JPH1083914A - Multilayer air-core coil and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a multilayer air-core coil, suitable for the antenna coil or the like of an IC card by a method wherein the coil is reduced by a thickness of one conductor wire component by leading out both terminals of a conductor wire from the innermost peripheral layer of the coil and reduction in the thickness of the coil can be contrived. SOLUTION: A conductor wire 15 of a length required for winding a multilayer air-core coil is stored in a wire storage part 13 and thereafter, with one end of the conductor wire 15 fixed on a first wound core 11, the other end of the wire 15 is fixed on a second wound core 12 and the wound cores 11 and 12 are rotated in the opposite direction to each other in a state that an elastic force is applied to both ends of the wire 15 by the storage part 13, whereby the multilayer air-core coil is formed into a constitution, wherein both terminals of the wire 15 are led out from the innermost peripheral layer of the air-core coil.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a multilayer air-core coil and a method for manufacturing the same, and more particularly to a thin multilayer air-core coil suitable for an antenna coil for an IC card and a method for manufacturing the same.

[0002]

2. Description of the Related Art FIG. 18 shows an example of a conventional multilayer air-core coil. One end 5a of a winding wire 5 is led out of the outermost circumference and the other end 5b is led out of the innermost circumference. . Japanese Patent Publication No. 47442/1992 discloses a multilayer coil in which both the winding start end and the winding end end are led out from the outermost periphery.

FIG. 19 shows an example of the structure of an IC card using a conventional multi-layer air-core coil having one terminal from the outermost periphery and the other terminal from the innermost periphery as an antenna coil. An IC card requires an antenna coil for supplying power or a signal by electromagnetic induction in order to write information to an IC (ROM) in the card in a non-contact manner. In this figure, reference numeral 1 denotes an IC card main body, on which an IC 2 and an antenna coil 3 are mounted. Further, an embossed portion 4 is formed on the IC card main body 1. The antenna coil 3 is incorporated so as to avoid the embossed portion 4 or to go around the outer periphery of the IC card main body 1 in order to increase the efficiency of electromagnetic induction.
C2 is arranged inside the antenna coil 3. The antenna coil 3 has a structure in which one terminal 3a is derived from the outermost periphery and the other terminal 3b is derived from the innermost periphery, as shown in FIGS. 20 (A) and 20 (B). In order to derive both ends 3a and 3b of the winding, the outermost terminal 3a must be extended inward across the plane of the winding end of the antenna coil. Added to thickness.

[0004]

However, the IC card needs to be as thin as possible (0.8 mm thick).
), The thinner the antenna coil 3, the easier the configuration of the IC card.

Although it has been considered to incorporate an IC into a magnetic card, a magnetic card also has a thickness of 0.8 m.
m.

However, the antenna coil 3 according to the conventional general winding method has a structure in which one terminal 3a is derived from the outermost periphery and the other terminal 3b is derived from the innermost periphery, as described above. In order to lead both of the terminals 3a and 3b to the inside of the antenna coil 3, the outermost terminal 3a must be led inward across the plane of the winding end of the antenna coil. It is added to the thickness of the antenna coil 3 and becomes a useless thickness.

[0007] Further, the terminal 3a, which is drawn inward across the plane of the winding end of the antenna coil, intersects with the winding portion and partially protrudes, so that it is rubbed at the time of manufacturing an IC card, so that poor insulation is likely to occur.

[0008] In view of the above, the present invention can reduce the thickness of one conductor by leading both terminals from the innermost layer, thereby achieving a thinner antenna coil for an IC card. It is an object of the present invention to provide a multilayer air-core coil suitable for, for example, and a method for manufacturing the same.

Other objects and novel features of the present invention will be clarified in embodiments described later.

[0010]

In order to achieve the above object, a multilayer air-core coil according to the present invention has a structure in which a conductor is wound in multiple layers by aligned winding, and both terminals of the conductor are derived from the innermost peripheral layer. The configuration is as follows.

Further, in the method for manufacturing a multilayer air-core coil according to the present invention, after storing a lead wire having a length necessary for winding the multilayer air-core coil in a storage portion, one end of the conductive wire is connected to the first core. And the other end is fixed to a second winding core, and the first and second winding cores are rotated in opposite directions to each other in a state where tension is applied to both ends of the conductor by the storage wire portion. It is characterized by.

In the above method for manufacturing a multilayer air-core coil,
The storage unit may include a winder that feeds out the conductor wound by the first rotation operation at a substantially constant tension by a second rotation operation in a direction opposite to the first rotation operation.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a multilayer air-core coil and a method of manufacturing the same according to the present invention will be described with reference to the drawings.

A first embodiment, which is a conceptual configuration of the present invention, will be described with reference to FIGS. In these figures, 11 is a first winding core, 12 is a second winding core, 13 is a wire storage part, and the first winding core 11 and the second winding core 12 have the same center of rotation relative to each other. The first core 11 is a temporary fixing chuck 21 and the second core 12 is a temporary fixing chuck 2.
2 respectively. The storage wire section 13 has tension means 14 for applying tension to the lead wire 15 which has been drawn out to a required length. Conductor wire 1 used here
Reference numeral 5 denotes a self-fusing conductive wire (so-called cement wire), which has a property that an insulating coating around a conductive wire such as a copper wire is fused by a solvent or hot air, and is wound by applying a solvent or hot air when winding the conductive wire. It can be fixed in a rotating state.

In the first embodiment, the production of the multilayer air-core coil is performed according to the following procedure.

First, as shown in FIG. 1, a conductive wire 15 having a required length is prepared in advance near the opposing surfaces of the first core 11 and the second core 12, and each of the cores 11, 12 has Temporarily fixing both ends of the conductive wire 15 with the temporary fixing chucks 21 and 22,
Further, the central part of the conductor 15 whose both ends are temporarily fixed is pulled by the tension means 14 of the wire storage part 13.

Then, as shown in FIG. 2, the first winding core 11 and the second winding core 12 are rotated in opposite directions about the same rotation center, and the predetermined tension is applied by the tension means 14. The conductor 15 is wound around each core.

At this time, as shown in FIG. 3, the first and second winding cores 11 and 12 are integrally provided with conducting wire guide walls 31 and 32, and the two conducting wires 15 and 32 are provided between the opposing surfaces of the two walls 31 and 32. By providing a gap corresponding to the number of wires, it is possible to perform a multilayer winding of two rows by aligned winding. That is, the 1 wound around the outer periphery of the first core 11
The winding part of the row is above (outside) the terminal 15a of the conductor 15
In the state where the conductor is wound in multiple layers, the second-row winding portion wound around the outer periphery of the second core 12 is connected to the terminal 15 of the conductor 15.
A conductive wire is wound in a multilayer on the upper side (outer side) of b.
Therefore, after the wound conductors 15 are fixed to each other by a solvent or hot air, the temporary fixing chucks 21 and 22 are temporarily removed, and the first core 11 and the second core 12 are separated from each other. For example, as shown in FIG. 4A, a multilayer air-core coil 10 in which the conductor 15 is wound in multiple layers by aligned winding and both terminals 15a and 15b of the conductor are led out from the innermost peripheral layer is obtained.
Then, as shown in FIG. 4 (B), by pulling out the terminals 15a and 15b of the multilayer air-core coil 10 to the inner peripheral side, a shape suitable for use in an IC card or the like can be obtained.

According to the first embodiment, since both ends of the conductor are led out from the innermost peripheral layer, the thickness of one conductor is reduced as compared with a conventional general multi-layer air-core coil. It can be seen that the multi-layer air-core coil 10 having a small thickness can be obtained.

In the first embodiment shown in FIGS. 1 to 4, the multilayer air core coil 10 wound in a circular shape is shown, but it is also possible to wind it in a square shape according to the same principle. Figure 5
FIG. 6 shows a second embodiment of the present invention. First
Except that the outer shapes of the second winding cores 41 and 42 are prismatic, a square multilayer air-core coil 40 is obtained as shown in FIG. 6A in the same manner as in the first embodiment. . Also in this case, the multilayer air-core coil 40 has a structure in which the conductor 15 is wound in multiple layers by aligned winding, and both terminals 15a and 15b of the conductor are led out from the innermost peripheral layer, as shown in FIG. By pulling out the terminals 15a and 15b of the air core coil 40 to the inner peripheral side, it is possible to obtain a shape suitable for use in an IC card or the like.

According to the second embodiment, in addition to the effects of the first embodiment, since the multilayer air-core coil 40 can be formed in a square shape, the coil can be formed along the outer peripheral edge of the IC card body. Can be arranged, and a structure more suitable for the antenna coil of the IC card can be obtained. That is, as described with reference to FIG. 20, the conventional antenna coil 3 in the IC card necessarily has the conductor terminal 3a led inward from the outermost periphery indicated by the hatched portion in FIG. ,
By using the multilayer air core coil 40 obtained in the second embodiment as the antenna coil in the IC card as shown in FIG. 7B, the conductor terminal 15a shown in the shaded portion in FIG. 7 is derived from the innermost circumference. It becomes possible to connect to IC2 (it is no longer derived from the outermost periphery). Therefore, compared to the conventional general multi-layer air core coil, the thickness of one conductor is reduced to make it thinner,
In addition, since there is no conductive wire terminal extending inward across the plane of the winding end of the multilayer air core coil 40 as an antenna coil, there is no occurrence of insulation failure due to rubbing during IC card production.

FIGS. 8 to 13 show a third embodiment of the present invention using a more specific winding machine. In these figures, reference numeral 51 denotes a first winding core, 52 denotes a second winding core, 53 denotes a wire storage portion, and the first winding core 51 and the second winding core 52 have the same rotation center relative to each other. The first winding core 51 has a temporary fixing chuck 61 and a wire guide wall 71, and the second winding core 52
Has a temporary fixing chuck 62 and a wire guide wall 72. In the joined state of the winding cores 51 and 52 in FIGS. 10 to 12, the conductor guide walls 71 and 72 are opposed to each other with a gap of two conductors 15 therebetween.
Holes (or grooves) 73 through which the conducting wires 15 pass are formed at the bases of the bases 1 and 72 as shown in FIGS. Further, a first motor M1 is provided for rotating and driving the first core 51, and a second motor M2 is provided for rotating and driving the second core 52.

The wire storage section 53 is configured to draw out and wind the conductor 15 for a required length, and to pay out the conductor 15 while applying a substantially constant tension to the conductor 15.
The winder 55 is moved to the tri-limiter 56 and the clutch 57.
, And is rotatably driven by the third motor M3 via the. The winder 55, the trim limiter 56, the clutch 57, and the third motor M3 are mounted on, for example, a linear moving table, and can move in a direction orthogonal to the rotation centers of the first and second cores 51, 52. Has become.
The winder 55 is provided with a flange 5 on both sides of the winding drum 55a.
5b, and has a pole (pin) 55c that protrudes radially from the winding drum 55a to hook the conducting wire 15.

The winder 55 and the third
The motor M3 is provided because it is necessary to temporarily wind the conductor 15 in a small space. Also, the trim limiter 56 is configured such that the winder 55 is
After winding the wire 5, the wire 15 is provided so that the conducting wire 15 can be fed out while keeping tension between the winding cores 51 and 52 at a constant torque. The clutch 57 is inserted between the motor M3 and the trim limiter 56 in order to wind and release the conducting wire 15 on the axis of the winder 55.

In the third embodiment, a multilayer air-core coil is manufactured in the following procedure.

First, as shown in FIG. 8, the conductor 15 is passed through holes (or grooves) 73 of the first core 51 and the second core 52, and the tip of the conductor 15 is temporarily inserted into the second core 52. It is temporarily fixed by the fixing chuck 62.

Next, in FIG. 9, the conducting wire 15 is hung on the pole 55c of the winder 55, and the entire storage section 53 moves linearly away from the rotation centers of the winding cores 51 and 52 as shown by the arrow P. By this movement, the total length of the conductor 15 to be wound is adjusted, and the conductor 15 necessary for producing a required multilayer air-core coil is drawn out.

Then, in FIG. 10, the clutch 57 is connected and the third motor M3 sets the tri-limiter 56.
Then, the winder 55 is rotated via the clutch 57, and the winding wire 55 is used to wind up the conductor 15, and the storage unit 5 is wound.
The whole 3 moves linearly in a direction approaching the center of rotation of the winding cores 51 and 52 as indicated by arrow Q, and returns to the original position in FIG. At this time, the first core 51 and the second core 52 are in a joined state, and the conductor guide walls 71 and 72 face each other with a gap of two conductors 15 therebetween.

Next, in FIG. 11, the conducting wire 15 is temporarily fixed by the temporary fixing chuck 61 of the first core 51, and the conducting wire 15 extending outside the temporary fixing chuck 61 is cut by the cutter means 65.

Thereafter, the first motor M1 shown in FIG.
And the first core 51 and the second core 5 by the second motor M2.
2 is rotated in the opposite direction about the same center of rotation, and
5 is wound from the surfaces of the winding cores 51 and 52 between the conductor guide walls 71 and 72, respectively (the timing of winding the left and right layers is the same). At this time, the winder 55 draws out the wound wire 15 with a constant torque specified by the tri-limiter 56 with the clutch 57 of the wire storage 53 disconnected, and the wire 15 is fed with a substantially constant required tension.
Is wound around each core. At this time, the conductive wire 15 is fixed to the wound state by blowing hot air to the wound conductive wire 15 by applying hot air or applying a solvent.

Finally, as shown in FIG. 13, the temporary fixing chucks 61 and 62 of the first and second cores 51 and 52 are opened to release both terminals 15a and 15b of the conductor 15, and the first core is released. 51 and the second core 52 are separated from each other to
Take out 0.

The multilayer air-core coil 5 thus obtained
No. 0 has a structure in which the conductor 15 is wound in multiple layers by aligned winding and both terminals 15a, 15b of the conductor are led out from the innermost peripheral layer. When the winding cores 51 and 52 have a prismatic shape as shown in FIG. 4, a square coil is formed as shown in FIG.

In the first to third embodiments described so far, two rows (one row on one core and one row on the other core)
Was wound in multiple layers to form a multilayer air core coil, but four rows (two rows on one core and two rows on the other core)
A multi-layer air-core coil can be formed by winding in multiple layers by the above-mentioned arrangement winding. This case will be described with reference to FIGS. 14 to 16 as a fourth embodiment of the present invention. The structure of the winding machine used in the fourth embodiment may be the same as that used in the third embodiment, but the conductors provided integrally with the first and second winding cores 51 and 52. The guide walls 71 and 72 are
In the joined state of 52, the conductors 15 are opposed to each other with a gap of four conductors 15 therebetween.

Before explaining the winding formation according to FIG. 14, a description will be given of a general multilayer winding method by aligned winding of conductive wires and the manner in which the winding is formed with reference to FIG. When one end of the conductor 15 is fixed to the core 80 and the other is pulled with a constant tension, the core 80 is rotated in one direction, and the conductor 15 has a plurality of gaps (two rows in the drawing). The first layer is formed starting from the winding so as to satisfy all of them, and then the second layer, the third layer, and the winding are performed in a direction of increasing the number of layers. However, as the number of rows increases, one end of the conductive wire 15 pulled by tension becomes unable to form each layer accurately. Therefore, a traverse operation is performed as necessary.

Therefore, as shown in FIG.
When two layers of windings are wound in two layers on the other winding core 52 and on the other winding core 52, two rows of gaps on the winding core 51 and two rows of windings on the winding core 52 as shown in FIG. The conductors 15 are wound so as to fill the gaps, and winding is sequentially performed on each winding core in the direction of increasing the number of layers, such as the second and third layers. For this reason, the winding process is performed in the same process as in the third embodiment, so that both ends 15a and 15b of the conductor 15 are led out from the innermost peripheral layer, and the four-row aligned-winding multilayer air core is formed. A coil can be obtained.

FIG. 17 shows a fifth embodiment of the present invention, in which the number of rows formed on the left and right winding cores is different (two rows on the left side and one row on the right side in the case of FIG. 3 in total). Is shown. The structure of the winding machine used in the fifth embodiment may be the same as that used in the third embodiment, except that the conductors provided integrally with the first and second winding cores 51 and 52. Guide wall 7
1 and 72 are opposed to each other with a gap corresponding to three conductors 15 in the joined state of the cores 51 and 52. The winding procedure may be the same as that of the third embodiment, but the number of rotations of the left and right winding cores 51 and 52 is changed in accordance with the number of conductors of each layer wound on the left and right winding cores. It is necessary to match the timing of each layer. In the illustrated case, two rows on the left core 51 and one row on the right core 52 must be formed at the same timing. For example, the number of rotations of the left core 51 is n. Then, the rotation speed of the right winding core 52 is set to n / 2.

As can be seen from the fourth and fifth embodiments, the multi-layer air core of the aligned winding with an arbitrary number of rows (regardless of even rows or odd rows) in which both terminals are derived from the innermost layer. A coil can be obtained.

Although the embodiments of the present invention have been described above, it is obvious to those skilled in the art that the present invention is not limited to the embodiments and various modifications and changes can be made within the scope of the claims. There will be.

[0039]

As described above, according to the present invention,
Both ends of the conductor of the multilayer air-core coil can be derived from the innermost layer, and there is no terminal derived from the outermost periphery as in the conventional multilayer air-core coil. It is not necessary to derive to the inner circumference across. Therefore, the thickness of one conductive wire is not added to the winding portion, and the thickness can be reduced. In addition, since there is no conductive wire terminal derived from the outermost periphery, the possibility of insulation failure due to the terminal crossing the coil winding portion and partially protruding is eliminated, and the reliability and durability are improved. Can be planned.

For example, an IC card has a limited space,
It is necessary to increase the efficiency of electromagnetic induction within the thickness, and it is necessary to have reliability and durability that can withstand severe use conditions, but if the multilayer air core coil according to the present invention is used as an antenna coil of an IC card, , Eliminating the disadvantages of conventional coils, reducing the thickness and improving the efficiency of electromagnetic induction,
Reliability and durability can be improved, and the effect is remarkable.

It is needless to say that the multilayer air-core coil according to the present invention can be used not only for the above-mentioned antenna coil for an IC card but also for various other uses.

[Brief description of the drawings]

FIG. 1 is a first embodiment for conceptually explaining the present invention, and is a perspective view showing a state before rotation of a core.

FIG. 2 is a perspective view showing a state where the core is rotated.

FIG. 3 is a front sectional view showing the first embodiment.

FIG. 4 is a perspective view showing a multilayer air-core coil obtained in the first embodiment.

FIG. 5 is a second embodiment of the present invention and is a perspective view showing a core structure in the case of manufacturing a square multilayer air-core coil.

FIG. 6 is a perspective view showing a multilayer air-core coil obtained in a second embodiment.

FIG. 7 is an explanatory diagram showing a case where the square multilayer air-core coil obtained in the second embodiment is used as an antenna coil of an IC card.

FIG. 8 is a front view of a third embodiment of the present invention, in which a more specific winding machine is used, and showing a part of a step of attaching a conductor to each core. is there.

FIG. 9 is a front view of a third embodiment, illustrating a step of drawing out a required length of a conductive wire by a wire storage part.

FIG. 10 is a front view showing a step of winding a lead wire of the same length by a wire storage part.

FIG. 11 is a front view showing a state where the left and right winding cores are joined to start winding.

FIG. 12 is a front view in which a part of the same winding completed state is shown in section.

FIG. 13 is a front view showing a state where the left and right winding cores are separated from each other and the multilayer air-core coil is taken out.

FIG. 14 is a front sectional view of a fourth embodiment of the present invention, in which a multilayer air core coil having four rows is manufactured.

FIG. 15 is an explanatory view showing a state of winding of a general multilayer air-core coil.

FIG. 16 is an explanatory diagram showing a state of a winding in the fourth embodiment.

FIG. 17 is a front sectional view of a fifth embodiment of the present invention, in which three rows (odd rows) of multilayer air-core coils are manufactured.

FIG. 18 is a plan view showing a conventional multilayer air-core coil.

FIG. 19 is a structural diagram of an IC card using a conventional multilayer air-core coil as an antenna coil.

20 is an explanatory diagram showing a main part A of FIG. 19 in an enlarged manner.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 IC card main body 2 IC 3 Antenna coil 3a, 3b, 5a, 5b, 15a, 15b Terminal 4 Emboss part 5,15 Lead wire 10,40,50 Multilayer air core coil 11,12,41,42,51,52,80 Core 13, 53 Storage part 14 Tension means 21, 22, 61, 62 Temporary fixing chuck 55 Winder 56 Torque limiter 57 Clutch 65 Cutter means 71, 72 Lead wire guide wall 73 Hole (or groove) M1, M2, M3 Motor

Claims (3)

[Claims] 1. A multilayer air-core coil, wherein a conductor is wound in multiple layers by aligned winding, and both terminals of the conductor are led out of an innermost peripheral layer. 2. A wire having a length required for winding a multilayer air-core coil is stored in a wire storage portion, and one end of the wire is fixed to a first core and the other end is a second core. , And tension is applied to both ends of the conductive wire by the storage wire portion.
And rotating the second winding core in opposite directions to each other. 3. The storage section includes a conductor wound by a first rotation operation, and a second conductor in a direction opposite to the first rotation operation.
3. The method for manufacturing a multilayer air-core coil according to claim 2, further comprising a winder that feeds out at a substantially constant tension by the rotating operation.