JPH0677078A - Coil and manufacture thereof - Google Patents

Abstract

PURPOSE:To enable coils to be efficiently manufactured by a coil winding machine by a method wherein an intermediate point of a wire located at nearly the halfway point of the insulated electric wire is inserted into a cut provided to an insulating sheet, and the half and the other half of the electric wire separated from each other at an intermediate point are wound on a spacer and another spacer respectively in opposite directions. CONSTITUTION:An intermediate point B located nearly at the halfway point of an insulated electric wire A between a first and a second bobbin, 8 and 9, is inserted to a cut 4 provided to an insulating sheet 2 and pushed down so as to come into contact with a spacer 5. Then, a support shaft 1 is fixed not to rotate by a proper means, and the first bobbin 8 and the second bobbin 9 are rotated on their own axes respectively and revolved in opposite directions. An insulated electric wire A unwound from the first bobbin 8 is wound on the left spacer 5, and an insulated electric wire A unwound from the second bobbin 9 is wound on the right spacer 5 to form a coil.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a coil, particularly a coil having a structure in which an insulating sheet is inserted in the center in the winding width direction.

[0002]

2. Description of the Related Art The present inventor has previously filed a patent application for a coil having a special structure capable of simultaneously generating heat and a magnetic field. This coil has a conductivity (IACS) of 5
It is a flat plate having a small winding width in which about 95% of the insulated electric wire is wound by air core winding, and an insulating sheet such as mica is inserted in the center in the winding width direction.

Since this coil has a special structure in which the winding start is on the innermost circumference, the winding end is on the outermost circumference, and an insulating sheet is provided in the middle, a special winding method is used. Since it is wound by hand, it is very difficult to wind it by automatic winding (mechanical winding), and there is a disadvantage that mass production is not possible.

[0004]

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to obtain a method capable of efficiently manufacturing a coil having the above structure by mechanical winding.

[0005]

[Means for Solving the Problem] The problem is to form a cut in the insulating sheet from its outer peripheral edge toward its center, and then sandwich the insulating sheet from both sides thereof with the spacers serving as cores, and then wind the sheet. Pass the middle point, which is approximately the middle of the insulated wire of the length to be turned, through the notch of the insulating sheet, and then one part from the middle point of the insulated wire to one spacer and the other part from the middle point of the insulated wire to the other. This is solved by a method in which the spacers are wound in opposite directions.

The present invention will be described in detail below. Figure 1
Is for explaining an example of the manufacturing method of the present invention, and reference numeral 1 in the drawing is a support shaft. The support shaft 1 has a round bar shape, and both ends thereof are threaded. This support shaft 1
An insulating sheet 2 is attached to a substantially central portion of the shaft in the axial direction.

As shown in FIG. 2, the insulating sheet 2 has a rectangular outer shape, and has a hole 3 formed in the center thereof, into which the support shaft 1 is inserted. Further, a notch 4 is formed from one corner of the outer peripheral edge of the insulating sheet 2 toward the hole 3. The notch 4 may reach the hole 3 but may not reach the hole 3 as long as the notch 4 is cut before the hole 3. Further, it is preferable that the cut 4 has substantially no width in terms of insulation. Further, the above-mentioned corner is shown in FIG.
As shown in FIG. 3, the insulating wire is cut in a concave shape so that the insulated wire can be easily introduced into the cut 4.

The insulating sheet 2 has a thickness of 0.1 to 3
Mica, glass cloth, glass mat, ceramic cloth, etc. having a size of about mm are used, and it is preferable that the surface thereof is coated with a heat-melting type heat-resistant adhesive. In addition, as another example of the insulating sheet 2, a sheet material made of a magnetic material such as an iron plate, a steel plate, a silicon steel plate, or a ferrite plate and having an insulating material such as mica, glass cloth, glass mat, or ceramic cloth attached to both surfaces is also used. It is possible to use, and it is preferable to apply a heat-melting type heat-resistant adhesive on the surface of the insulating material in the same manner.

Two spacers 5, 5 serving as winding cores are attached to both sides of the insulating sheet 2 so as to penetrate the support shaft 1. The spacer 5 has a cylindrical shape,
The outer diameter determines the inner diameter of the coil, and the axial length thereof determines the winding width of the coil. Collar-shaped guide plates 6 and 6 are provided on the outer sides of the spacers 5 and 5 respectively so as to penetrate the support shaft 1, and these are respectively nuts 7 and 7.
Are fastened by being screwed onto the support shaft 1. The guide plate 6 is a disk-shaped member having substantially the same size as the insulating sheet 2, and the outer peripheral portions of the guide plates 6 are each gently curved outward so that the insulated wire can be easily guided. .

On the other hand, reference numeral 8 in FIG. 1 is a first bobbin, 9 is a second bobbin, and the first bobbin 8 has about half the length of one insulated wire A to be wound. The second bobbin 9 is wound up, and the remaining half of the insulated wire A is wound up around the second bobbin 9. In addition, these bobbins 8 and 9 send out the insulated electric wire A which is itself rotated and wound around the bobbin 8 and 9 and has the same axis around the support shaft 1 with the center axis C of the support shaft 1 as the rotation center axis. It is supposed to revolve around.

The insulated wire A here is not particularly limited, but if it is intended to generate heat and a magnetic field at the same time, a conductor having a conductivity (IACS) of 5 to 95% is ceramic-insulated. Those coated with a heat-resistant insulating coating such as a coating are used. For the purpose of generating only a magnetic field, a conductor having a conductivity of 95% or more is made of polyester, polyamide ester, polyimide, polyester imide, polyurethane, epoxy, phenoxy, etc. Those coated with an insulating film are used.

In the above-mentioned state, the intermediate portion B of the insulated wire A between the first and second bobbins 8 and 9, that is, the intermediate point B which is substantially the middle of the entire length of the wound insulated wire A, is first set in the insulating sheet 2. Pass it through the notch 4 and drop it toward the center of the insulating sheet 2 until it contacts the spacer 5. Next, the support shaft 1 is fixed by an appropriate means so as not to rotate, and the first bobbin 8 and the second bobbin 9 are revolved in the opposite directions while rotating on their own axis, and are fed from the first bobbin 8. The insulated electric wire A is wound around the spacer 5 on the left side in FIG. 1, and the insulated electric wire A sent from the second bobbin 9 is wound around the spacer 5 on the right side to form a coil.

When the insulated wires A having a predetermined length have been wound, a large current is passed through the insulated wires A for a short time to heat the coil and melt the heat-melting adhesive of the insulating sheet 2. The insulating sheet 2 and the winding are fixed to each other, and the winding end portion of the insulated wire A is fixed. Next, remove the nuts 7 and 7, remove the guide plates 6 and 6, and then the spacers 5 and 5.
By taking out 5, the coil having the intended air-core winding and the insulating sheet 2 interposed in the middle in the winding width direction is obtained as shown in FIG.

According to such a manufacturing method, the coil having the above structure can be efficiently produced by mechanical winding. In particular, by forming the notch 4 in the insulating sheet 2, the insulated wire A can be dropped from the outside of the insulating sheet 2 to the vicinity of the hole 3, and it is not necessary to pass the insulated wire through the hole 3 and It will be possible to automate.

The manufacturing method of the present invention can be variously modified in addition to the above-mentioned examples. For example, a spacer and a guide plate integrated with each other may be used, or an insulating sheet without a hole may be used, and the insulating plate may be strongly sandwiched between the guide plates without using the support shaft. Furthermore, insulated wire A
At the time of winding, the assembly part composed of the insulating sheet 2, the spacers 5, 5, and the guide plates 6, 6 is rotated about its own axis, and only one bobbin 8 (9) is rotated about its own axis, thereby obtaining a similar coil. You can In this case, the other bobbin 9 (8) needs to be revolved in the same direction as the rotation direction of the assembled portion at twice the number of rotations.

The number of windings and the number of winding layers of the windings wound around the spacers 5 and 5 are not particularly limited, but the number of windings as shown in FIG. In the above, the coils arranged in one row are particularly preferable because the generation of the magnetic field is good.

Then, similar insulating sheets are arranged on both side surfaces of the coil thus obtained, and side plates made of a magnetic material such as an iron plate and a stainless plate are arranged on the outer sides of the insulating sheets and compressed. A coil element that concentrates the magnetic field generated in the coil at its center and generates a strong magnetic field with few windings can be obtained.

[0018]

As described above, according to the coil manufacturing method of the present invention, a cut is formed in the insulating sheet from its outer peripheral edge toward its center, and then this insulating sheet is formed with the spacers serving as winding cores from both sides thereof. After sandwiching, pass the middle point, which is approximately the middle of the insulated wire of the length to be wound, through the notch of the insulating sheet, then one part from the middle point of the insulated wire to one spacer, from the middle point of the insulated wire Since the other part of is wound around the other spacer in the opposite directions, the core is wound by air, and the coil having the structure in which the insulating sheet is inserted in the middle of the winding width is mechanically wound. It can be produced efficiently.

[Brief description of drawings]

FIG. 1 is a schematic configuration diagram illustrating an example of a manufacturing method of the present invention.

FIG. 2 is a plan view showing an example of an insulating sheet used in the manufacturing method of the present invention.

FIG. 3 is a partial cross-sectional perspective view showing an example of a coil manufactured by the manufacturing method of the present invention.

[Explanation of symbols]

 2 Insulation sheet 4 Notch 5 Spacer A Insulated wire B Intermediate point

Claims (2)

[Claims] 1. An insulating sheet is formed with a notch extending from its outer peripheral edge toward its center, and the insulating sheet is sandwiched from both sides thereof by the spacers serving as winding cores. Pass the middle point, which is almost in the middle, through the cut in the insulating sheet, and then one part from the middle point of the insulated wire to one spacer and the other part from the middle point of the insulated wire to the other spacer in opposite directions. How to make a coil that winds. 2. A coil manufactured by the manufacturing method according to claim 1.