TWI849619B - Method for forming magnetic element winding - Google Patents
Method for forming magnetic element winding Download PDFInfo
- Publication number
- TWI849619B TWI849619B TW111147939A TW111147939A TWI849619B TW I849619 B TWI849619 B TW I849619B TW 111147939 A TW111147939 A TW 111147939A TW 111147939 A TW111147939 A TW 111147939A TW I849619 B TWI849619 B TW I849619B
- Authority
- TW
- Taiwan
- Prior art keywords
- winding
- wire
- magnetic element
- coils
- turns
- Prior art date
Links
- 238000004804 winding Methods 0.000 title claims abstract description 118
- 238000000034 method Methods 0.000 title claims abstract description 31
- 238000007493 shaping process Methods 0.000 claims abstract description 11
- 239000003292 glue Substances 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 7
- 239000002390 adhesive tape Substances 0.000 claims description 2
- 238000010586 diagram Methods 0.000 description 11
- 238000007796 conventional method Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000011265 semifinished product Substances 0.000 description 1
Abstract
一種磁性元件繞組的成形方法，首先提供一繞線架，續以一線材對該繞線架進行複數匝基礎線圈的繞製，該線材兩末端每一到繞成該些基礎線圈部份的線段長度大於該線材進行複數匝線圈繞製的長度。再以該線材上接連該基礎線圈兩端的二線段分別續行所述複數匝線圈的繞製，完成一磁性元件繞組。此後，對該磁性元件繞組實施定型作業，並移除該繞線架。該磁性元件繞組具有二出線末端，該二出線末端均是由所述複數線圈中位於最外側者延伸形成。 A method for forming a magnetic element winding, first providing a winding frame, and then using a wire to wind a plurality of turns of basic coils on the winding frame, wherein the length of each wire segment at both ends of the wire that winds the basic coils is greater than the length of the wire for winding the plurality of turns of coils. Then, two wire segments connected to the two ends of the basic coil on the wire are used to respectively wind the plurality of turns of coils, thereby completing a magnetic element winding. Thereafter, the magnetic element winding is subjected to a shaping operation, and the winding frame is removed. The magnetic element winding has two outgoing wire ends, and the two outgoing wire ends are both formed by extending from the outermost of the plurality of coils.
Description
本發明涉及一種磁性元件繞組的成形方法，尤指一種令磁性元件繞組二出線末端均是由複數線圈中位於最外側者延伸形成的成形方法。 The present invention relates to a forming method for a magnetic element winding, and in particular to a forming method in which the two outgoing wire ends of the magnetic element winding are both formed by extending the outermost coils among a plurality of coils.
繞組為磁性元件的重要組成之一，撇除現今以積體電路實施的方案，繞組主要有二實施方案，其一為直接纏繞於繞線架上，其二為一部件(線餅)型態參與該磁性元件的組構。前述二實施方案的任一於該繞組的繞製上，均是以一線材靠近一末端的部份對一繞線架進行起繞，起繞後僅是沿同一方向不停纏繞，待纏繞圈數(即繞線匝數)達到設定時，停止續繞，剪去該線材的部份後，以該線材二端作為二出線末端。 The winding is one of the important components of the magnetic element. Apart from the current integrated circuit implementation, there are two main implementation schemes for the winding. One is to directly wind it on the winding frame, and the other is to participate in the structure of the magnetic element in the form of a component (coil cake). In the winding of the winding of either of the above two implementation schemes, a portion of a wire close to one end is wound around a winding frame. After winding, it is only wound continuously in the same direction. When the number of winding turns (i.e. the number of winding turns) reaches the setting, the winding is stopped, and after cutting off part of the wire, the two ends of the wire are used as the two outlet ends.
然而，當前繞製手法使該二出線末端其中之一是由該繞組的內圈出線(如圖1所繪的50)，而使該繞組存在因內圈出線部份調整位置所產生的重疊，前述重疊的部份的高度至少為該線材線徑，進而影響該磁性元件的功率密度，不符當前的研發趨勢。 However, the current winding method makes one of the two wire ends be the inner wire of the winding (as shown in 50 in FIG. 1 ), which causes the winding to overlap due to the adjustment of the position of the inner wire portion. The height of the overlapping portion is at least the wire diameter of the wire, which in turn affects the power density of the magnetic component and is inconsistent with the current research and development trend.
本發明的主要目的，在於解決現有磁性元件繞組成形方法所衍生的後續實施問題。 The main purpose of the present invention is to solve the subsequent implementation problems derived from the existing magnetic element winding forming method.
為達上述目的，本發明提供一種磁性元件繞組的成形方法，包含以下步驟：步驟一：提供一繞線架；步驟二：以一線材對該繞線架進行複數匝基礎線圈的繞製，該線材兩末端每一到繞成該些基礎線圈部份的線段長度大於該線材進行複數匝線圈繞製的長度； 步驟三：以該線材上接連該基礎線圈兩端的二線段分別續行所述複數匝線圈的繞製，完成一磁性元件繞組，該磁性元件繞組具有二出線末端，該二出線末端均是由所述複數線圈中位於最外側者延伸形成；以及步驟四：對該磁性元件繞組實施定型作業，並移除該繞線架。 To achieve the above-mentioned purpose, the present invention provides a method for forming a magnetic element winding, comprising the following steps: Step 1: providing a winding frame; Step 2: using a wire to wind a plurality of turns of basic coils on the winding frame, the length of each wire segment at both ends of the wire that winds the basic coils is greater than the length of the wire for winding the plurality of turns of coils; Step 3: using two wire segments connected to the two ends of the basic coil on the wire to respectively continue winding the plurality of turns of coils, completing a magnetic element winding, the magnetic element winding having two outgoing wire ends, the two outgoing wire ends are both formed by extending from the outermost of the plurality of coils; and Step 4: performing a shaping operation on the magnetic element winding, and removing the winding frame.
一實施例中，於該步驟三中，先以該二線段其中之一進行複數匝線圈的繞製並形成一第一部份，再以該二線段其中另一以該第一部份為基礎進行剩餘所述複數匝線圈的繞製並形成一與該第一部份相疊的第二部份，該二出線末端分別由該第一部份與該第二部份中最外側者延伸形成。 In one embodiment, in step three, one of the two wire segments is first used to wind a plurality of turns of coils to form a first portion, and then the other of the two wire segments is used to wind the remaining plurality of turns of coils based on the first portion to form a second portion overlapping the first portion, and the two outgoing wire ends are formed by extending from the outermost of the first portion and the second portion, respectively.
一實施例中，於該步驟二中，以該線材非屬末端的一部份作為一起繞處，並分別以該線材上鄰接該起繞處的二部份續行該些基礎線圈的繞製，該二部份繞成的線圈匝數不同。 In one embodiment, in the second step, a portion of the wire that is not the end is used as a winding point, and two portions of the wire adjacent to the winding point are used to continue winding the basic coils, and the number of turns of the coils wound by the two portions is different.
一實施例中，該線材包含一金屬內芯以及一披覆該金屬內芯外的可熱熔外皮。 In one embodiment, the wire comprises a metal inner core and a heat-fusible outer skin covering the metal inner core.
一實施例中，該定型作業以點膠實施。 In one embodiment, the shaping operation is performed by dispensing glue.
一實施例中，該定型作業以纏上膠帶實施。 In one embodiment, the shaping operation is performed by wrapping an adhesive tape.
透過本發明前述實施，相較於習用具有以下特點：本發明方法繞線初始產生的該些基礎線圈助於後續該些線圈的續繞，使整體繞線步驟簡易。本發明透過前述方法，繞成後的該磁性元件繞組不再因內圈出線部份調整位置所產生重疊該些線圈的部份，而不再影響應用該磁性元件繞組的一磁性元件的功率密度。 Through the aforementioned implementation of the present invention, compared with the conventional method, the following characteristics are achieved: the basic coils initially generated by the winding method of the present invention help to continue winding the coils, making the overall winding steps simple. Through the aforementioned method, the magnetic element winding after winding no longer overlaps the coils due to the position adjustment of the inner coil outlet part, and no longer affects the power density of a magnetic element using the magnetic element winding.
20:磁性元件繞組 20: Magnetic element winding
21:出線末端 21: Outgoing line end
22:線圈 22: Coil
23:基礎線圈 23: Basic coil
241:第一部份 241: Part 1
242:第二部份 242: Part 2
30:方法 30: Methods
31:步驟一 31: Step 1
32:步驟二 32: Step 2
33:步驟三 33: Step 3
34:步驟四 34: Step 4
40:繞線架 40: Winding rack
41:線材 41: Wires
411:金屬內芯 411:Metal core
412:可熱熔外皮 412: Hot meltable outer skin
42:線段 42: Line segment
50:重疊部份 50: Overlapping part
60:點膠處 60: Glue point
61:膠帶 61: Tape
圖1，習用磁性元件繞組的結構示意圖。 Figure 1, schematic diagram of the structure of the commonly used magnetic element winding.
圖2，本發明一實施例磁性元件繞組的結構示意圖。 Figure 2 is a schematic diagram of the structure of the magnetic element winding of an embodiment of the present invention.
圖3，本發明一實施例磁性元件繞組的成形方法的步驟示意圖。 Figure 3 is a schematic diagram of the steps of the method for forming a magnetic element winding according to an embodiment of the present invention.
圖4，本發明一實施例磁性元件繞組的成形方法的實施示意圖(一)。 Figure 4 is a schematic diagram of the implementation method of the magnetic element winding forming method of an embodiment of the present invention (I).
圖5，本發明一實施例磁性元件繞組的成形方法的實施示意圖(二)。 Figure 5 is a schematic diagram of the implementation method of the magnetic element winding forming method of an embodiment of the present invention (II).
圖6，本發明一實施例磁性元件繞組的成形方法的實施示意圖(三)。 Figure 6, schematic diagram of the implementation method of the magnetic element winding forming method of an embodiment of the present invention (III).
圖7，本發明另一實施例磁性元件繞組的成形方法的步驟示意圖。 Figure 7 is a schematic diagram of the steps of forming a magnetic element winding according to another embodiment of the present invention.
圖8，本發明一實施例磁性元件繞組所用線材的剖面結構示意圖。 Figure 8 is a schematic diagram of the cross-sectional structure of the wire used in the magnetic element winding of an embodiment of the present invention.
圖9，本發明另一實施例磁性元件繞組的結構示意圖。 Figure 9 is a schematic diagram of the structure of the magnetic element winding of another embodiment of the present invention.
圖10，本發明再一實施例磁性元件繞組的結構示意圖。 Figure 10 is a schematic diagram of the structure of a magnetic element winding in another embodiment of the present invention.
本發明詳細說明及技術內容，茲配合圖式說明如下： The detailed description and technical contents of this invention are as follows with the help of diagrams:
請參閱圖2，本發明提供一種磁性元件繞組20，該磁性元件繞組20特徵在於：該磁性元件繞組20的二出線末端21均是由該磁性元件繞組20所包含複數線圈22中位於最外側者延伸形成。本發明該磁性元件繞組20不具備由該磁性元件繞組20內圈出線的部份，使該磁性元件繞組20不再因內圈出線部份調整位置所產生重疊該些線圈22的部份，而不再影響應用該磁性元件繞組20的一磁性元件的功率密度。另一方面，本發明該磁性元件繞組20可為用以組構成該磁性元件的一獨立部件(如圖1所繪，業界稱為線餅)，又或者該磁性元件繞組20可為一變壓器於繞製過程中產生的一繞組。 Please refer to FIG. 2 . The present invention provides a magnetic element winding 20. The magnetic element winding 20 is characterized in that: the two outgoing wire ends 21 of the magnetic element winding 20 are formed by extending from the outermost of the plurality of coils 22 included in the magnetic element winding 20. The magnetic element winding 20 of the present invention does not have a portion of the outgoing wire from the inner coil of the magnetic element winding 20, so that the magnetic element winding 20 no longer overlaps the coils 22 due to the position adjustment of the inner coil outgoing wire portion, and no longer affects the power density of a magnetic element using the magnetic element winding 20. On the other hand, the magnetic element winding 20 of the present invention can be an independent component (as shown in FIG. 1 , referred to as a coil in the industry) used to form the magnetic element, or the magnetic element winding 20 can be a winding generated during the winding process of a transformer.
併請參閱圖2、圖3以及圖4，為製成前述該磁性元件繞組20，本發明亦提供一種磁性元件繞組的成形方法30，包含以下步驟：步驟一31，提供一繞線架40；步驟二32：以一線材41對該繞線架40進行複數匝基礎線圈23的繞製，該線材41兩末端每一到繞成該些基礎線圈23部份的線段長度大於該線材41進行複數匝線圈22繞製的長度；以及步驟三33：以該線材41上接連該些基礎線圈23兩端的二線段42分別續行所述複數匝線圈22的繞製，以完成該磁性元件繞組20，該磁性元件繞 組20具有該二出線末端21，該二出線末端21均是由所述複數匝線圈22中位於最外側者延伸形成。 Referring to FIG. 2, FIG. 3 and FIG. 4, in order to manufacture the magnetic element winding 20, the present invention also provides a method 30 for forming a magnetic element winding, comprising the following steps: Step 1 31, providing a winding frame 40; Step 2 32: using a wire 41 to wind a plurality of turns of a basic coil 23 on the winding frame 40, wherein the length of each of the two ends of the wire 41 to wind the basic coils 23 is greater than The length of the wire 41 for winding the multiple turns of the coil 22; and step three 33: using two wire segments 42 on the wire 41 connected to the two ends of the basic coils 23 to respectively continue winding the multiple turns of the coil 22 to complete the magnetic element winding 20, the magnetic element winding 20 has the two outgoing wire ends 21, and the two outgoing wire ends 21 are formed by extending from the outermost of the multiple turns of the coil 22.
進一步說明，該繞線架40可根據實施需求選用適當形式，該繞線架40可為一變壓器線架實施，又或者是可於該磁性元件繞組20製成後可分離者。另一方面，該線材41可為一漆包線、一多層絕緣線等。 To further explain, the winding frame 40 can be selected in an appropriate form according to the implementation requirements. The winding frame 40 can be implemented as a transformer winding frame, or can be separated after the magnetic element winding 20 is manufactured. On the other hand, the wire 41 can be an enameled wire, a multi-layer insulated wire, etc.
復請參閱圖3及圖4，於該步驟二32中，該線材41以非屬末端的一部份作為起繞處，進一步來說，該線材41起繞後所保留的線段長度並非僅作為該二出線末端21其中一者，而仍可進行一定匝數的繞製。於一實施例中，該步驟二32實施過程中，以該線材41上鄰接該起繞處的二部份進行該些基礎線圈23的繞製，該二部份繞成的線圈匝數不同，舉例來說，該二部份其中之一繞一匝，該二部份其中另一繞二匝。再者，本文前指該二部份為該線材41不可分割者，該二部份完成繞製後剩餘的線段將續行該步驟三33的實施，也就是說，該線材41完成該些基礎線圈23的繞製後，該線材41兩末端每一到繞成該些基礎線圈23部份的線段長度將大於該線材41進行複數匝線圈22繞製的長度，前述該線材41兩末端每一到繞成該些基礎線圈23的部份相當於前述該二部份完成繞製後剩餘的線段。此外，前述該二部份進行該些基礎線圈23繞製的過程中，該二部份其中之一繞成的該些基礎線圈23的至少其中之一將沿該繞線架40疊於該二部份其中另一繞成的該些基礎線圈23的至少其中之一上。 Please refer to FIG. 3 and FIG. 4 again. In step 2 32, the wire 41 uses a portion other than the end as the winding starting point. Specifically, the length of the wire segment retained after the winding of the wire 41 is not only used as one of the two outgoing wire ends 21, but can still be wound with a certain number of turns. In one embodiment, during the implementation of step 2 32, the basic coils 23 are wound with two portions of the wire 41 adjacent to the winding starting point. The coils wound with the two portions have different numbers of turns. For example, one of the two portions is wound with one turn, and the other of the two portions is wound with two turns. Furthermore, the two parts referred to in this article are inseparable from the wire 41. After the two parts are wound, the remaining line segments will continue to implement the step three 33. That is to say, after the wire 41 completes the winding of the basic coils 23, the length of the line segments of each of the two ends of the wire 41 that are wound around the basic coils 23 will be greater than the length of the wire 41 that is wound around multiple turns of coils 22. The aforementioned parts of each of the two ends of the wire 41 that are wound around the basic coils 23 are equivalent to the remaining line segments after the two parts are wound. In addition, during the process of winding the basic coils 23 by the two parts, at least one of the basic coils 23 wound by one of the two parts will be overlapped on at least one of the basic coils 23 wound by the other of the two parts along the winding frame 40.
復請參閱圖3、圖5及圖6，該步驟二32完成後，續行該步驟三33的實施。以該線材41上接連該些基礎線圈23兩端的該二線段42(即前述該二部份完成繞製後剩餘的線段)分別進行所述複數匝線圈22的繞製，於繞製過程中，該二線段42分別以所連接的該些基礎線圈23其中之一為起點進行繞製，繞製的方向不是沿著該繞線架40進行，而以一圈疊一圈的方式繞製。於完成預定匝數的繞製後，即完成該磁性元件繞組20，該磁性元件繞組20透過本發明方法令該二出線末端21均是由所述複數匝線圈22中位 於最外側者延伸形成，進而解決前述內圈出線所衍生的種種問題。再者，本文前述預定匝數非指該磁性元件繞組20的總匝數，該磁性元件繞組20的總匝數為該些基礎線圈23的匝數加上該些線圈22的匝數。於一實施例中，於該步驟三33中，先以該二線段42其中之一進行所述複數匝線圈22的繞製並形成一第一部份241，再以該二線段42其中另一以該第一部份241為基礎進行剩餘所述複數匝線圈22的繞製並形成一與該第一部份241相疊的第二部份242，該二出線末端21分別由該第一部份241與該第二部份242中位於最外側者延伸形成。 Please refer to FIG. 3, FIG. 5 and FIG. 6 again. After the step 2 32 is completed, the step 3 33 is continued. The two wire segments 42 on the wire 41 connected to the two ends of the basic coils 23 (i.e., the remaining wire segments after the two parts are wound) are used to wind the plurality of turns of the coils 22. During the winding process, the two wire segments 42 are wound starting from one of the connected basic coils 23. The winding direction is not along the winding frame 40, but is wound in a circle-by-circle manner. After the predetermined number of turns is completed, the magnetic element winding 20 is completed. The magnetic element winding 20 is formed by extending the two outgoing wire ends 21 of the plurality of turns of the coil 22 located at the outermost side through the method of the present invention, thereby solving the various problems derived from the inner coil outgoing wire. Furthermore, the predetermined number of turns mentioned in this article does not refer to the total number of turns of the magnetic element winding 20. The total number of turns of the magnetic element winding 20 is the number of turns of the basic coils 23 plus the number of turns of the coils 22. In one embodiment, in step three 33, one of the two wire segments 42 is first used to wind the plurality of turns of the coil 22 and form a first portion 241, and then the other of the two wire segments 42 is used to wind the remaining plurality of turns of the coil 22 based on the first portion 241 and form a second portion 242 overlapping the first portion 241. The two outgoing wire ends 21 are respectively formed by extending from the outermost of the first portion 241 and the second portion 242.
併請參閱圖7，一實施例中，該磁性元件繞組的成形方法30更包含一步驟四34：對該磁性元件繞組20實施定型作業，並移除該繞線架40。於本實施例該步驟四34實施完成後，該磁性元件繞組20將可以部件的型態參與後續磁性元件的組構。併請參閱圖8，於一實施例中，該線材41包含一金屬內芯411以及一披覆該金屬內芯411外的可熱熔外皮412。該定型作業的實施則是對該磁性元件繞組20的半成品進行加熱，以令該可熱熔外皮412熱熔，再冷卻後，完成定型。除前述之外，該定型作業亦可為點膠實施或纏上膠帶實施，點膠處可依實施需求選擇，點膠可如圖9所揭，圖9中的標號60為點膠處，而纏上膠帶的方案則可如圖10所示，圖10中標號61為膠帶。 Please refer to FIG. 7 , in one embodiment, the forming method 30 of the magnetic element winding further includes a fourth step 34: performing a shaping operation on the magnetic element winding 20 and removing the winding frame 40. After the fourth step 34 of this embodiment is completed, the magnetic element winding 20 can participate in the subsequent magnetic element structure in the form of a component. Please refer to FIG. 8 , in one embodiment, the wire 41 includes a metal inner core 411 and a heat-meltable outer skin 412 covering the metal inner core 411. The shaping operation is performed by heating the semi-finished product of the magnetic element winding 20 to melt the heat-meltable outer skin 412, and then cooling it to complete the shaping. In addition to the above, the shaping operation can also be implemented by glue application or tape application. The glue application location can be selected according to the implementation requirements. The glue application can be as shown in Figure 9, where the reference numeral 60 in Figure 9 is the glue application location, and the tape application solution can be as shown in Figure 10, where the reference numeral 61 in Figure 10 is the tape.
30:方法 30: Methods
31:步驟一 31: Step 1
32:步驟二 32: Step 2
33:步驟三 33: Step 3
Claims (7)
Publications (2)
| Publication Number | Publication Date |
|---|---|
| TW202425019A TW202425019A (en) | 2024-06-16 |
| TWI849619B true TWI849619B (en) | 2024-07-21 |
Family
ID=
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20200279686A1 (en) | 2017-11-20 | 2020-09-03 | Huawei Technologies Co., Ltd. | Coil, wireless charging receiving apparatus, wireless charging transmission apparatus, and system |
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20200279686A1 (en) | 2017-11-20 | 2020-09-03 | Huawei Technologies Co., Ltd. | Coil, wireless charging receiving apparatus, wireless charging transmission apparatus, and system |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| JPWO2008096487A1 (en) | Winding type coil and winding method thereof | |
| JPH06181135A (en) | Transformer for power distribution | |
| WO2020164645A2 (en) | Inductive component and manufacturing method | |
| TW201630003A (en) | Transformer, transformer winding assembly and manufacturing method thereof | |
| EP0583521B1 (en) | Multi-layered insulated wire for high frequency transformer winding | |
| TWI849619B (en) | Method for forming magnetic element winding | |
| TW202425019A (en) | Method for forming magnetic element winding | |
| US2180420A (en) | Insulated spool for electromagnets | |
| CN107332379B (en) | A kind of manufacturing method of frog shape winding | |
| JP2000215972A (en) | Induction heating coil and its manufacture | |
| CN218826449U (en) | Magnetic element winding | |
| JP2002358840A (en) | Flat braided litz wire for high frequency coil | |
| US20240223052A1 (en) | Manufacturing method of magnetic assembly winding | |
| CA2761612C (en) | Method for producing a disk winding | |
| CN209859646U (en) | Electromagnetic wire | |
| CN108899186B (en) | RM8 step-up transformer manufacturing process | |
| CN106783144B (en) | Multi-section layered drum type winding process | |
| JPS6091603A (en) | Coil of flat type wire and manufacture thereof | |
| EP0724765B1 (en) | A method of manufacturing an electrical coil or transformer winding having an insulation device | |
| TWI660382B (en) | Coupled inductor structure and a method for manufacturing the sam | |
| CN114242314B (en) | Polyester glass fiber covered wire and manufacturing method thereof | |
| JPS58190008A (en) | Manufacture of multi-layer coil | |
| JP3393222B2 (en) | Method and apparatus for split winding of inductance element | |
| JPS6111851Y2 (en) | ||
| JPH0539620Y2 (en) |