JP2005222997A - Coil sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To simply, easily, and inexpensively achieve one coil in which a number of spiral flat coils are laminated in one piece to form the one coil by one coil sheet by reducing troubles and required time. <P>SOLUTION: Two spiral flat coils 21, 22 making the direction of a magnetic flux and an axis of the coils coincident are laid on both the front and rear of a foldable insulating sheet 1, and the inner edges of both the flat coils are allowed to be electrically continuous mutually, thus providing a flat coil unit 2 on the insulating sheet. And a plurality of flat coil units 2 are evenly arranged on the insulating sheet, the directions of the flux of adjacent flat coil units are reversed each other, and the adjacent flat coils are allowed to successively continue in series at mutual outer edges for electrically connecting all flat coils in series. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

The present invention relates to a coil sheet used for coils of electromagnetic devices and electronic devices.

A printed wiring board in which a spiral flat coil is attached to an insulating substrate is already known for use in coils of electromagnetic devices and electronic devices as disclosed in Patent Documents 1 to 3.

An etching method is used to attach the flat coil to the printed wiring board, and a top coat of an electrical insulating film is applied to the surface of the flat coil formed by the etching method.

Moreover, the printed wiring board with a flat coil manufactured in this way is used as a single coil by electrically connecting the flat coils to each other in a single layer or a plurality of stacked layers. Two spiral flat coils that are electrically connected in series are juxtaposed on one surface of the substrate, the insulating substrate is folded in two, and the two coils are brought into contact with each other (Patent Document 1).
JP-A-10-199727 Japanese Patent Laid-Open No. 2000-124024 Japanese Utility Model Publication No. 6-66008

However, in any case, in the conventional printed wiring board with flat coils, the following problems arise when a large number of spiral flat coils are laminated and integrated into one coil.

(1) In order to stack a large number of spiral flat coils, it is necessary to individually produce a large number of independent printed wiring boards with flat coils, and each printed wiring board with flat coils has a terminal portion as a base. Coil patterns that extend to the edge are required, and the terminal portions of the design cannot be placed at a fixed position, making the coil pattern diversified and complicated, and the required printed wiring with a flat coil It takes a lot of time and effort to design and manufacture the substrate, and as a result, the cost of manufacturing the printed wiring board with the spiral flat coil is considerably increased.

(2) In order to superimpose a large number of printed wiring boards with flat coils to laminate those spiral flat coils, positioning means for setting each of them in a fixed position outside the printed wiring board with flat coils・ In order to connect the spiral flat coils electrically in series, the terminals of the coil patterns are electrically coupled outside the printed wiring board with the flat coils. In order to assemble the coil as a whole, it is necessary to attach it to a bobbin with a winding machine. Compared with the case of winding a coil, much more materials, labor and time are required, and here again, the cost is very high. Moreover, due to such a structure, the overall size is unreasonably large, and the electrical quality, performance, efficiency, and the like are lowered, and noise is easily generated.

The present invention is intended to solve these problems.

From this point of view, the coil sheet of claim 1 according to the present invention is provided with two spiral flat coils each having a common magnetic flux direction and axis on both the front and back surfaces of the foldable insulating sheet. By electrically connecting the inner ends to each other, a flat coil unit is provided on the insulating sheet. Further, a plurality of the flat coil units are uniformly arranged on the insulating sheet, and magnetic fluxes between adjacent flat coil units are arranged. All the flat coils are electrically connected in series by reversing the directions of the flat coils and continuously connecting the adjacent flat coils to each other at the outer ends.

The coil sheet according to claim 2 is the coil sheet according to claim 1, wherein the plurality of flat coil units are arranged in a row on the strip-shaped insulating sheet, and the insulating sheet is used as the flat coil unit. Corresponding to be folded in a zigzag shape.

With the coil sheet of the present invention, when a single coil sheet is electromagnetically manufactured by laminating a large number of spiral flat coils, it is sufficient to use one coil sheet. It is only necessary to fold the sheets appropriately and stack and superimpose the flat coil units on each other. The positioning means and structure for the conventional polymerization are also a number of external connection lines for connecting the spiral flat coils and soldering. Of course, there is no complication of external connection lines, etc., and the assembly can be done easily by both manual and mechanical work, requiring little labor and time, and does not incur high costs. . In addition, the overall size is not unduly enlarged, electrical quality, performance, efficiency and the like are not deteriorated, and noise is not easily generated. In addition, it can be easily and easily adapted to coils of various forms, sizes, and thicknesses such as plate, box, and cylinder, and is widely used for coils of various electrical and electronic devices. be able to.

In the coil sheet of the present invention, since it is sufficient to use a single coil sheet for laminating a large number of spiral flat coils as described above, existing plating means or the like can be applied to a foldable insulating sheet of a required size. The above-mentioned flat coil units can be easily and easily attached at once, and there is no need to individually produce a large number of independent printed wiring boards with flat coils as in the conventional case. It is not necessary to form a coil pattern in which the terminal part extends to the base edge of the base, and of course, it is difficult to arrange the terminal part, and the coil pattern is not diversified and complicated. The coil sheet can be manufactured at low cost without much time and effort in designing and manufacturing the coil sheet.

Further, the above-described flat coil units are arranged in a row on a strip-shaped insulating sheet, and the insulating sheet is folded in a zigzag manner so as to correspond to the flat coil units. Therefore, it can be easily and easily used by cutting it to any length as required, and its folding can be done easily and easily. Moreover, it can be continuously mass-produced by an automatic production machine, and the cost can be greatly reduced and provided at low cost.

FIG. 1 is a front view showing an embodiment of a coil sheet according to the present invention, FIG. 2 is a rear view thereof, in which 1 is an insulating sheet, 2 is a plurality of flats attached to the insulating sheet 1 It is a coil unit.

The insulating sheet 1 also includes a film, but is formed into a strip shape with a synthetic resin, and is divided into a row for each region 11 suitable for the size of the flat coil unit 2, and each boundary portion 12 is sequentially front side and back side. The zigzag-shaped folding shown in FIGS. 3 and 4 is possible, and a through hole 13 is formed in the center of each region 11 and cut at appropriate positions on the edge of each through hole 13. 14 is provided.

The flat coil unit 2 is provided with two spiral flat coils 21 and 22 each having a common magnetic flux direction and axis centering on the through hole 13 on both front and back surfaces of each region 11 divided by the insulating sheet 1. Then, as shown in the electric circuit of FIG. 6, the inner ends 23 and 24 of both flat coils are electrically connected to each other to form a unit composed of a pair of spiral flat coils 21 and 22, respectively. As apparent from FIGS. 1 and 2, the spiral directions of both spiral flat coils 21 and 22 when viewed from one side of the front surface or the back surface are one spiral from the outside to the inside and the other spiral from the inside to the outside. Since the inner ends 23 and 24 are close to each other, the inner ends 23 and 24 can be electrically connected to each other easily and easily through the notch 14 of the insulating sheet 1.

Further, the flat coil unit 2 arranged in each divided region 11 of the insulating sheet 1 in this way has the direction of the magnetic flux between the adjacent flat coil units 2 opposite to each other, and the outer ends 25 of the adjacent flat coils, By continuously connecting the 26 one after another, all the flat coils are electrically connected in series as shown in the electric circuit of FIG. The reason why the directions of the magnetic fluxes between the adjacent flat coil units 2 are reversed is to make the direction of the magnetic flux common when the insulating sheet 1 is folded and the flat coil units 2 are overlapped with each other. is there.

However, in the one shown in FIGS. 1 to 6, the outer ends 25 and 26 of the spiral flat coils 21 and 22 at the front end and the end of the flat coil unit 2 at both ends are connected to the terminal portions 27 and 28 of a specific form. Although formed, as shown in FIGS. 7 and 8, the same shape as the outer ends 25 and 26 of the spiral flat coils 21 and 22 in the intermediate flat coil unit 2 may be used. The latter is more convenient when it is used by cutting it into an arbitrary length mainly by forming it into a long object. Then, as shown in FIGS. 1 to 4 and 6, lead wires 3 and 4 are connected to the terminal portions 27 and 28 by soldering or the like.

By the way, as shown in FIG. 5, in order to attach the plurality of flat coil units 2 to the insulating sheet 1, that is, to each of the spiral flat coils 21 and 22 to the divided regions 11, and to electrically connect them, the insulating sheet An undercoat 5 of an insulating film is applied to both the front and back surfaces of 1 and formed all at once by existing plating means such as a vacuum evaporation method and an etching method of a conductive material, and a topcoat 6 of an insulating film is applied thereon. If it is particularly necessary to connect the inner ends 23 and 24 of the spiral flat coils 21 and 22 on the front and back sides, a conductive piece is inserted in advance into the notch 14 of the insulating sheet 1 and attached to the front and back surfaces of the insulating sheet 1. It is good to attach it. Of course, it is possible to wrap around the front and back with plating. The undercoat 5 is not necessary if the insulating sheet 1 has a surface suitable for plating.

When a single coil is electromagnetically manufactured by laminating a large number of spiral flat coils, as shown in FIG. 3 and FIG. In step 12, the front side and the back side are alternately folded and zigzag folded, and all the flat coil units 2, that is, all the spiral flat coils 21, 22 are laminated and polymerized.

In the above-described coil sheet, the segmented regions 11 are arranged in a line on the strip-shaped insulating sheet 1 and the flat coil units 2 are provided respectively. However, the segmented regions 11 are arranged uniformly in a plurality of rows. A flat coil unit 2 may be provided. The attachment of the flat coil unit 2 to the insulating sheet 1 can also be performed by printing a conductive material by other printing means. As long as the flat coil unit 2 can be attached, the insulating sheet 1 may be other materials such as insulating paper. Further, in the illustrated case, a through hole 13 is formed in the center of each partition region 11 of the insulating sheet 1 assuming that it is fitted to an iron core, and the through hole 13 is formed in a circular shape. The through holes 13 may be triangular, quadrangular, or other polygonal shapes corresponding to what is used, and may be non-through holes depending on what is used. This also applies to the shape of the edge of each partition region 11 in the insulating sheet 1 or the shape of each spiral flat coil 21, 22 attached to each partition region 11.

The coil sheet of the present invention can be widely used for coils of transformers, transformers, electromagnets, electric motors and other various electric devices, choke coils and coils of other various electronic devices.

It is a surface view which shows embodiment of the coil sheet which concerns on this invention. FIG. It is a perspective view in the middle of the folding. It is a perspective view after the folding. It is an expanded sectional view of the principal part. It is the same electrical circuit diagram. It is a surface view which shows other embodiment of the coil sheet which concerns on this invention. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Insulation sheet 2 Flat coil unit 3, 4 Lead wire 5 Undercoat 6 Topcoat 11 Area | region 12 Boundary part 13 Through-hole 14 Notch | 21, 22 Spiral flat coil 23, 24 Inner end 25, 26 Outer end 27, 28 Terminal Part

Claims (2)

  Two spiral flat coils that share the same magnetic flux direction and axis are individually attached to both the front and back sides of the foldable insulating sheet, and the inner ends of both flat coils are electrically connected to each other, thereby making the insulating sheet A flat coil unit is provided, and the insulating sheet has a plurality of the flat coil units arranged uniformly, and the directions of the magnetic fluxes between the adjacent flat coil units are reversed, and the adjacent flat coils are arranged. A coil sheet characterized in that all the flat coils are electrically connected in series by continuously connecting the outer ends one after another.   The coil sheet according to claim 1, wherein the plurality of flat coil units are arranged in a row on the strip-shaped insulating sheet, and the insulating sheet is folded in a zigzag manner so as to correspond to the flat coil units.