JPH03148812A - Manufacture of flat coil - Google Patents
Manufacture of flat coilInfo
- Publication number
- JPH03148812A JPH03148812A JP28756589A JP28756589A JPH03148812A JP H03148812 A JPH03148812 A JP H03148812A JP 28756589 A JP28756589 A JP 28756589A JP 28756589 A JP28756589 A JP 28756589A JP H03148812 A JPH03148812 A JP H03148812A
- Authority
- JP
- Japan
- Prior art keywords
- cut
- insulating layer
- wound
- flat coil
- manufacture
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 20
- 239000011888 foil Substances 0.000 claims abstract description 43
- 238000000034 method Methods 0.000 claims abstract description 16
- 239000006061 abrasive grain Substances 0.000 claims abstract description 12
- 229910052751 metal Inorganic materials 0.000 claims description 42
- 239000002184 metal Substances 0.000 claims description 42
- 238000005520 cutting process Methods 0.000 claims description 13
- 230000005514 two-phase flow Effects 0.000 claims description 11
- 238000004804 winding Methods 0.000 claims description 5
- 230000007547 defect Effects 0.000 abstract description 9
- 238000009413 insulation Methods 0.000 abstract description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 abstract description 2
- 229910052782 aluminium Inorganic materials 0.000 abstract description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 abstract description 2
- 229910052802 copper Inorganic materials 0.000 abstract description 2
- 239000010949 copper Substances 0.000 abstract description 2
- 239000002985 plastic film Substances 0.000 abstract description 2
- 229920006255 plastic film Polymers 0.000 abstract description 2
- 239000007767 bonding agent Substances 0.000 abstract 2
- 239000007788 liquid Substances 0.000 abstract 2
- 239000007787 solid Substances 0.000 abstract 2
- 230000002950 deficient Effects 0.000 abstract 1
- 239000007789 gas Substances 0.000 description 18
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 238000005530 etching Methods 0.000 description 3
- 239000011810 insulating material Substances 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 241000252233 Cyprinus carpio Species 0.000 description 2
- 238000009760 electrical discharge machining Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 238000002791 soaking Methods 0.000 description 2
- FGRBYDKOBBBPOI-UHFFFAOYSA-N 10,10-dioxo-2-[4-(N-phenylanilino)phenyl]thioxanthen-9-one Chemical compound O=C1c2ccccc2S(=O)(=O)c2ccc(cc12)-c1ccc(cc1)N(c1ccccc1)c1ccccc1 FGRBYDKOBBBPOI-UHFFFAOYSA-N 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Landscapes
- Manufacture Of Motors, Generators (AREA)
Abstract
Description
〔産業上の利用分野〕
本発明は、モータ、偏向ヨーク、トランス等に使用され
るフラットコイルの製造方法に関するものであり、特に
金属箔の巻回体の切断面に遊離砥粒と気体の固気２相流
を噴射して加工するフラットコイルの製造方法に関する
ものである。
（発明の概要］
本発明は、絶縁層を被着形成した金属箔を圧着−しなが
ら中心軸に巻回し金属箔の巻回体を作成し、該巻回体を
前記中心軸と直交する方向で所定の厚さに切断し、該切
断された巻回体の切断面に遊離砥粒と気体の固気２相流
を噴射することにより、絶縁層は弾性があるため加工性
が悪く、従って切断面において絶縁層が金属箔よりもや
や突出した状態となり、金属箔間の絶縁が保たれ、信顛
性の高いフラットコイルを生産性良く製造する。
〔従来の技術〕
従来、絶縁層を被着形成した金属箔を圧着しながら中心
軸に巻回し金属箔の巻回体を作成し、該巻回体を前記中
心軸と直交する方向で放電加工法により所定の厚さに切
断し、フラットコイルを作製するという考え方が特開昭
６２−２９０１１６に提案されている。ｌ！縁層を被着
形成した金属箔の巻回体を放電加工法により切断すると
、その切断面において絶縁層が金属箔よりもやや突出し
た状態となり、金属箔間の絶縁が保たれ、金属箔間の短
絡等の不良の発生が抑えられた。しかし、放電加工法に
よれば、金属箔の巻回体をまとめて同時に切断できるも
のの、その切断加工時間が大幅に掛かり、放電加工機等
の設備費も高くなる問題点があった。
そこで他の従来の製造方法として、機械的切断手段であ
るスライサを用いて切断すると、切断面の金属箔が第３
図に示すようにダして金属箔間の絶縁層が薄くなり、金
属箔間が短絡する不良が発生する問題点があった。同図
において、ｌはフラットコイル、２１よ金属箔、３は絶
縁物、ｌａは切断面を示し、矢印は切断方向を示す。そ
こでダした部分をエッチング液に浸けて落とす工程が必
要になった。所がこのようなダした部分をエッチング液
に浸けて落とすのでは、膨大な加工時間を必要とすると
共に、金属箔間の短絡不良の発生を完全に防止できない
ことから、とても量産に向かなかった。
［発明が解決しようとする課題］
以上のように、金属箔の巻回体を放電加工法により切断
したり、又はスライサを用いて切断した−後、ダした部
分をエッチング液に浸けて落としてフラットコイルを作
製しようとした場合、膨大な加工時間を必要とし、量産
化が困難であった。しかも、金属箔間の短絡不良の発生
を完全に防止できないため信頼性に欠ける問題点があっ
た。
本発明は、これらの従来の問題点を解消するためになさ
れたものであって、金属箔間の短絡等の不良が発生する
ことなく、信頼性の高いフラットコイルを生産性良く製
造することを課題とする。[Industrial Application Field] The present invention relates to a method for manufacturing flat coils used in motors, deflection yokes, transformers, etc., and in particular, the present invention relates to a method for manufacturing flat coils used in motors, deflection yokes, transformers, etc. The present invention relates to a method for manufacturing a flat coil that is processed by injecting a gas two-phase flow. (Summary of the Invention) The present invention involves creating a wound body of metal foil by winding a metal foil on which an insulating layer is adhered and formed around a central axis while crimping it, and rolling the wound body in a direction perpendicular to the central axis. By cutting the wound body into a predetermined thickness with At the cut surface, the insulating layer protrudes slightly beyond the metal foil, maintaining insulation between the metal foils, and producing highly reliable flat coils with high productivity. [Conventional technology] Conventionally, the insulating layer was covered with The formed metal foil is wound around a central axis while being crimped to create a rolled body of metal foil, and the rolled body is cut to a predetermined thickness by electric discharge machining in a direction perpendicular to the central axis, and then flattened. The idea of producing a coil is proposed in JP-A-62-290116.l! When a wound body of metal foil with an edge layer adhered thereon is cut by electrical discharge machining, the insulating layer becomes metal at the cut surface. The metal foils protrude slightly from each other, maintaining insulation between the metal foils and preventing defects such as short circuits between the metal foils.However, according to the electric discharge machining method, the rolled body of metal foils cannot be assembled Although it is possible to cut at the same time, there are problems in that the cutting process takes a long time and the cost of equipment such as electric discharge machines increases.Therefore, as another conventional manufacturing method, a slicer, which is a mechanical cutting means, has been used. When cutting, the metal foil on the cut surface becomes the third
As shown in the figure, the insulating layer between the metal foils became thinner, resulting in problems such as short circuits between the metal foils. In the figure, l indicates a flat coil, 21 indicates a metal foil, 3 indicates an insulator, la indicates a cutting surface, and an arrow indicates a cutting direction. Therefore, it became necessary to remove the removed parts by soaking them in an etching solution. However, removing such rough parts by soaking them in etching solution requires a huge amount of processing time, and it is not possible to completely prevent short circuits between the metal foils, making it extremely unsuitable for mass production. Ta. [Problems to be Solved by the Invention] As described above, after cutting a rolled body of metal foil by electrical discharge machining or cutting it using a slicer, the cut portion is immersed in an etching solution and removed. When attempting to produce a flat coil, a huge amount of processing time is required, making mass production difficult. Furthermore, since the occurrence of short-circuit defects between metal foils cannot be completely prevented, there is a problem of lack of reliability. The present invention was made to solve these conventional problems, and it is possible to manufacture highly reliable flat coils with high productivity without causing defects such as short circuits between metal foils. Take it as a challenge.
本発明のフラットコイルの製造方法では、絶縁層を被着
形成した金属箔を圧着しながら中心軸に巻回し金属箔壱
同体を作成する工程と、前記巻回体を前記中心軸と直交
する方向で所定の厚さに切断する工程と、前記切断され
た巻回体の切断面に遊離砥粒と気体の固気２相流を噴射
する工程とを有することを特徴とする特
＊作用〕
切断された巻回体の切断面に遊離砥粒と気体の固気２相
流を噴射して加工することにより、ゴムやプラスチック
等の絶縁物からできている絶縁層は弾性があるために加
工性が悪く、金属は固いため良好な加工性があり、従っ
て前記切断面において絶縁層が金属箔よりもやや突出し
た状態に加工されることになり、金属箔間の絶縁が保た
れ、短絡等の不良の発生が防止できる。
しかも、遊離砥粒と気体の固気２相流を噴射して加工す
る方法は、加工効率が非常に良いので、生産性が飛躍的
に向上する。
〔実施例〕
本発明は、遊離砥粒と気体の固気２相流を噴射してフラ
ットコイルの助断面の加工を行うもので、このような遊
離砥粒噴射式加工装置は、本出願人が特願平０１−１１
１１０１及び特願平Ｏｆ−１７１７１０テ既に出願して
いる。
以下、本発明によるフラットコイルの製造方法を実施例
により説明する。
フラットコイルｌを製造するには、先ず、第１図（Ａ）
に示すように、銅やアルミニウムからからなる金属箔２
にプラスチックフィルムからなる絶縁層３を接着剤４を
介して接着し、絶縁層３の上には、更に接着剤５をラミ
ネニトシて、積層体亙を得ている。前記金属箔２の厚さ
は、数ｐｍから数１０＃ｍの薄膜を用いる。
続いて第１図（Ｂ）に示すように、断面略三角形の中心
軸７に積層体旦を圧着しながら巻き付け、金属箔２の巻
回体ｌを得る。巻回体工は前記接着剤４．５により接着
固定される。壱回体工の巻回数は、通常数ターンから数
百ターンまでである。
また、前記中心軸７の形状は、必要なコイルの形状に合
わせて変更すればよく、円形、楕円形、四角形、多角形
等、種々の形状を選定することができる。
次に第１図（Ｃ）に示すように、巻回体工を前記中心軸
７と直交する方向で、例えは機械的切断手段であるスラ
イサを用いて切断して、フラットコイルｌを得る。中心
軸７は図示のように付けたまま切断しても、取り外して
から切断してもよい。
第１図（Ｄ）はフラットコイルｌの外観形状を示す。
例えば機械的切断手段であるスライサを用いて切断する
と、従来の技術の所で第３図を使って説明したように、
金属箔２のダした部分が発生する。
金属箔２がダレると金属箔２間の絶縁層３が藩くなり、
金属箔２間が短絡する不良の発生の原因となる。
そこで切断された巻同体主、耶ちフラットコイルｌの両
切断面１ａ、■ｂに、第１図（Ｅ）に示すように、噴射
ノズル９から１−１０μｍ程度の粒径のＡＩｌ□ｏ！、
Ｓｉｆｔ、ＳｉＣ％ＳｉｚＮｎ等の遊離砥粒と１ ＝
１０ ｋｇ ／ ｃｄ程度の高圧の気体の混合流である
固気２相流ｌＯを噴射する。遊離砥粒と気体の固気２相
流１０を噴射して加工する方法では、ゴムやプラスチッ
ク等の絶縁物からできている絶縁層３は弾性があるため
に加工性が悪く、金属は固いため良好の加工性があり、
従って、第２図に示すように、前記切断面１ａ、１ｂに
おいて絶縁層３−が金属箔２よりもやや突出した状態に
加工されることになり、金属箔２間の絶縁が保たれ、短
絡等の不良の発生が防止できる。
〔発明の効果〕
本発明のフラットコイルの製造方法では、切断された巻
回体の切断面に遊離砥粒と気体の固気２相流を噴射して
加工することにより、ゴムやプラスチック等の絶縁物か
らなる絶縁層は弾性があるために加工性が悪く、金属は
固いため良好な加工性があり、従って前記切断面におい
て絶縁層が金属箔よりもやや突出した状態に加工される
ことになり、金属箔間の絶縁が保たれ、短絡等の不良の
発生が防止できる。
しかも、遊離砥粒と気体の固気２相流を噴射して加工す
る方法は、加工効率が非常に良いので、生産性が飛躍的
に向上する。The method for manufacturing a flat coil of the present invention includes the steps of: creating a metal foil body by winding a metal foil on which an insulating layer is adhered around a central axis while pressing the metal foil, and rolling the wound body in a direction perpendicular to the central axis. A special function characterized by comprising the steps of: cutting the wound body to a predetermined thickness; and injecting a solid-gas two-phase flow of free abrasive grains and gas onto the cut surface of the cut wound body. By injecting a solid-gas two-phase flow of free abrasive grains and gas onto the cut surface of the rolled body, the insulating layer made of insulating materials such as rubber and plastic has elasticity, making it easy to process. Since the metal is hard, it has good workability, so the insulating layer is processed to be slightly more protruding than the metal foil at the cut surface, and the insulation between the metal foils is maintained and short circuits etc. The occurrence of defects can be prevented. Moreover, the method of processing by injecting a solid-gas two-phase flow of free abrasive grains and gas has very high processing efficiency, so productivity is dramatically improved. [Example] The present invention processes a auxiliary section of a flat coil by injecting a solid-gas two-phase flow of free abrasive grains and gas. Patent application: Hei 01-11
1101 and Japanese Patent Application No. 171710 have already been filed. Hereinafter, the method for manufacturing a flat coil according to the present invention will be explained using examples. To manufacture the flat coil l, first, as shown in Fig. 1 (A)
As shown in the figure, metal foil 2 made of copper or aluminum
An insulating layer 3 made of a plastic film is adhered to the insulating layer 3 via an adhesive 4, and an adhesive 5 is further applied on the insulating layer 3 to obtain a laminate. The thickness of the metal foil 2 used is a thin film ranging from several pm to several 10 #m. Subsequently, as shown in FIG. 1(B), the laminate is wound around the central axis 7 having a substantially triangular cross section while being pressed, thereby obtaining a rolled body 1 of the metal foil 2. The winding structure is adhesively fixed with the adhesive 4.5. The number of turns of Ichikaitaikou is usually from a few turns to several hundred turns. Further, the shape of the central axis 7 may be changed according to the shape of the required coil, and various shapes such as a circle, an ellipse, a quadrangle, and a polygon can be selected. Next, as shown in FIG. 1C, the wound body is cut in a direction perpendicular to the central axis 7 using, for example, a slicer, which is a mechanical cutting means, to obtain a flat coil I. The central shaft 7 may be cut while attached as shown, or may be removed and then cut. FIG. 1(D) shows the external shape of the flat coil l. For example, when cutting using a slicer, which is a mechanical cutting means, as explained using FIG. 3 in the conventional technology section,
A dull portion of the metal foil 2 occurs. When the metal foil 2 sag, the insulating layer 3 between the metal foils 2 becomes dry.
This may cause a defect such as a short circuit between the metal foils 2. As shown in FIG. 1(E), AIl□o! having a particle size of about 1 to 10 μm is sprayed from the injection nozzle 9 on both cut surfaces 1a and 1b of the main flat coil l that was cut there. ,
Sift, free abrasive grains such as SiC%SizNn and 1 =
A solid-gas two-phase flow IO, which is a mixed flow of gases at a high pressure of about 10 kg/cd, is injected. In the method of processing by injecting a solid-gas two-phase flow 10 of free abrasive grains and gas, the insulating layer 3 made of an insulating material such as rubber or plastic is elastic and has poor workability, while metal is hard. It has good workability,
Therefore, as shown in FIG. 2, the insulating layer 3- is processed to be slightly protruding from the metal foil 2 on the cut surfaces 1a and 1b, so that the insulation between the metal foils 2 is maintained and short circuits occur. It is possible to prevent the occurrence of defects such as [Effects of the Invention] In the method for manufacturing a flat coil of the present invention, a solid-air two-phase flow of free abrasive grains and gas is injected onto the cut surface of the cut winding body to process it, thereby removing rubber, plastic, etc. The insulating layer made of an insulating material has poor workability due to its elasticity, while metal has good workability due to its hardness. Therefore, the insulating layer is processed into a state in which it protrudes slightly more than the metal foil at the cut surface. This maintains the insulation between the metal foils and prevents defects such as short circuits. Moreover, the method of processing by injecting a solid-gas two-phase flow of free abrasive grains and gas has very high processing efficiency, so productivity is dramatically improved.
第１図（Ａ）乃至第１図（Ｅ）は本発明のフラットコイ
ルの製造方法の説明図である。第２図は本発明のフラッ
トコイルの切断面の拡大断面図である。 第３図は従来
のフラットコイルの切断面の拡大断面図である。
１−−−−−−−−・−一一−−−−フラットコイルＩ
ａ、 ｌｔｔ−−−−−−一切断面
２−−−−−−−−−−−−−−一金属箔３−−−−−
−−−−−−−−・−絶縁層４．５−−−−−−−−一
接着剤
一彫一−−−・−−−−・−−−〜−・積層体？−−−
−−−−−−−−−・−中心軸８−−−−−−−−−−
−−−−−−一巻回体９−−−−−−−−−−−−−−
−一噴射ノズル１０−−−−−−−−−−−−−−−−
一遊離砥粒と気体の固気２相流０【
ａ積層木
第１１２（Ａ） 本発明のフラットコイルの製造方
法の１１図（Ｂ） 不覚明のフラットコイｌしの製造
方法の８免明図
第１図（Ｃ） 木兄明のフラットコイＪしの製造方法の
９噴村ノズル
１ ″ｆｍａフラ１ントコイＪし
ｔｙ＋断面
拡大断面図FIG. 1(A) to FIG. 1(E) are explanatory diagrams of the method for manufacturing a flat coil of the present invention. FIG. 2 is an enlarged sectional view of the cut surface of the flat coil of the present invention. FIG. 3 is an enlarged sectional view of a cut surface of a conventional flat coil. 1--------------・-11----Flat coil I
a.
−−−−−−−−・−Insulating layer 4.5−−−−−−−−One adhesive one carving−−−・−−−−・−−−～−・Laminated body? ---
−−−−−−−−−・−Center axis 8−−−−−−−−−−
−−−−−−One roll body 9−−−−−−−−−−−−−
−One injection nozzle 10−−−−−−−−−−−−−−−−
- Solid-gas two-phase flow of free abrasive grains and gas 0 [a Laminated wood No. 112 (A) Figure 11 (B) of the method of manufacturing a flat coil of the present invention 8 Illustration of the method of manufacturing an unknown flat coil Figure 1 (C) 9 Fumimura nozzle 1 ″fma flat carp J type + cross-sectional enlarged cross-sectional view of Akira Kinie's flat carp J type manufacturing method
Claims (1)
巻回し金属箔の巻回体を作成する工程と、前記巻回体を
前記中心軸と直交する方向で所定の厚さに切断する工程
と、 前記切断された巻回体の切断面に遊離砥粒と気体の固気
２相流を噴射する工程とを有することを特徴とするフラ
ットコイルの製造方法。[Claims] A step of creating a wound body of metal foil by winding the metal foil on which an insulating layer has been deposited around a central axis while being crimped; and a step of forming a wound body of metal foil in a predetermined direction perpendicular to the central axis. 1. A method for manufacturing a flat coil, comprising: cutting the wound body into a thickness of 100 mm, and injecting a solid-gas two-phase flow of free abrasive grains and gas onto the cut surface of the cut wound body.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP28756589A JPH03148812A (en) | 1989-11-06 | 1989-11-06 | Manufacture of flat coil |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP28756589A JPH03148812A (en) | 1989-11-06 | 1989-11-06 | Manufacture of flat coil |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH03148812A true JPH03148812A (en) | 1991-06-25 |
Family
ID=17718987
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP28756589A Pending JPH03148812A (en) | 1989-11-06 | 1989-11-06 | Manufacture of flat coil |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH03148812A (en) |
-
1989
- 1989-11-06 JP JP28756589A patent/JPH03148812A/en active Pending
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