first end member connecting step S150, and the second end member inserting step S160 and the second end member connecting step S170 are referred to as a "middle step", and the insulating layer forming step S180 is referred to as a "step". It is a "post-process". All of these will be collectively referred to as "electromagnetic coil forming work S100".

Hereinafter, the description will be continued on the assumption that the electromagnetic coil 1 is composed of a braided wire 20 and a “coil conducting wire 110 in which a plurality of conductive substrates are bundled”.

(1) First end member setup process S110
The first end member setup step S110 is a step of performing the pre-setup of the middle step by preparing the first end member 130 as shown in FIG. 3 (first end member preparation step S112) and the like.

(2) Second end member setup process S120
The second end member setup step S120 is a step of performing the pre-setup of the middle step by preparing the second end member 140 as shown in FIG. 4 (second end member preparation step S122) and the like.
In this step, the circuit connection terminal 105 may be masked in advance (terminal portion masking step S124). Specifically, the circuit connection terminal 105 is coated with a permeable insulating coating material such as polyesterimide, polyamideimide, polyimide, enamel, urethane, and varnish to perform masking in advance. As a result, measures are taken to prevent the insulating material from adhering in the insulating layer forming step S180 described later.

(3) Coil conductor setup process S130
The coil lead wire setup step S130 is a step of preparing the coil lead wire 110 and setting up the coil lead wire 110 for a subsequent step (insertion, fitting, and connection to the first end member). The coil lead wire setup step S130 includes a braided wire preparation step S132 and a braided wire forming step S134.

(3-1) Braided line preparation step S132
The braided wire preparation step S132 is a step of creating and preparing the braided wire 20 as the coil lead wire 110.
FIG. 6 is a diagram for explaining the preparation of the coil lead wire 110 (braided wire 20). FIG. 6A is a cross-sectional view when the stranded wire 15 and the braided wire 20 are cut along a plane perpendicular to the longitudinal direction.
In the braided wire preparation step S132, first, a stranded wire 15 is created by twisting a bare conductor wire 11 (here, a tin-plated wire is assumed) as a conductive base material 10 in units of 6, and this is used as an intermediate material. << See FIGS. 6 (a) and 6 (i) >>. Next, three sets of the twisted wires 15 are gathered together and knitted with each other to form a braided wire 20 << see FIGS. 6A and 6 (ii) >>. At this stage, lightly forming may be performed by pressing the periphery of the braided wire 20 from the outside as a whole. The braided wire 20 thus produced is a substantially plate-shaped coil lead wire 110 having a predetermined thickness as shown in the perspective view of FIG. 6B.
In the electromagnetic coil 1 of the first embodiment, two coil conductors 110 are used for the effective coil portion 102, but it is preferable that the two coil conductors 110 have the same specifications. By doing so, the required number of braided wires 20 can be collectively created in batch processing in the braided wire preparation step S132.

(3-2) Braided wire forming step S134
FIG. 7 is a diagram for explaining a manufacturing process (part) of the electromagnetic coil 1 according to the first embodiment. FIG. 7A is a perspective view for explaining the braided wire forming step S134.

In the braided wire forming step S134, first, the braided wire 20 is cut to adjust the length to a predetermined length (see the figure on the left side of FIG. 7A). Next, at one end side 111 and the other end side 112, which are both ends of the braided wire 20, the periphery is crushed from the outside over a predetermined length (the length corresponding to the overlap portions 132, 142 described above). Decrease the outer diameter dimension of both ends of the braided wire 20 << see the figure on the right side of FIG. 7A >>. As a result, both ends of the braided wire 20 can be inserted into the opening 131 of the first end member 130 and the opening 141 of the second end member 140.

(4) First end member insertion step S140
FIG. 7B is a perspective view for explaining the first end member insertion step S140 and the second end member insertion step S160.
In the first end member insertion step S140, one end side 111 of the coil lead wire 110 (braided wire 20) crushed in the braided wire forming step S134 to reduce the external dimensions is inserted from the opening 131 of the first end member 130. This is a step of inserting and fitting to the overlap portion 132 << see FIG. 7 (b) >>.

(5) First end member connecting step S150
FIG. 7C is a perspective view for explaining the first end member connecting step S150 and the second end member connecting step S170.
The first end member connecting step S150 is a step of firmly connecting the first end member 130 fitted in the first end member inserting step S140 and the coil lead wire 110 << see FIG. 7C >>.
The connection between the first end member 130 and the coil lead wire 110 may be performed by caulking and fixing. For caulking fixing, for example, the first end member 130 is fixed to a predetermined portion << see the caulked portion 137 in FIG. 7C >> located in the overlapping portion 132 of the first end member 130 by using a crimping tool or the like. Pressure is applied from the outside to plastically deform the overlapping portion 132 of the first end member 130. Then, the inner wall of the opening 131 of the first end member 130 strongly presses the outer circumference of the coil lead wire 110. As a result, the first end member 130 is electrically connected while being firmly fixed so as to be in close contact with the one end side 111 of the coil lead wire 110.
After the caulking fixing is performed, a treatment for joining and fixing between the first end member 130 and the coil conducting wire 110 may be further performed by using a conductive material such as solder.

(6) Second end member insertion step S160 and second end member connection step S170
In the second end member insertion step S160, the other end side 112 of the coil lead wire 110 whose external dimensions have been reduced by crushing in the braided wire forming step S134 is inserted from the opening 141 of the second end member 140 and overlaps. FIG. 7 (b), which is a process of fitting to the portion 142.
The second end member connecting step S170 is a step of firmly connecting the second end member 140 fitted in the second end member inserting step S160 and the coil lead wire 110 << see FIG. 7C >>. Similar to the first end member connecting step S150, the second end member 140 may be connected by caulking and fixing to the caulking portion 147 located in the overlapping portion 142 of the second end member 140 by using a crimping tool or the like.
The second end member insertion step S160 and the second end member connection step S170 can be carried out with basically the same contents as the first end member insertion step S140 and the first end member connection step S150 described above.

(7) Insulation layer forming step S180
The insulating layer forming step S180 is a step of providing the insulating layer 106 on at least the surface of a region (site) other than the circuit connection terminal 105.

Although not shown, the insulating layer forming step S180 includes a permeation step of infiltrating a water-soluble material using an insulating solute into at least the coil lead wire 110, and a solidification step of solidifying the permeated water-soluble material. And, it is preferable to carry out in this order. In this case, it is preferable to use a water-soluble material having an insulating property and an adhesive property.
In the permeation step, the water-soluble material may also be attached to the surfaces of the first end member 130 and the second end member 140 (excluding the masked portion).

The insulating layer forming step S180 may be carried out as follows, for example. That is, after filling the inside of the liquid tank, the container, etc. (hereinafter, simply referred to as the liquid tank) with the solution of the thermosetting resin, the first end member connecting step S150 and the second end member connecting are inside the liquid tank. The electromagnetic coil carried out in step S170 (assembled) is put in. Then, the water-soluble material permeates (penetrates) between the plurality of conductive base materials 10 constituting the coil lead wire 110. At this time, the water-soluble material also adheres to the surfaces of the first end member 130 and the second end member 140 (excluding the masked portion). With the water-soluble material attached to the periphery of the conductive base material 10 and the like in this way, the coil lead wire 110, the first end member 130, and the second end member 140 (object to be coated) are pulled up from the liquid tank. Then, by heating the object to be coated to which the water-soluble material is attached, the material derived from the water-soluble material adhered to the periphery of the object to be coated is solidified.

Further, it is more preferable to permeate and solidify the water-soluble material by so-called electrodeposition insulating coating.
For example, the liquid tank is filled with an aqueous solution containing a water-soluble material, and the object to be coated is put into the inside of the bathtub so that the object to be coated is completely submerged in the aqueous solution. By doing so, the water-soluble material permeates (penetrates) between the plurality of conductive base materials 10 constituting the coil lead wire 110 among the objects to be coated. In this state, a DC voltage for controlling the film thickness of the insulating film is applied between the object to be coated and the electrode, and the circumference of the coil lead wire 110 (microscopically speaking, the conductive base material 10) or the first. An electrodeposition insulating coating film derived from a water-soluble material is deposited on the surfaces of the end member 130 and the second end member 140 (excluding the masked portion). As a result, an insulating layer 106 made of an electrodeposition insulating coating film can be formed around the conductive base material 10 and on the surfaces of the first end member 130 and the second end member 140 (excluding the masked portion).
When applying a DC voltage, ultrasonic waves may be applied to the aqueous solution in the liquid tank. By applying ultrasonic waves, air bubbles and impurities can be removed from the periphery of the object to be coated, and the insulation quality can be improved.

The formation of the insulating layer 106 is not limited to the electrodeposition insulating coating described above. For example, although not shown, an insulating material is applied to the periphery of the conductive base material 10 of the coil lead wire 110 and the surfaces of the first end member 130 and the second end member 140 (excluding the masked portion) to insulate. A method of forming a coating film and using the insulating coating film as an insulating layer 106 may be adopted. In the method of forming the insulating coating film by coating as described above, the insulating layer 106 can be formed at a lower cost than in the case of electrodeposition insulating coating, and an economically advantageous coil can be obtained.

By carrying out the steps described above, the electromagnetic coil 1 according to the first embodiment can be obtained.

For reference, after obtaining the electromagnetic coil 1, the superposition work S300 << the work of superimposing a plurality of electromagnetic coils 1 as shown in FIG. 1B >> and the coil assembly forming work S500 can be performed. (For details, refer to the chapter "1. Configuration of the electromagnetic coil 1 according to the first embodiment" above). Further, after the coil assembly is assembled by the coil assembly forming work S500, the masking applied to the circuit connection terminal 105 can be selectively removed by heating, for example, in a soldering furnace. (Terminal mask removal work S600).

3. 3. Experimental Example The inventor conducted an experiment on the generation of eddy current due to the movement of a magnet in an electromechanical device, and obtained new knowledge about a coil that suppresses the generation of eddy current, which will be described below.

(1) Experimental configuration FIG. 8 is a schematic diagram showing an experimental configuration in an experimental example.
In order to schematically reproduce the movement of the magnet of the electromechanical device, a pendulum-shaped experimental jig was configured as shown in FIG. Specifically, permanent magnets MGa and MGb are arranged on one end side 710b of the rod 710 via a fixing member 720 (reference numeral 730 indicates a pair of permanent magnets MGa and MGb), and the other end side 710a of the rod 710 is attached. It was fixed to the rotating shaft AX2. The other end side 710a of the rod 710 was connected to the bearing shaft so as to rotate under a low coefficient of friction.
Then, a sample (denoted as Sample in the figure) is arranged immediately below the rotation shaft AX2. The sample is fixed to the upper surface of the sample fixing table 740 made of a non-magnetic material, and a gap G is set between the level of the upper surface of the sample and the permanent magnet pair 730 arranged at the tip of the pendulum. The sample and the permanent magnet pair 730 were prevented from spatially contacting each other.

(2) Sample / Experimental method (2-1) Sample The sample is basically assumed to be an electromagnetic coil, but specifically, "Conductive member (for example, conductive base material 10, for coil)". Various candidates for the materials of the conductor 110, the first end member 130, and the second end member 140) were assumed, and these samples were submitted to the experiment. More specifically, various materials as shown in the second column of the table shown in FIG. 9 (described later) were shaped into a rectangular shape of 30 mm × 10 mm in a plan view, and each was prepared as a sample.

(2-2) Experimental method First, the sample corresponding to the experimental number is placed on the sample fixing table 740. At that time, the position of the sample fixing table 740 shall be adjusted so that the gap G is about 1 mm regardless of the experimental number.
Then, the permanent magnet pair 730 is lifted to the state drawn by the solid line in FIG. 8 so that the height of the center of the permanent magnet pair 730 matches the height of the rotation axis AX2 (that is, the rod 710 is horizontal). ..
Then release the pendulum.
Then, the permanent magnet pair 730 starts to move in the direction of the arrow C0 in FIG. 8, and vibrates in a reciprocating manner so as to move alternately in the direction of the arrow C1 and the direction of the arrow C2 directly above the sample. Such vibration is attenuated due to the resistance between the pendulum and the air, and the loss due to the generation of eddy current mainly caused by the permanent magnet pair 730 passing in the vicinity of the sample, and eventually stops. Experimental data shall be obtained by observing this reciprocating vibration. The observation contents are the number of times the pendulum reciprocates (the number of times the pendulum stops, hereinafter simply referred to as the number of reciprocations) and the time of vibration (the time required until the pendulum stops, hereinafter simply referred to as the vibration time). Under the assumption that the larger the number of round trips and / or the vibration time, the smaller the loss due to the generation of eddy currents, it is determined that the larger the number of round trips and / or the vibration time, the smaller the generation of eddy currents. It was decided to. Although the samples of Experiment Nos. 6 and 7 are not conductor wires, they were also observed for comparison. Experiments Nos. 1 to 7 were carried out by the above experimental methods.

(3) Experimental results FIG. 9 is a table showing the experimental results in the experimental examples.
As shown in FIG. 9, for Experiment Nos. 2, 4 and 5 in which the average radius of the conductive substrate (conductor portion) is 100 μm or less, the number of round trips and the vibration time are relatively large, and eddy currents are generated. small. Further, when the average radius of the conductive base material (conductor portion) is 50 μm or less, the generation of eddy current becomes smaller. Further, for Experiment Nos. 4 and 5, which are braided wires in which a plurality of bare conductor wires are braided, the number of round trips and the vibration time are relatively large, and the generation of eddy current is small. Further, the magnet wire of Experiment No. 2 (a conductive portion having an insulating film applied in advance as a conductive base material) also has a relatively large number of round trips and a vibration time, and generates a small amount of eddy current. Further, also in the plated copper wire of Experiment No. 3, the number of round trips and the vibration time are relatively large, and the generation of eddy current is small.

(4) Consideration (4-1) From the above experimental results, it is preferable that the average radius of the conductive base material 10 is 120 μm or less, and further 100 μm or less, in constructing the electromagnetic coil 1 according to the first embodiment. It has been clarified that the presence is more preferable, and further, it is more preferable to be 50 μm or less (Experiment Nos. 2, 4, 5).
(4-2) In configuring the electromagnetic coil 1 according to the first embodiment, the coil conducting wire 110 is a braided wire 20 in which a plurality of bare conductor wires 11 are braided under the condition of (1) above. Was found to be more preferable (Experiment Nos. 4 and 5).
(4-3) In constructing the electromagnetic coil 1 according to the first embodiment, under the condition of (1) above, the coil lead wire 110 is a "magnet wire" in which an insulating film is previously applied to the conductive base material 10. It became clear that it was more preferable to be used (Experiment No. 2).
(4-4) It has also been clarified that the conductive base material 10 is suitable even if it is a nickel-plated wire in which a copper wire is nickel-plated or a tin-plated wire in which a copper wire is tin-plated (4-4). Experiment number 3).
Based on the above, the generation of eddy currents is reduced by adopting the conductive base material 10 and the coil lead wire 110 that satisfy any one of the above (4-1) to (4-4) or a combination thereof. It was confirmed by experiment that it can be done.

4. Effect of the electromagnetic coil 1 according to the first embodiment (1) Since the effective coil portion 102 of the electromagnetic coil 1 is composed of a coil lead wire 110 in which a plurality of conductive base materials 10 are bundled, an eddy current is generated. Can be reduced. As described in the chapter of [Experimental Example], in the "effective coil portion 102" which is easily affected by the movement of the magnet, for example, instead of using a solid conductive material made of metal (for example, a copper plate), a plurality of conductive materials are used. This is because the generation of eddy currents can be expected to be reduced by adopting a coil lead wire in which a sex substrate is bundled.

Further, since the first coil end portion 103 and the second coil end portion 104 are composed of the first end member 130 and the second end member 140 made of a solid conductive material instead of a member using a wire rod, the conventional electromagnetic wave is used. It is possible to wind around the air core region 101 while changing the direction from the longitudinal LD of the effective coil portion 102 to an acute angle without providing a curved portion such as a coil, and as a result, the coil end portion can be wound more than before. It can be made smaller.
Further, since the first end member 130 and the second end member 140 are made of a solid conductive material, that is, they are not twisted / woven, there is no problem in the processing process of wire breakage and wire diameter distortion.
Therefore, the electromagnetic coil 1 according to the first embodiment can reduce the generation of eddy current, make the coil end portion smaller than the conventional one, and process the wire breakage and wire diameter distortion due to the forming of the coil lead wire. It is an electromagnetic coil that can solve process problems.
In other words, in the electromagnetic coil 1 according to the first embodiment, for example, a braided wire 20 is adopted in the effective coil portion (region that effectively receives the influence of the movement of the magnet), and a magnet that can reduce the eddy current is arranged. A solid conductive material is placed at the coil end, which is not significantly affected by the movement of the magnet, to reduce the length and volume occupied by the coil end, and to solve the processing process problems of wire breakage and wire diameter distortion. ing.

(2) When the electromagnetic coil 1 according to the first embodiment has a smaller coil end portion than the conventional one and the path on the electric circuit is shortened by that amount, the resistance can be reduced by that amount. If the exciting voltage is the same, the current flowing through the electromagnetic coil can be made larger than before, and the torque can be further increased than before. From another point of view, if the same torque is obtained, the electromagnetic coil 1 can be made more compact than the conventional one (space efficiency can be improved).

(3) Since the first end member 130 and the second end member 140 are made of a solid conductive material, an appropriate outer shape can be formed. Therefore, when constructing a coil assembly 100 by combining electromagnetic coils having different shapes, an electromagnetic coil having a complicated three-dimensional shape such as a winding direction changing portion 134, a step 123d, etc., whose contour changes sharply. Even in the case of constructing using the above, according to the first embodiment, such an electromagnetic coil can be constructed relatively easily.

(4) The first end member 130 is caulked and fixed to one end side of the coil lead wire 110, and the second end member 140 is caulked and fixed to the other end side of the coil lead wire 110. Therefore, unlike welding, it does not require a heat source and can be easily connected, resulting in an electromagnetic coil 1 having excellent productivity.
Further, although not introduced as an embodiment of the present invention, for example, between the first end member 130 and the coil lead wire 110 and between the second end member 140 and the coil lead wire 110 are connected and fixed by "welding". In this case, an oxide film is formed on the welded portion, so that when a large current is passed through the electromagnetic coil, the Joule heat generated by the resistance component of the welded portion tends to increase. On the other hand, if it is fixed by caulking, such a problem does not occur.

(5) In the first embodiment, the insulating layer 106 in the effective coil portion 102 is preferably an insulating layer in which a water-soluble material permeated around the conductive base material 10 is solidified.
When the insulating layer 106 is made of an insulating coating film coated with an insulating coating material, it is easily affected by liquid dripping during coating, uneven adhesion of the coating material to the substrate, and the like. On the other hand, by forming the insulating layer 106 with "an insulating layer in which a water-soluble material permeated around the conductive base material 10 is solidified", the effect of the permeation causes the space between the conductive base materials inside the coil lead wire 110 to be solidified. Even so, the water-soluble material can spread and fill the gaps between the copper wire base materials, and the above-mentioned liquid dripping and uneven adhesion do not occur, and a homogeneous insulating layer is obtained regardless of the part of the electromagnetic coil. Become. As a result, a uniform withstand voltage characteristic can be obtained, and a high quality electromagnetic coil with stable insulation characteristics can be obtained.

(6) Further, it is more preferable that the insulating layer 106 in the effective coil portion 102 is an electrodeposition insulating coating film formed around the conductive base material 10.
The electrodeposition coating film is generally formed by completely submerging an object to be coated in an electrodeposition coating solution and applying a predetermined voltage. The electrodeposition coating solution penetrates so as to spread to the outside and the inside of the coil lead wire 110, and is conductive not only to the conductive base material 10 located outside the coil lead wire 110 but also to the inside. Since the voltage is similarly applied to the base material 10, the insulating layer 106 becomes uniform from the outside to the inside of the coil lead wire 110. Therefore, a more uniform withstand voltage characteristic can be obtained regardless of the portion, and a high-quality electromagnetic coil with stable insulation characteristics can be obtained.

[Embodiment 2]
FIG. 10 is a diagram for explaining the electromagnetic coil 2 according to the second embodiment. FIG. 10A is a perspective view of the electromagnetic coil 2. For the components having the same basic configuration and features as those of the first embodiment, the hundred digits of the code in the first embodiment are replaced with 1 to 2 (in the 100s in the first embodiment and in the 200s in the second embodiment). The description of the component in the first embodiment (corresponding to this) shall be incorporated, and the description here will be omitted.

The electromagnetic coil 2 according to the second embodiment basically has the same configuration as the electromagnetic coil 1 according to the first embodiment, but is different from the electromagnetic coil 1 according to the first embodiment in the number of turns of the "conductive member". ..

As shown in FIG. 10A, in the electromagnetic coil 2, the "conductive member" is sequentially from the lower right side, the second end member 240 ₁ , the coil lead wire 210 ₁ , the first end member 230 ₁ , and the coil. While being connected to the conductor wire 210 ₃ , the second end member 240 ₂ , the coil conductor wire 210 ₂ , the first end member 230 ₂ , the coil conductor wire 210 ₄ , and the second end member 240 ₃ , so as to surround the air core region 201. It is wound about 2 times (strictly speaking, it is wound 1 and 3/4 times. See also FIG. 11 described later).
Corresponding to this, the number of coil conductors 210 is four, the modes of the first end members 230 ₁ and 230 ₂ are different from each other, and the modes of the second end members 240 ₁ , 240 ₂ and 240 ₃ are different from each other. It's different. In particular, the second end member 240 ₂ constitutes a leg portion 224, and is provided with a winding direction changing portion and a crossover portion (not shown by reference numerals), and is provided with a coil lead wire 210 ₃ and a coil lead wire 210 ₂ Is electrically connected to and from. Further, the lower bottom portion 222 and the leg portion 224 are configured to form an angle θ2 of less than 90 degrees. However, other basic parts have the same design concept as that of the electromagnetic coil 1 according to the first embodiment, and have the same configuration.

FIG. 10B is a cross-sectional view when the effective coil portion 202 of the electromagnetic coil 2 is cut by the virtual surface PL2 shown in FIG. 10A and the cut surface is viewed along the arrow B.
As shown in FIG. 10B, in the cross section of the effective coil portion 202 in the electromagnetic coil 2, the coil lead wire 210 ₁ and the coil lead wire 210 ₂ in which a plurality of conductive base materials 10 are bundled are laminated in two stages. It is in the form of a coil. Each of the coil conductors 210 ₁ and the coil conductors 210 ₂ has the same structure as the coil conductors 110 according to the first embodiment when viewed individually.

The manufacturing method of the electromagnetic coil 2 basically has the same configuration as the manufacturing method of the electromagnetic coil 1 according to the first embodiment (see FIGS. 5 to 7). However, some ingenuity is required in the insulating layer forming step S180.

FIG. 11 is a diagram for explaining the state of the electromagnetic coil 2'in the insulating layer forming step S180 of the second embodiment.
In the electromagnetic coil 2 of the second embodiment, since the "conductive member" is wound twice (2T) as described above, the "conductive member" on the first lap and the "conductive member" on the second lap If an attempt is made to form an insulating layer in a state where the "member" is in close contact with the "member", the insulating layer may not be formed between the "conductive member" on the first lap and the "conductive member" on the second lap. ..
Therefore, as shown in FIG. 11, when the insulating layer forming step S180 is carried out, for example, the first end member 230 is spaced between the coil conductor 210 ₁ and the coil conductor 210 ₂ as shown by SP1. The first lap, such as the space indicated by SP2 between ₁ and the first end member 230 ₂ , and the space indicated by SP 3 between the second end member 240 ₂ and the second end member 240 ₃ . While keeping a space between the "conductive member" and the "conductive member" on the second lap, the "conductive member (coil conductor wire 210, first end member 230, second end member 240" is maintained. The index of the subscript is omitted) ”, and the insulating material is infiltrated, adhered, and applied.

The electromagnetic coil 2 according to the second embodiment has basically the same configuration as the electromagnetic coil 1 according to the first embodiment except for the number of turns of the "conductive member". Therefore, among the effects of the electromagnetic coil 1 according to the first embodiment, the corresponding effect is similarly obtained.

[Embodiment 3]
FIG. 12 is a diagram (perspective view) shown for explaining a manufacturing process (part) of the electromagnetic coil 3 according to the third embodiment. For the components having the same basic configuration and features as those of the first embodiment, the hundred digits of the code in the first embodiment are replaced with 1 to 3 (in the 100s in the first embodiment and in the 300s in the third embodiment). The description of the component in the first embodiment (corresponding to this) shall be incorporated, and the description here will be omitted.

The electromagnetic coil 3 according to the third embodiment basically has the same configuration as the electromagnetic coil 1 according to the first embodiment, but is carried out in that a spacer 40 such as metal is attached to the end of the coil lead wire 310. It is different from the electromagnetic coil 1 according to the first embodiment.

That is, in the electromagnetic coil 3 according to the third embodiment, the spacer 40 is attached to the end portion (one end side 311, the other end side 312) of the coil lead wire 310, and the end portion (one end side) of the coil lead wire 310. 311, the other end side 312) are connected to the first end member 330 and the second end member 340 ₁ , 340 ₂ , respectively. In other words, the first end member 330 and the coil lead wire 310 are connected via a spacer 40. Further, the second end members 340 ₁ , 340 ₂ and the coil lead wire 310 are connected via a spacer 40. Although not shown, the outer dimensions of the spacer 40 are designed to correspond to the inner dimensions of the opening 331 of the first end member 330 and the opening 341 of the second end member 340, and are fitted to each other. Can be done.

In the method for manufacturing the electromagnetic coil 3 according to the third embodiment, a new spacer mounting step is required.
As shown in the figure on the left side of FIG. 12A, after performing the braided wire forming step S134 of the coil lead wire setup step S130, the spacer 40 is attached to one end side 311 and the other end side 312 of the coil lead wire 310. (Spacer mounting step). Specifically, the spacers 40 are inserted into the one end side 311 and the other end side 312 of the coil lead wire 310, respectively, and pressure is applied from the outside of each spacer 40 using a crimping tool or the like to "caulk" them to fix them. Further, instead of "caulking" or in addition to "caulking", fixing by welding may be performed, or fixing by a conductive adhesive may be performed. In any case, after fixing, the state shown on the right side of FIG. 12A is obtained.

After that, as shown in FIG. 12B, the end portion of the coil lead wire 310 to which the spacer 40 is mounted is inserted in the same manner as in the first end member insertion step S140 and the second end member insertion step S160 in the first embodiment. It can be inserted into the opening 331 of the first end member 330 and the opening 341 of the second end members 340 ₁ , 340 ₂ .

When the electromagnetic coil 3 is manufactured in this way, the first end member 330 and the coil lead wire 310 are "indirectly connected" via the spacer 40. Further, the second end member 340 and the coil lead wire 310 are "indirectly connected" via the spacer 40.
Also in this case, the first end member 330 or the second end member 340 and the coil lead wire 310 can be connected by caulking and fixing.

When, for example, a braided wire is adopted as the coil lead wire 310, it is possible to insert the end portion of the braided wire directly into the opening 331 of the first end member 330 and fit it, but it is conductive to the end portion of the braided wire. Fraying, fluffing, etc. of the sex substrate 10 (wire rod) may occur.
On the other hand, in the third embodiment, by introducing the spacer 40, the spacer 40 is once attached to the end of the braided wire in the above case, so that such fraying, fluffing and the like can be eliminated, and the connection reliability is further improved. It becomes a high electromagnetic coil.

The electromagnetic coil 3 according to the third embodiment has basically the same configuration as the electromagnetic coil 1 according to the first embodiment, except that the spacer 40 is attached to the end of the coil lead wire. (See FIGS. 5 to 7). Therefore, among the effects of the electromagnetic coil 1 according to the first embodiment, the corresponding effect is similarly obtained.

[Embodiment 4]
The electromagnetic coil 4 according to the fourth embodiment basically has the same configuration as the electromagnetic coil 2 according to the second embodiment, but relates to the second embodiment in that a spacer 40 is attached to the end of the coil lead wire. It is different from the electromagnetic coil 2 (not shown).
That is, in the electromagnetic coil 4 according to the fourth embodiment, the number of turns of the "conductive member" is about two times (the same configuration as the electromagnetic coil 2 according to the second embodiment), and the same as the third embodiment. , Spacers 40 are attached to both ends of the coil lead wire 410. That is, a spacer 40 is attached to the end of the coil lead wire 410, and the end of the coil lead wire 410 is connected to the first end member 430 and the second end member 440, respectively. In other words, the first end member 430 and the coil lead wire 410 are connected via a spacer 40. Further, the second end member 440 and the coil lead wire 410 are connected via a spacer 40 (not shown).

The electromagnetic coil 4 according to the fourth embodiment has basically the same configuration as the electromagnetic coil 2 according to the second embodiment, except that the spacer 40 is attached to the end of the coil lead wire. Therefore, among the effects of the electromagnetic coil 2 according to the second embodiment, the corresponding effect is similarly obtained.

Although the present invention has been described above based on the above embodiment, the present invention is not limited to the above embodiment. It can be carried out in various embodiments within a range that does not deviate from the purpose, and for example, the following modifications are also possible.

(1) In each embodiment, the connection / fixing between the first end member and / and the second end member and the coil lead wire has been described with reference to an example of caulking fixing, but the present invention is limited thereto. It's not a thing.
For example, the solid conductive material is made of metal, the first end member is welded and fixed to one end side of the coil lead wire, and the second end member is welded and fixed to the other end side of the coil lead wire. May be good. Here, "welding and fixing" refers to heating and melting metal powders such as silver and tin, and so-called soldering is also included in the welding and fixing of the present invention. According to welding fixing, the welding material can fill the space between the first end member / second end member and the coil lead wire, the contact resistance is reduced, and the electromagnetic coil has high connection reliability.

Further, for example, the solid conductive material is made of metal, the first end member is fixed to one end side of the coil lead wire with a conductive adhesive, and the second end member is fixed to the other end side of the coil lead wire with a conductive adhesive. It may be configured to be fixed with. Here, "fixing with a conductive adhesive" means fixing by applying, for example, silver paste (grease containing silver powder) to the adhesive portion and joining them, and then heating to remove organic components and cure them. Similar to welding, the adhesive can fill the space between the first end member / second end member and the coil lead wire, the contact resistance is reduced, and the electromagnetic coil has high connection reliability.

(2) In each embodiment, an example in which the braided wire 20 in which the bare conductor wire 11 is used as the conductive base material 10 is used as the coil conducting wire has been described, but the present invention is not limited thereto.
For example, the conductive base material 10 may be an enamel wire 12, and the coil conductor may be configured to be a “litz wire 30” in which a plurality of enamel wires 12 are twisted (not shown).
The so-called litz wire 30 is cheaper than the braided wire 20 and is industrially attractive. .. However, according to the present invention, since the coil lead wire is not used in the coil end portion and only the linear effective coil portion is incorporated, it can be adopted without worrying about the above problem. Therefore, the litz wire 30 can be suitably used for the present invention, and an economical electromagnetic coil can be realized.

(3) In each embodiment, the example in which the "conductive member" is wound about once (1T) or about twice (2T) has been described, but the present invention is not limited thereto. do not have. For example, it may be wound three or more times. However, in the present invention, an electromagnetic coil in which the number of turns of the "conductive member" is 2 or less is more preferable. If the coil is wound three times or more, the difficulty of the step of providing the insulating coating agent between the coil conductors (braided wire or the like) to be stacked (insulation layer forming step S180) increases. If the number of turns of the "conductive member" is 2 or less, the electromagnetic coil can be an economically advantageous electromagnetic coil with excellent manufacturability.

(4) In each embodiment, the upper bottom portion 121,221,321,421 is arranged at a position farther from the rotation axis AX1 than the lower bottom portion 122,222,322,422, but the present invention is limited to this. It is not something that will be done. On the contrary, the lower bottom portion 122, 222, 322, 422 may be arranged at a distant position.
Further, in each embodiment, the positions of the steps 123d, 223d, 323d, and 423d are arranged closer to the lower bottom portion 122, 222, 322, 422, but the present invention is not limited thereto. On the contrary, the steps 123d, 223d, 323d, 423d may be arranged closer to the upper bottom portions 121,221,321,421.

(5) In each embodiment, an electromechanical device that operates by being excited by two phases has been described as an example (FIG. 1 and the like), but the present invention is not limited thereto. For example, it can be applied to an electromechanical device excited by three phases. In this case, the drawings and explanations such as the arrangement relationship of the plurality of electromagnetic coils and the connection method can be incorporated in the present specification by referring to the contents of Patent Document 1 previously invented by the inventor of the present application.

(6) Although a coreless motor has been described as an example of application of the present invention, the present invention is not limited thereto. For example, it can be applied to general electric mechanical devices such as coreless generators, regenerative brakes, and actuators. Furthermore, the application of the present invention is not limited to coreless (without iron core) electromechanical devices. The present invention may be applied to a cored electromechanical device (having an iron core and arranging the electromagnetic coil around the iron core).

(7) In each embodiment, an electromechanical device premised on rotation of a coreless motor or the like has been described as an example, but the present invention is not limited thereto. For example, it can also be used for a linear type electromechanical device. For example, a coil assembly for a linear electromechanical device can be obtained by constructing a cage-type coil assembly shown in FIG. 1 (a) by virtually cutting and unfolding one place in the circumferential direction. You can also do it. In this case, the rotor (rotor) in the present specification can be read as a mover (movable element).

1,1a, 1b, 1c, 2,2', 3,4,9 ... Electromagnetic coil, 10 ... Conductive substrate, 11 ... Bare conductor wire, 12 ... Enamel wire, 15 ... Stranded wire, 20 ... Braided wire, 30 ... Litz wire, 40 ... Spacer, 100 ... Coil assembly, 101, 101c, 201,901 ... Air core region, 102, 202, 902 ... Effective coil part, 103, 903 ... First coil end part, 104,904 ... 2nd coil end, 105,905 ... Circuit connection terminal, 106,107 ... Insulation layer, 110, 110 ₁ , 110 ₂ , 210 ₁ , 210 ₂ , 210 ₃ , 210 ₄ , 210, 310, 410 ... Coil Lead wire, 111, 311 ... One end side (of the coil lead wire), 112, 312 ... The other end side (of the coil lead wire), 121, 121a, 121b, 121c, 221, 321, 421, 921 ... Upper bottom, 122 , 122a, 122b, 122c, 222,322,422,922 ... Lower bottom, 123,123a, 123b, 123c, 223,224,923,924 ... Legs, 123d, 223d, 323d, 423d, 923a, 924a ... Steps , 130, 230, 230 ₁ , 230 ₂ , 330, 430 ... First end member, 131, 331 ... (first end member) opening, 132, 142 ... Connecting part (overlap part), 133 ... Crossing part , 134, 934, 944 ... Winding direction changing part, 137, 147 ... Caulking part, 140, 240, 240 ₁ , 240 ₂ , 240 ₃ , 340, 340 ₁ , 340 ₂ , 440 ... Second end member, 141, 341 ... Opening (of the second end member), 710 ... Rod, 710a ... The other end of the rod, 710b ... One end of the rod, 720 ... Fixing member, 730 ... Permanent magnet pair, 740 ... Sample fixing base

Claims (12)

An electromagnetic coil in which a conductive member is wound so as to surround an air core region and is arranged along the moving direction of a magnet of an electromechanical device.
When the entire electromagnetic coil is viewed in a plan view, the electromagnetic coil has a lower bottom portion facing the upper bottom portion and the upper bottom portion, and a leg portion connecting the upper bottom portion and the lower bottom portion, and the leg portion. The angle between the portion and the lower bottom portion is formed to be less than 90 degrees, and the upper bottom portion, the lower bottom portion, and the leg portion are arranged so as to surround the air core region. ,
The upper bottom portion is arranged on a predetermined first surface, and the lower bottom portion is arranged on a second surface different from the first surface.
The upper bottom portion and the lower bottom portion include an effective coil portion, and the upper bottom portion and the lower bottom portion include an effective coil portion.
The electromagnetic coil has an effective coil portion, a first coil end portion located on one side of the effective coil portion in the longitudinal direction, and a second coil end portion located on the other side of the effective coil portion in the longitudinal direction. And have
The effective coil portion is composed of a coil lead wire formed by bundling a plurality of conductive substrates.
The first coil end portion is composed of a first end member made of a solid conductive material.
The first end member is connected to one end side of each of the one coil lead wire and the other coil lead wire constituting the effective coil portion, and is connected to the one coil lead wire and the other coil lead wire. There is an electrical connection between them,
The second coil end portion is composed of a second end member made of a solid conductive material.
The second end member is connected to the other end side of the coil lead wire constituting the effective coil portion.
An electromagnetic coil characterized by that. In the electromagnetic coil according to claim 1,
An electromagnetic coil characterized in that a spacer is attached to an end portion of the coil lead wire, and the end portion of the coil lead wire is connected to the first end member and the second end member. In the electromagnetic coil according to claim 1 or 2.
The solid conductive material is made of metal and is made of metal.
The first end member is caulked and fixed to one end side of the coil lead wire.
The second end member is caulked and fixed to the other end side of the coil lead wire.
An electromagnetic coil characterized by that. In the electromagnetic coil according to claim 1 or 2.
The solid conductive material is made of metal and is made of metal.
The first end member is welded and fixed to one end side of the coil lead wire.
The second end member is welded and fixed to the other end side of the coil lead wire.
An electromagnetic coil characterized by that. In the electromagnetic coil according to claim 1 or 2.
The solid conductive material is made of metal and is made of metal.
The first end member is fixed to one end side of the coil lead wire with a conductive adhesive.
The second end member is fixed to the other end side of the coil lead wire with a conductive adhesive.
An electromagnetic coil characterized by that. In the electromagnetic coil according to any one of claims 1 to 5.
The wire used as the conductive base material is a conductive wire containing copper, and is a conductive wire.
The average radius of the conductive substrate is 120 μm or less.
An electromagnetic coil characterized by that. In the electromagnetic coil according to claim 6,
The conductive base material is a bare conductor wire and is
The coil lead wire is a braided wire in which a plurality of the bare conductor wires are braided.
An electromagnetic coil characterized by that. In the electromagnetic coil according to claim 6,
The conductive substrate is an enamel wire and is
The coil lead wire is composed of a "litz wire" in which a plurality of the enamel wires are twisted.
An electromagnetic coil characterized by that. In the electromagnetic coil according to any one of claims 1 to 8.
The second coil end portion is provided with a circuit connection terminal coupled to or connected to the second end member.
The electromagnetic coil is provided with an insulating layer on the entire surface other than the circuit connection terminal.
An electromagnetic coil characterized by that. In the electromagnetic coil according to claim 9,
The insulating layer in the effective coil portion is an electromagnetic coil characterized in that the insulating layer is a solidified water-soluble material that has permeated around the conductive base material. In the electromagnetic coil according to claim 10,
An electromagnetic coil characterized in that the insulating layer in the effective coil portion is an electrodeposition insulating coating film formed around the conductive base material. In the electromagnetic coil according to claim 9,
An electromagnetic coil characterized in that the insulating layer in the effective coil portion is an insulating coating film formed around the conductive base material.

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