JPH0833289A - Method for manufacturing flat air core coil - Google Patents
Method for manufacturing flat air core coilInfo
- Publication number
- JPH0833289A JPH0833289A JP6180543A JP18054394A JPH0833289A JP H0833289 A JPH0833289 A JP H0833289A JP 6180543 A JP6180543 A JP 6180543A JP 18054394 A JP18054394 A JP 18054394A JP H0833289 A JPH0833289 A JP H0833289A
- Authority
- JP
- Japan
- Prior art keywords
- adhesive
- start end
- winding start
- core coil
- flat air
- 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.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 19
- 238000000034 method Methods 0.000 title claims abstract description 16
- 238000004804 winding Methods 0.000 claims abstract description 57
- 239000000853 adhesive Substances 0.000 claims abstract description 43
- 230000001070 adhesive effect Effects 0.000 claims abstract description 43
- 239000004020 conductor Substances 0.000 claims abstract description 6
- 239000011888 foil Substances 0.000 claims abstract description 6
- 239000007788 liquid Substances 0.000 claims description 6
- 230000002093 peripheral effect Effects 0.000 description 6
- 230000003014 reinforcing effect Effects 0.000 description 5
- 238000000926 separation method Methods 0.000 description 3
- 238000007796 conventional method Methods 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 239000002313 adhesive film Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000004070 electrodeposition Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
Landscapes
- Manufacturing Cores, Coils, And Magnets (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
(57)【要約】 （修正有）
【目的】 巻始端部のほぐれを解消した扁平空芯コイル
の製造方法を得る。
【構成】 導体箔と絶縁層からなる積層体が巻回され、
内周に巻始端部４を有し外周に巻終端部を有する扁平空
芯コイルの製造方法。巻回された積層体の巻始端部４を
接着剤５で覆った後に、所定の厚さに切断して形成す
る。
(57) [Summary] (Correction) [Purpose] To obtain a method for manufacturing a flat air-core coil in which loosening of the winding start end is eliminated. [Structure] A laminated body composed of a conductor foil and an insulating layer is wound,
A method for manufacturing a flat air-core coil having a winding start end portion 4 on the inner circumference and a winding end portion on the outer circumference. The winding start end 4 of the wound laminated body is covered with an adhesive 5 and then cut to a predetermined thickness.
Description
【０００１】[0001]
【産業上の利用分野】本発明は、薄型モータ等に適用可
能な扁平空芯コイルの製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a flat air core coil applicable to a thin motor or the like.
【０００２】[0002]
【従来の技術】薄型のモータなどに使用されるコイルと
して、扁平空芯コイルが知られている。このような扁平
空芯コイルは通常、以下のような手順で形成される。ま
ず、シート状の導体箔の表面に絶縁層を形成して積層体
を形成し、この積層体を図示しない棒状の芯の外周に沿
って複数回巻回した後、所定の形状に成形し、棒状の芯
を引き抜くことによって、図４に示すよう巻回体３を得
る。成形によって巻回体３の断面形状は台形状となって
おり、さらに、棒状の芯を引き抜くことによって巻回体
３の中央には台形状の孔３ａが生じている。孔３ａの内
面には積層体を巻回した際の巻始端部４が位置してい
る。2. Description of the Related Art A flat air core coil is known as a coil used in a thin motor or the like. Such a flat air core coil is usually formed by the following procedure. First, an insulating layer is formed on the surface of a sheet-shaped conductor foil to form a laminated body, and the laminated body is wound a plurality of times along the outer circumference of a rod-shaped core (not shown), and then molded into a predetermined shape, By pulling out the rod-shaped core, the wound body 3 is obtained as shown in FIG. The winding body 3 has a trapezoidal cross-sectional shape due to the molding, and a rod-shaped core is pulled out to form a trapezoidal hole 3a in the center of the winding body 3. The winding start end portion 4 when the laminated body is wound is located on the inner surface of the hole 3a.
【０００３】次に、上記巻回体３を、孔３ａ方向と直交
する方向に図５に示すようなワイヤーソー８、あるい
は、ダイシングソー等で切断することにより、図６に示
すような空芯コイル１が得られる。空芯コイル１は、孔
３ａの内周面に存在する巻始端部４の近傍、及び、図示
しない外周面に位置する巻終端部の近傍の絶縁層が剥離
されて、電極９、９’が形成されている。Next, the wound body 3 is cut by a wire saw 8 as shown in FIG. 5 or a dicing saw in a direction orthogonal to the direction of the holes 3a, so that an air core as shown in FIG. Coil 1 is obtained. In the air-core coil 1, the insulating layers in the vicinity of the winding start end portion 4 existing on the inner peripheral surface of the hole 3a and in the vicinity of the winding end portion located on the outer peripheral surface (not shown) are peeled off, so that the electrodes 9, 9'are formed. Has been formed.
【０００４】[0004]
【発明が解決しようとする課題】以上のような従来の扁
平空芯コイルの製造方法によれば、巻回体３を切断する
際、応力によって孔３ａの内周面に形成された巻始端部
４がほぐれてしまうことがあり、図７に示すような、巻
始端部４がコイル本体から分離した不良な空芯コイル１
が数多く生じていた。このような巻始端部４が分離した
空芯コイル１は、基板等と電気的に接続するのが難し
く、使用に適していない。According to the conventional method for manufacturing a flat air-core coil as described above, when the winding body 3 is cut, the winding start end portion formed on the inner peripheral surface of the hole 3a by stress. 4 may be loosened, and a defective air core coil 1 in which the winding start end 4 is separated from the coil body as shown in FIG.
Was happening a lot. The air-core coil 1 in which the winding start portion 4 is separated is difficult to electrically connect to a substrate or the like and is not suitable for use.
【０００５】切断時の応力によって巻始端部４がほぐれ
て分離するのを防止する方法として、図８に示すよう
に、補強板１１で孔３ａの内周面を補強する方法があ
る。この方法は、特開昭６３−２２０７３５号公報に記
載されている。しかし、補強板１１の使用によって、巻
始端部４のほぐれや分離は解消できるが、その反面、積
層体３の巻回し時間や巻始端部４の補強処理に時間を要
することとなるため、あまり実用的な解消方法ではなか
った。As a method of preventing the winding start end portion 4 from being loosened and separated by the stress at the time of cutting, there is a method of reinforcing the inner peripheral surface of the hole 3a with a reinforcing plate 11 as shown in FIG. This method is described in JP-A-63-220735. However, the use of the reinforcing plate 11 can eliminate loosening and separation of the winding start end portion 4, but on the other hand, it takes much time to wind the laminated body 3 and to reinforce the winding start end portion 4, so it is not so much. It was not a practical solution.
【０００６】本発明は以上のような従来技術の問題点を
解消するためになされたもので、巻始端部のほぐれを解
消した扁平空芯コイルの製造方法を提供することを目的
とする。The present invention has been made in order to solve the above problems of the prior art, and an object of the present invention is to provide a method of manufacturing a flat air-core coil in which loosening of the winding start end is eliminated.
【０００７】[0007]
【課題を解決するための手段】請求項１記載の発明は、
導体箔と絶縁層からなる積層体が巻回され、内周に巻始
端部を有し外周に巻終端部を有する扁平空芯コイルの製
造において、巻回された積層体の巻始端部を接着剤で覆
った後に、巻回された上記積層体を所定の厚さに切断さ
れることを特徴とする。According to the first aspect of the present invention,
In the manufacture of a flat air-core coil in which a laminated body including a conductor foil and an insulating layer is wound, and a winding start end portion is provided on the inner circumference and a winding end portion is provided on the outer circumference, the winding start end portion of the wound laminated body is bonded. After being covered with the agent, the rolled laminated body is cut into a predetermined thickness.
【０００８】請求項２記載の発明は、積層体の孔にディ
スペンサーを挿入し、このディスペンサーの先端から液
状の接着剤を塗出し、巻始端部を接着剤で覆うことを特
徴とする。The invention according to claim 2 is characterized in that a dispenser is inserted into the hole of the laminate, a liquid adhesive is applied from the tip of the dispenser, and the winding start end is covered with the adhesive.
【０００９】請求項３記載の発明は、積層体の孔にフィ
ルム状の接着剤を挿入した後、接着剤を加熱溶融させて
巻始端部を覆うことを特徴とする。The invention according to claim 3 is characterized in that after the film-like adhesive is inserted into the hole of the laminate, the adhesive is heated and melted to cover the winding start end.
【００１０】請求項４記載の発明は、積層体の孔に棒状
の接着剤を挿入した後、接着剤を加熱溶融させて巻始端
部を覆うことを特徴とする。The invention according to claim 4 is characterized in that after the rod-shaped adhesive is inserted into the hole of the laminate, the adhesive is heated and melted to cover the winding start end.
【００１１】[0011]
【作用】巻回された積層体の巻始端部を接着剤が覆い、
かつ、補強するため、切断時に巻始端部がほぐれること
なく、扁平空芯コイルが製造される。[Operation] An adhesive covers the winding start end of the wound laminated body,
Moreover, because of the reinforcement, the flat air-core coil is manufactured without loosening the winding start end portion at the time of cutting.
【００１２】[0012]
【実施例】以下、本発明にかかる扁平空芯コイルの製造
方法について図面を参照しながら説明する。なお、扁平
空芯コイルの基本的な製造方法は、従来例と同じである
ため、ここでは説明を省略し、巻始端部の補強について
重点的に説明する。DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method of manufacturing a flat air core coil according to the present invention will be described below with reference to the drawings. Since the basic manufacturing method of the flat air-core coil is the same as that of the conventional example, description thereof will be omitted here, and reinforcement of the winding start end portion will be mainly described.
【００１３】図１において、シート状の導体箔と、導体
箔の一面を覆う絶縁層から構成される積層体を、所定回
数巻回して形成された巻回体３は中央に孔３ａを有して
いる。積層体の巻回方向は図１において紙面に直交する
方向である。孔３ａは、積層体を巻回す際に用いられた
芯を、引き抜くことによって生じたもので、内周面には
積層体の巻始端部４が位置している。このような、巻回
体３の孔３ａにディスペンサー６が挿入される。挿入さ
れたディスペンサー６は、孔３ａの最も奥に位置する端
部から、挿入口側の端部まで、先端部から液体状の接着
剤５を放出しながら移動される。こうすることにより、
孔３ａの内周面の巻始端部４が全体に渡って接着剤５で
覆われ、接着剤５が硬化することにより巻始端部４が補
強される。その後、巻回体３をその長さ方向に直交する
方向に所定の長さで切断する。このように、ディスペン
サー６から放出される接着剤５で巻始端部４を補強する
ことにより、巻回体３を所定の厚さ寸法で切断して扁平
空芯コイルを形成しても、巻始端部４がほぐれて分離す
ることがない。従って、歩留まり率を飛躍的に向上させ
ることができる。また、ディスペンサー６を使用した接
着剤５による巻始端部４の補強処理は、積層体を巻回し
た後の巻回体３に対して施されるため安価でありコスト
の高騰等を招くこともない。さらに、接着剤５に予め着
色しておけば、巻回体３を切断して、扁平空芯コイルを
構成した際に、コイルの電極位置を知る目印にもなり、
基板への実装ミスを低減することができる。In FIG. 1, a wound body 3 formed by winding a laminated body composed of a sheet-shaped conductor foil and an insulating layer covering one surface of the conductor foil a predetermined number of times has a hole 3a in the center. ing. The winding direction of the laminate is a direction orthogonal to the paper surface in FIG. The hole 3a is created by pulling out the core used for winding the laminated body, and the winding start end portion 4 of the laminated body is located on the inner peripheral surface. The dispenser 6 is inserted into the hole 3a of the wound body 3 as described above. The inserted dispenser 6 is moved from the deepest end of the hole 3a to the end on the insertion opening side while discharging the liquid adhesive 5 from the front end. By doing this,
The winding start end 4 on the inner peripheral surface of the hole 3a is entirely covered with the adhesive 5, and the curing of the adhesive 5 reinforces the winding start end 4. Then, the wound body 3 is cut into a predetermined length in a direction orthogonal to the length direction. In this way, by reinforcing the winding start end portion 4 with the adhesive 5 discharged from the dispenser 6, even if the winding body 3 is cut to a predetermined thickness dimension to form a flat air-core coil, the winding start end portion 4 The part 4 does not unravel and separate. Therefore, the yield rate can be dramatically improved. Further, the reinforcing treatment of the winding start end portion 4 with the adhesive 5 using the dispenser 6 is inexpensive because it is performed on the winding body 3 after winding the laminated body, which may cause a cost increase. Absent. Furthermore, if the adhesive 5 is colored in advance, it serves as a mark to know the electrode position of the coil when the wound body 3 is cut to form a flat air-core coil,
It is possible to reduce mounting mistakes on the board.
【００１４】なお、巻回体３の孔３ａの径寸法が小さく
なると、ディスペンサー６が挿入できなかったり、ある
いは、図２に示すように接着剤５に液溜まり５ａが生じ
て孔３ａが塞がれることがあり、孔３ａ内にブラシレス
モータの磁気センサなどを配置しようとしても配置でき
ないことがある。このような問題を解消するには、ディ
スペンサー６を使用せず、図３（ａ）に示すように、プ
リプレグ等からなる熱を加えると融けるフィルム状の接
着剤７を用いればよい。即ち、フィルム状の接着剤７を
孔３ａ内に挿入して巻始端部４上に重ね、この状態で巻
回体３を加熱する。こうすることにより、フィルム状の
接着剤７は融けて巻始端部４を覆い、冷却して硬化させ
ることにより、巻始端部４を補強することができ、切断
時のほぐれや分離を防止することができる。また、接着
剤７はフィルム状であるため液溜まりが発生することが
なく、このため孔３ａを塞ぐことも皆無である。さら
に、フィルム状の接着剤７を使用する代わりに、図３
（ｂ）に示すような、棒状の接着剤１０を使用してもよ
い。フィルム状の接着剤７と同様に、加熱することによ
り融けて巻始端部４を覆うため、巻始端部４を補強し切
断時のほぐれや分離を解消することができる。When the diameter of the hole 3a of the wound body 3 becomes smaller, the dispenser 6 cannot be inserted, or as shown in FIG. 2, a liquid pool 5a is formed in the adhesive 5 to close the hole 3a. The magnetic sensor of the brushless motor or the like may not be arranged even if it is arranged inside the hole 3a. To solve such a problem, the dispenser 6 is not used, and a film-shaped adhesive 7 made of prepreg or the like that melts when heat is applied, as shown in FIG. That is, the film adhesive 7 is inserted into the hole 3a and overlapped on the winding start end portion 4, and the wound body 3 is heated in this state. By doing so, the film adhesive 7 melts and covers the winding start end portion 4, and by cooling and hardening, the winding start end portion 4 can be reinforced, and the loosening and separation at the time of cutting can be prevented. You can Further, since the adhesive 7 is in the form of a film, no liquid pool is generated, and therefore the hole 3a is never blocked. Furthermore, instead of using the adhesive film 7,
A rod-shaped adhesive 10 as shown in (b) may be used. Similar to the film-shaped adhesive 7, since it is melted by heating and covers the winding start end portion 4, it is possible to reinforce the winding start end portion 4 and eliminate loosening and separation at the time of cutting.
【００１５】[0015]
【発明の効果】請求項１記載の発明によれば、巻回され
た積層体の巻始端部を接着剤で覆った後に、巻回された
積層体を所定の厚さに切断しするため、巻始端部のほぐ
れのない扁平空芯コイルを得ることが可能となる。According to the first aspect of the present invention, after covering the winding start end of the wound laminated body with the adhesive, the wound laminated body is cut into a predetermined thickness. It is possible to obtain a flat air-core coil with no looseness at the winding start end.
【００１６】請求項２記載の発明によれば、積層体の孔
にディスペンサーを挿入し、このディスペンサーの先端
から液状の接着剤を塗出し、接着剤で巻始端部を覆った
ため、簡易で安価な方法により巻始端部のほぐれのない
扁平空芯コイルを得ることが可能となる。According to the second aspect of the present invention, the dispenser is inserted into the hole of the laminate, the liquid adhesive is applied from the tip of the dispenser, and the winding start end is covered with the adhesive. Therefore, it is simple and inexpensive. According to the method, it is possible to obtain a flat air-core coil with no looseness at the winding start end.
【００１７】請求項３記載の発明によれば、積層体の孔
にフィルム状の接着剤を挿入した後、加熱溶融させて巻
始端部を接着剤で覆ったため、孔径の小さなコイルであ
っても孔が接着剤で塞がれることがなく、かつ、巻始端
部のほぐれのない扁平空芯コイルを得ることが可能とな
る。According to the third aspect of the present invention, after the film-shaped adhesive is inserted into the holes of the laminate, it is heated and melted to cover the winding start end with the adhesive, so that even a coil having a small hole diameter can be used. It is possible to obtain a flat air-core coil in which the holes are not blocked with the adhesive and the winding start end portion is not unraveled.
【００１８】請求項４記載の発明によれば、積層体の孔
に棒状の接着剤を挿入した後、加熱溶融させて巻始端部
を接着剤で覆ったため、孔径の小さなコイルであっても
孔が接着剤で塞がれることがなく、かつ、巻始端部のほ
ぐれのない扁平空芯コイルを得ることが可能となる。According to the fourth aspect of the present invention, since the rod-shaped adhesive is inserted into the hole of the laminated body, it is heated and melted and the winding start end is covered with the adhesive. It is possible to obtain a flat air-core coil in which the winding start end is not unraveled and is not blocked by the adhesive.
【図１】本発明にかかる扁平空芯コイルの製造方法の一
工程の例を示す断面図。FIG. 1 is a sectional view showing an example of one step of a method for manufacturing a flat air-core coil according to the present invention.
【図２】本発明にかかる扁平空芯コイルの製造方法にお
いて、接着剤で巻回体の孔が塞がれた場合の例を示す断
面図。FIG. 2 is a cross-sectional view showing an example in which the hole of the wound body is closed with an adhesive in the method for manufacturing a flat air-core coil according to the present invention.
【図３】本発明にかかる扁平空芯コイルの製造方法に適
用可能な、（ａ）はシート状接着剤を、（ｂ）は棒状接
着剤を使用した場合の一工程の例を示す斜視図。FIG. 3 is a perspective view showing an example of one step applicable to the method for manufacturing a flat air-core coil according to the present invention, where (a) is a sheet adhesive and (b) is a rod adhesive. .
【図４】従来の扁平空芯コイルの製造方法の一工程の例
を示す断面図。FIG. 4 is a cross-sectional view showing an example of one step of a conventional method for manufacturing a flat air-core coil.
【図５】同上扁平空芯コイルの製造方法の一工程の例を
示す断面図。FIG. 5 is a cross-sectional view showing an example of one step of a method for manufacturing the flat air-core coil of the same.
【図６】同上扁平空芯コイルの例を示す斜視図。FIG. 6 is a perspective view showing an example of the above flat air-core coil.
【図７】従来の扁平空芯コイルの別の例を示す斜視図。FIG. 7 is a perspective view showing another example of a conventional flat air-core coil.
【図８】従来の扁平空芯コイルのさらに別の例を示す斜
視図。FIG. 8 is a perspective view showing still another example of a conventional flat air-core coil.
４ 巻始端部 ５ 接着剤 ６ ディスペンサー ７ フィルム状の接着剤 １０ 棒状の接着剤 4 Roll start end 5 Adhesive 6 Dispenser 7 Film adhesive 10 Rod adhesive
Claims (4)
れ、内周に巻始端部を有し外周に巻終端部を有する扁平
空芯コイルの製造方法において、 巻回された上記積層体の巻始端部を接着剤で覆った後
に、巻回された上記積層体を所定の厚さに切断すること
を特徴とする扁平空芯コイルの製造方法。1. A method for manufacturing a flat air-core coil in which a laminated body including a conductor foil and an insulating layer is wound, and a winding start end portion is provided on an inner circumference and a winding end portion is provided on an outer circumference. A method for manufacturing a flat air-core coil, which comprises covering the winding start end portion of the body with an adhesive and then cutting the wound laminated body to a predetermined thickness.
このディスペンサーの先端から液状の接着剤を塗出し、
接着剤で巻始端部を覆うことを特徴とする請求項１記載
の扁平空芯コイルの製造方法。2. A dispenser is inserted into the hole of the laminate,
Apply liquid adhesive from the tip of this dispenser,
The method for manufacturing a flat air-core coil according to claim 1, wherein the winding start end is covered with an adhesive.
した後、加熱溶融させて巻始端部を接着剤で覆うことを
特徴とする請求項１記載の扁平空芯コイルの製造方法。3. The method for producing a flat air-core coil according to claim 1, wherein after the film-shaped adhesive is inserted into the holes of the laminate, the film is heated and melted to cover the winding start end with the adhesive.
後、加熱溶融させて巻始端部を接着剤で覆うことを特徴
とする請求項１記載の扁平空芯コイルの製造方法。4. The method for producing a flat air-core coil according to claim 1, wherein after the rod-shaped adhesive is inserted into the hole of the laminate, it is heated and melted to cover the winding start end with the adhesive.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP6180543A JP3013972B2 (en) | 1994-07-07 | 1994-07-07 | Manufacturing method of flat air core coil |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP6180543A JP3013972B2 (en) | 1994-07-07 | 1994-07-07 | Manufacturing method of flat air core coil |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0833289A true JPH0833289A (en) | 1996-02-02 |
| JP3013972B2 JP3013972B2 (en) | 2000-02-28 |
Family
ID=16085119
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP6180543A Expired - Lifetime JP3013972B2 (en) | 1994-07-07 | 1994-07-07 | Manufacturing method of flat air core coil |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3013972B2 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2006060052A (en) * | 2004-08-20 | 2006-03-02 | Honda Motor Co Ltd | Bobbinless coil and method for manufacturing bobbinless coil |
| JP2011129956A (en) * | 2011-03-28 | 2011-06-30 | Honda Motor Co Ltd | Method of manufacturing bobbinless coil |
-
1994
- 1994-07-07 JP JP6180543A patent/JP3013972B2/en not_active Expired - Lifetime
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2006060052A (en) * | 2004-08-20 | 2006-03-02 | Honda Motor Co Ltd | Bobbinless coil and method for manufacturing bobbinless coil |
| JP2011129956A (en) * | 2011-03-28 | 2011-06-30 | Honda Motor Co Ltd | Method of manufacturing bobbinless coil |
Also Published As
| Publication number | Publication date |
|---|---|
| JP3013972B2 (en) | 2000-02-28 |
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