JP2005072428A - High-density coil manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To increase the conventionally achievable space factor of 83-87% of a round copper wire wound in a complete array coil to ≥91% without damaging the wire by limiting the range of the elongation rate and by heating and pressing the wire. <P>SOLUTION: A round copper wire having an elongation rate of 30-40% is wound in a complete array coil heated to 150-230°C, and then pressed. Vacancies 3 between wires are easily filled up in this process, and this increases the space factor to ≥91% without damaging the characteristics of the round copper wire. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

本発明は、空芯コイルの占積率を９１％以上に巻いた高密度コイル製造方法に関するものである。   The present invention relates to a high-density coil manufacturing method in which the space factor of an air-core coil is wound to 91% or more.

丸銅線を占積率の最も高い完全整列巻きコイルにすると、実質占積率は８３〜８７％で、この製造方法では最大占積率は９１％を超える事は無い。   When a round copper wire is used as a fully aligned winding coil having the highest space factor, the real space factor is 83 to 87%, and the maximum space factor does not exceed 91% in this manufacturing method.

この改善策として、平角線４をエッジワイズ巻きにすると、占積率を最大で９６％にする事が可能、図３はエッジワイズ巻きの断面図。但し、エッジワイズ巻きは、巻き方、形状、線径、インダクタンス等に制限が有り任意のコイルが製造出来ないと言う欠点があった。   As an improvement measure, when the rectangular wire 4 is edgewise wound, the space factor can be increased to 96% at maximum. FIG. 3 is a cross-sectional view of edgewise winding. However, edgewise winding has a drawback in that any coil cannot be manufactured due to limitations in winding method, shape, wire diameter, inductance, and the like.

又占積率を上げる為に丸銅線を真四角線４に加工し整列巻きにすると、占積率を理論的に限りなく９９％に近づける事が出来るが、線材加工が極めて難しい為製造コストが高く、尚且つ平角線同様製造上問題が多く、特定のコイル製造にしか適用出来ないと言う欠点があった。図４は真四角線整列巻きの断面図。   Also, to increase the space factor, if the round copper wire is processed into a square wire 4 and aligned and wound, the space factor can theoretically approach 99% as much as possible, but the wire processing is extremely difficult, so the manufacturing cost However, there are many drawbacks in manufacturing as in the case of the rectangular wire, and there is a drawback that it can be applied only to specific coil manufacturing. FIG. 4 is a cross-sectional view of a straight square aligned winding.

又占積率を向上させる方法として、筒状コイルを形成した後、コイルの内周、外周を拘束しながら高さ方向に圧縮し導線断面を塑性変形させる方法が提案されているが、圧縮のみで変形をする場合、変形に大きな圧力が必要、その結果として絶縁被覆に大きな力が加わり絶縁劣化と言う欠点、圧縮しても占積率（スペースファクタと同意語）が９２％にしか向上出来ないと言う欠点があった。（例えば、特許文献1参照。）本発明はこのような欠点を除去する為変形性の良い線材を使用し、加熱押し圧する事で最大占積率９７．５％を可能とした。
特開５６―１６１６３１号公報 As a method for improving the space factor, a method has been proposed in which a cylindrical coil is formed, and then the inner and outer circumferences of the coil are constrained and compressed in the height direction to plastically deform the conductor cross section. When deforming with, a large pressure is required for deformation, and as a result, a large force is applied to the insulation coating, resulting in the disadvantage of insulation deterioration, and even when compressed, the space factor (synonymous with space factor) can only be improved to 92% There was a drawback of not. (For example, refer to Patent Document 1.) In the present invention, the maximum space factor of 97.5% is made possible by using a wire material having good deformability in order to eliminate such drawbacks, and by heating and pressing.
Japanese Patent Laid-Open No. 56-161631

解決しようとする問題点は、丸銅線を占積率の最も大きくなる完全整列巻を実施しても、丸銅線の外周が接して空隙が出来、その空隙を埋めることが出来ない為占積率が低い点にある。 The problem to be solved is that even if the fully aligned winding with the largest space factor is performed on the round copper wire, the outer circumference of the round copper wire is in contact with it to form a void, and the void cannot be filled. The product rate is low.

本発明は、丸銅線の外周が接して出来た空隙を巻き線後、加熱押し圧する事で空隙部分を埋め、コイルの同一断面積でより多くの巻き線又は太い丸銅線を使用出来る事を特徴とする。 In the present invention, after winding a gap formed by contacting the outer periphery of a round copper wire, the gap portion is filled by heating and pressing, and more windings or thick round copper wires can be used with the same cross-sectional area of the coil. It is characterized by.

本発明の高密度コイル製造方法は、一般的に使用されている丸銅線を用い占積率９１％以上にし、同一コイルサイズに於いてインダクタンスを５〜１５％大なコイル又は低抵抗のコイルが製造出来ると言う利点がある。   The high-density coil manufacturing method of the present invention uses a commonly used round copper wire to have a space factor of 91% or more, and a coil having a large inductance of 5 to 15% or a low resistance coil in the same coil size. There is an advantage that can be manufactured.

伸び率３０〜４０％の丸銅線を空芯で巻き、巻き線後加熱し丸銅線の温度が約１５０〜２３０℃に達してから、一方向又は垂直、水平に方向を押し圧する事で丸銅線が変形し、線が密着する事で空隙部分が無くなる、結果としてコイルの断面積が減少し、減少した分、余分に巻き線をする事が出来、インダクタンスを大幅に増加したコイルの製造が実現した。   By winding a round copper wire with an elongation of 30 to 40% with an air core, heating after winding and the temperature of the round copper wire reaches about 150 to 230 ° C, pressing the direction in one direction or vertically or horizontally The round copper wire is deformed and the gaps are eliminated when the wires are in close contact with each other. As a result, the coil cross-sectional area is reduced. Manufacturing realized.

図１は、本発明の製造方法で製作したコイルの断面図であって、１は押し圧後の線、図２は、完全整列巻きの断面図であって、２は丸銅線、３は空隙部分を示す。   FIG. 1 is a cross-sectional view of a coil manufactured by the manufacturing method of the present invention, wherein 1 is a line after pressing, FIG. 2 is a cross-sectional view of fully aligned winding, 2 is a round copper wire, The void portion is shown.

伸び率３０〜４０％の丸銅線を巻き線機に装着し、完全整列巻きで巻上げる、巻き上げ後は図２の状態である。   A round copper wire having an elongation rate of 30 to 40% is mounted on a winding machine and wound up by completely aligned winding. After winding, the state is as shown in FIG.

巻き上げ後通電、熱風、又は赤外線加熱し１５０〜２３０℃にする。   After winding, energization, hot air, or infrared heating is performed to 150 to 230 ° C.

加熱後押し圧冶具に装着し一方向又は垂直、水平を押し圧し丸銅線を変形させる、変形後の断面図は図１である。   FIG. 1 is a cross-sectional view after deformation, which is mounted on a pressing jig after heating and deforms a round copper wire by pressing in one direction or vertical and horizontal directions.

巻き線後１５０〜２３０℃に加熱した金型に装着し一方向又は垂直,水平を押し圧し丸銅線を変形する、変形後は前項と同様の結果が得られる。   After winding, it is mounted on a mold heated to 150 to 230 ° C. and pressed in one direction or vertical and horizontal to deform the round copper wire. After deformation, the same result as in the previous section is obtained.

本発明の製造方法で製作したコイルは、同一断面積により多くの巻き線が出来る、結果として、同一断面積のコイルに比較し５〜１５％大きなインダクタンス、又は小型化のコイルが実現し電子、電気機器の性能向上に貢献する。   The coil manufactured by the manufacturing method of the present invention can have many windings with the same cross-sectional area. As a result, a coil having an inductance that is 5 to 15% larger than that of the coil having the same cross-sectional area, or a miniaturized coil is realized. Contributes to improving the performance of electrical equipment.

伸び率２８〜４２％の丸銅線を巻き線機に装着し、空芯で横１００列縦２０段の完全整列巻きを実施、押し圧前占積率８４％のコイルを約１９０℃に加熱後垂直、水平方向に３９２ＭＰａの圧力で押し圧したコイルの占積率を丸銅線の伸び率による占積率を表１に示す。表１より丸銅線の伸び率が大きいほど占積率が大きくなることが分かる、但し伸び率が４０％になると空隙が殆ど埋まってしまう為伸び率を大きくしても、占積率は殆ど変化しない、従って作業性と占積率を確保する為の伸び率は３０〜４０％が範囲で、最適値は３６〜４０％が適している事が分かる。   A round copper wire with an elongation of 28-42% is attached to the winding machine, complete aligned winding of 100 rows and 20 columns with an air core, and a coil with a space factor of 84% before pressing is heated to about 190 ° C. Table 1 shows the space factor of the coil that was pressed with a pressure of 392 MPa in the vertical and horizontal directions. From Table 1, it can be seen that the larger the elongation rate of the round copper wire, the larger the space factor. However, when the elongation rate becomes 40%, the voids are almost filled, so even if the elongation rate is increased, the space factor is almost the same. It can be seen that the rate of elongation for ensuring workability and space factor is in the range of 30 to 40%, and the optimum value of 36 to 40% is suitable.

巻上げたコイルに一方向又は垂直、水平に方向を押し圧する事で変形できる線材の選択と加熱すれば種種のコイル製造に適用できる、又本発明の製造方法で製作したコイルは大きなインダクタンス及び低抵抗を得ることが出来、電子、電気機器の性能向上、小型化に活用できる。   Selection of wire that can be deformed by pressing the coiled coil in one direction or vertically and horizontally, and heating can be applied to various types of coil manufacturing. The coil manufactured by the manufacturing method of the present invention has large inductance and low resistance. Can be used to improve the performance and miniaturization of electronic and electrical equipment.

本発明の製造方法で製作したコイルの断面図。Sectional drawing of the coil manufactured with the manufacturing method of this invention. 完全整列巻きの断面図。Sectional drawing of fully aligned winding. エッジワイズ巻きの断面図。Sectional drawing of edgewise winding. 真四角線整列巻きの断面図。Sectional drawing of a true square line alignment winding.

符号の説明Explanation of symbols

１ 押し圧後の線
２ 丸銅線
３ 空隙部分
４ 平角線
５ 真四角銅線
1 Wire after pressing 2 Round copper wire 3 Void part 4 Flat wire 5 True copper wire

Claims (3)

融着被覆、絶縁被覆を持つ丸銅線（以降丸銅線と言う）を空芯で巻いたコイルの製造方法において、伸び率３０〜４０％の丸銅線を用い空芯で巻上げた後、コイルを通電加熱し、通電停止後一方向又は垂直、水平二方向を押し圧しコイルの占積率を９１％以上にした事を特徴とする高密度コイルの製造方法。   In a method of manufacturing a coil in which a round copper wire (hereinafter referred to as a round copper wire) having a fusion coating and an insulation coating is wound with an air core, after winding with an air core using a round copper wire with an elongation of 30 to 40%, A method for producing a high-density coil, wherein the coil is energized and heated and pressed in one direction or two vertical and horizontal directions after energization is stopped, so that the space factor of the coil is 91% or more. 伸び率３０〜４０％の丸銅線を用い空芯で巻上げた後、加熱した金型に装着し一方向又は垂直、水平二方向を押し圧しコイルの占積率を９１％以上にした事を特徴とする高密度コイルの製造方法。   After winding with an air core using a round copper wire with an elongation of 30 to 40%, it was mounted on a heated mold and pressed in one direction, vertical or horizontal direction to make the coil space factor 91% or more. A method for producing a high-density coil, which is characterized. 伸び率３０〜４０％の丸銅線を用い空芯で巻上げた後、赤外線又は熱風加熱後一方向又は垂直、水平二方向を押し圧しコイルの占積率を９１％以上にした事を特徴とする高密度コイルの製造方法。
After winding with an air core using a round copper wire with an elongation of 30 to 40%, after heating with infrared rays or hot air, pressing in one direction or vertical and two horizontal directions to make the coil space factor 91% or more A method for manufacturing a high-density coil.