Coil winding and coil winding forming method

Abstract

A coil winding is used for solving the problems that an existing stator coil is small in size, and manufacturing difficulty is too high in the mode that the stator coil is wound and then located on a printed circuit board. Comprising a winding base, the winding base is provided with at least one plate body, a winding column is located on a winding face, the winding column and the at least one plate body are integrally formed in an injection mode, the at least one plate body is provided with two winding parts, and the two winding parts are located at the two opposite ends of the at least one plate body respectively; the two winding parts and the at least one plate body are integrally formed in an injection mode, so that the two winding parts and the at least one plate body are made of the same material; and the wire body is wound on the winding post to form a coil, and two ends of the wire body are wound on the two winding parts. The invention further relates to a forming method of the coil winding. Therefore, the effects of simplifying the process and reducing the manufacturing cost can be achieved.

Description

Technical Field

[0001] This invention relates to a motor assembly, and more particularly to a coil winding and a method for forming a coil winding in a motor for providing a magnetic effect of current to generate a magnetic field. Background Technology

[0002] Generally, axial flux motors can be manufactured by directly integrating the stator coil onto a printed circuit board. Compared to an equivalent radial flux motor, this allows for adjustment of the air gap size, resulting in a flatter and wider structure, making it suitable for small, lightweight micro motors. However, the stator coil is extremely small, and the method of winding it and then positioning it on the printed circuit board is too difficult to manufacture, hindering yield improvement. Summary of the Invention

[0003] To address the aforementioned problems, the present invention aims to provide a coil winding and a coil winding forming method that can be easily manufactured.

[0004] The directions or similar terms used throughout this invention, such as "front," "back," "left," "right," "top," "bottom," "inner," "outer," and "side," are mainly for reference to the directions in the accompanying drawings. These directions or similar terms are only used to assist in explaining and understanding the various embodiments of this invention and are not intended to limit this invention.

[0005] The use of the quantifiers “a” or “an” for the elements and components described throughout this invention is for convenience and to provide the general meaning of the scope of the invention; in this invention, it should be interpreted as including one or at least one, and a single concept also includes multiple cases, unless it clearly means otherwise.

[0006] The terms “first,” “second,” … and “Nth” used throughout this invention are primarily used to distinguish different elements or features (such as elements, directions, or steps), and do not indicate the maximum or minimum number of these elements or features possessed by a corresponding subject or method, nor do they limit the order of priority.

[0007] The terms "combination," "integration," or "assembly" used throughout this invention mainly refer to the types of connections that allow for separation without damaging the components, or connections that make the components inseparable. Those skilled in the art can choose the appropriate term based on the material of the components to be connected or the assembly requirements.

[0008] The coil winding of the present invention includes: a winding base having at least one plate having a winding surface, a winding post located on the winding surface, the winding post and the at least one plate being integrally formed by injection molding, the at least one plate having two winding portions located at opposite ends of the at least one plate, the two winding portions and the at least one plate being integrally formed by injection molding such that the two winding portions and the at least one plate are made of the same material; and a wire wrapped around the winding post to form a coil, the two ends of the wire being wound around the two winding portions.

[0009] Therefore, the coil winding of the present invention is integrally formed by injection molding of the winding base and the winding post, and the wire can be wound around the winding post to form a coil. It can be easily formed in a motor to provide a coil winding that generates a magnetic field through the magnetic effect of current. In addition, the wire can be wound around the two winding parts to form a conductive part for current flow. The metal sheet can be omitted, thereby reducing the thickness of the winding base and the molding steps, which can achieve the effect of simplifying the process and reducing manufacturing costs.

[0010] The winding base is made of heat-resistant material. This allows the coil in the winding base to have better heat resistance when heated.

[0011] Each winding portion has an enlarged diameter end, and a winding section is formed between the enlarged diameter end and the at least one plate. The inlet and outlet ends of the wire are wound around the two winding sections. In this way, the enlarged diameter end can prevent the wire from coming off.

[0012] In this configuration, at least one plate has a wire-receiving groove recessed into the winding surface. A first end of the groove is adjacent to the winding post, and a second end is connected to one of the winding portions. The wire portion is located within the wire-receiving groove. Thus, when the wire is wound around the winding portion and then wound through the wire-receiving groove onto the circumferential surface, the first loop of the wire on the circumferential surface provides better adhesion to the winding surface.

[0013] The width of the wire-receiving groove gradually narrows from the second end toward the first end. This allows the wire to be easily inserted from the second end and ensures that the wire is close to the winding post when it is introduced into the first end.

[0014] The groove depth, from its opening to its bottom, tapers towards the first end. This allows the first loop of the wire on the circumferential surface to have better adhesion to the winding surface.

[0015] The winding post has an end face, and a positioning hole extends through the end face of the winding post and the at least one plate. Thus, the positioning hole allows for the insertion of a working shaft of a winding machine.

[0016] The winding base has two plates located at opposite ends of the winding post. This allows the wire to be easily inserted into the slot without slipping on the bottom of the slot.

[0017] The coil winding forming method of the present invention includes: injection molding a winding base having a plate having a winding surface and a winding post located on the winding surface; and winding a wire around the winding post to form the coil. Thus, a coil winding for providing a magnetic field generated by the magnetic effect of current can be easily formed in a motor, achieving the effect of simplifying the process and reducing manufacturing costs.

[0018] The plate has two winding sections located at opposite ends. The wire is wound around one winding section, then around the winding post to form a coil, and then wound around the other winding section. Thus, the two winding sections can be used to allow current to flow.

[0019] Specifically, a conductive material is coated onto the wire body of the two winding portions. This gives the wire body of the two winding portions better conductivity.

[0020] In this process, the wires of the two winding sections are devarnished before being coated with the conductive material. This gives the wires of the two winding sections better conductivity.

[0021] In this design, the two winding portions containing the conductive material each form a conductive section. Thus, these two conductive sections allow current to flow, and also eliminate the need for a metal sheet, thereby reducing the thickness of the winding base.

[0022] A positioning hole extends through the end face of the winding post and the board body. A winding machine's working shaft is inserted into the positioning hole, and the winding machine winds the wire around the winding post to form the coil. After that, the positioning hole is closed. In this way, the coil winding can be tightly held in place by a clamp during the process of attaching it to the circuit board without causing air leakage. Attached Figure Description

[0023] Figure 1 : A perspective view of the winding base according to the first embodiment of the present invention; Figure 2 :like Figure 1 The wire is wound around the winding base (see diagram). Figure 3 : A perspective view of the winding base according to the second embodiment of the present invention; Figure 4 :like Figure 3 The wire is wound around the base of the winding.

[0024] Explanation of reference numerals in the attached figures: 1: Winding base 11: Plate body 11a: Wire-wound surface 11b: Mating surface 12: Winding section 12a: Expanded diameter end 12b: Winding segment 13: Winding post 13a: End face 14: Circumferential surface 15: Positioning Hole 16: Cable tray 16a: First end 16b: Second end 161: Groove 162: Bottom of the trough 2: Line S: Coil winding. Detailed Implementation

[0025] To make the above and other objects, features and advantages of the present invention more apparent and understandable, preferred embodiments of the present invention are described below in detail with reference to the accompanying drawings; in addition, those symbols that are used in different drawings are considered to be the same and their descriptions will be omitted.

[0026] Please refer to Figure 1 , Figure 2 As shown, it is the first embodiment of the coil winding S of the present invention, including a winding base 1 and a wire body 2, which is wound on the winding base 1.

[0027] The winding base 1 may have a plate 11, which may have a winding surface 11a and a mating surface 11b. The winding surface 11a and the mating surface 11b may be located on opposite surfaces of the plate 11, and the mating surface 11b may be used to connect a circuit board. The plate 11 may have two winding portions 12, which may be located at opposite ends of the plate 11. The two winding portions 12 are used to wind the wire 2 to form a conductive portion for current flow. In detail, the two winding portions 12 can be integrally formed with the plate body 11 by injection molding. Each winding portion 12 can have an enlarged diameter end 12a. There can be a winding section 12b between the enlarged diameter end 12a and the plate body 11. The cross-sectional area of ​​the enlarged diameter end 12a is larger than the cross-sectional area of ​​the winding section 12b. Therefore, when the wire 2 is wound around the winding section 12b, the enlarged diameter end 12a can prevent the wire 2 from coming off.

[0028] The winding base 1 may have a winding post 13, which may be located on the winding surface 11a and protrude from the winding surface 11a, so that the winding post 13 may have an end face 13a and a circumferential surface 14, which is connected between the end face 13a and the winding surface 11a. Furthermore, the winding post 13 may be integrally formed with the plate 11 by injection molding.

[0029] The wire 2 can be wound several times around the circumferential surface 14 of the winding post 13 to form a coil. The wire 2 can be a self-bonding magnet wire, that is, a self-adhesive layer is coated on the outer layer of the enameled wire. The self-adhesive layer can be, for example, polyamide-imide. The self-adhesive layer can become viscous when heated or treated with a solvent, so that the wire 2 can be self-bonded after winding. Furthermore, the wire 2 can be wound from the winding surface 11a, adhering tightly to the circumferential surface 14, and gradually stacked several layers to form the coil. Also, the inlet and outlet ends of the wire 2 can be wound around the winding sections 12b of the two winding portions 12, so that the wire 2 can form terminals for current flow at the two winding portions 12. Furthermore, the winding base 1 may have a positioning hole 15, which may extend through the end face 13a of the winding post 13 and the plate 11. The positioning hole 15 may be used to allow the working shaft of a winding machine to be inserted.

[0030] Preferably, the plate 11 may have a wire receiving groove 16, which may be recessed into the winding surface 11a. A first end 16a of the wire receiving groove 16 may be adjacent to the winding post 13. The wire receiving groove 16 may extend toward one of the winding portions 12, so that a second end 16b of the wire receiving groove 16 may be connected to one of the winding portions 12. Furthermore, the winding portion 12 connected to the second end 16b may be the entry end of the wire 2. That is, when the wire 2 is wound around the winding portion 12 and then wound through the wire receiving groove 16 on the circumferential surface 14, the first loop of the wire 2 on the circumferential surface 14 may have better adhesion to the winding surface 11a. In this embodiment, the width of the wire receiving groove 16 can gradually decrease from the second end 16b towards the first end 16a. This allows the wire 2 to easily enter from the second end 16b, and the wire 2 to be close to the winding post 13 when introduced into the first end 16a. Furthermore, the depth of the wire receiving groove 16, from its opening 161 to its bottom 162, can gradually decrease towards the first end 16a from its proximity to the first end 16a. This allows the first loop of the wire 2 on the circumferential surface 14 to have better adhesion to the winding surface 11a.

[0031] Please refer to Figure 3 , Figure 4As shown, this is a second embodiment of the coil winding S of the present invention. In this embodiment, the winding base 1 may have two plates 11, which are respectively located at opposite ends of the winding post 13. The two winding portions 12 may be located on one of the plates 11, or both plates 11 may have the two winding portions 12, so that the winding base 1 is non-directional in use, thus having better ease of use. In addition, the two plates 11 may each have a wire receiving groove 16, which may be located on the winding surface 11a of the two plates 11 respectively. The two wire receiving grooves 16 may be opposite to each other, or they may be staggered, which is not limited by the present invention. In this way, the wire 2 can be wound on the winding post 13 between the two plates 11. Furthermore, the positioning hole 15 of the coil winding S may be omitted, and the winding machine can be clamped between the two plates 11 for winding operations.

[0032] Therefore, the coil winding S of the present invention can be injection molded in a molding die to form the winding base 1. For example, the winding base 1 can be made of a heat-resistant material, so that it will not deform when it is reflow ovened to be fixed with solder paste, and the winding base 1 can omit the metal sheet, thereby reducing the thickness of the winding base. Furthermore, the winding base 1 can be made of a material with a heat deflection temperature greater than 220°C, preferably a material with a heat deflection temperature greater than 250°C. Also, the winding base 1 can be injection molded from LCP (liquid crystal polymer), or a polymer mixed with glass fiber or minerals. After the wire 2 is wound around one of the winding portions 12 to form a terminal, it is wound around the winding post 13 to form the coil, and then wound around another winding portion 12 to form a terminal. Then, a conductive material is coated on the wire 2 of the two winding portions 12, and the conductive material can be, for example, tin. Preferably, the conductive material can be applied to the wire 2 of the winding portion 12 after removing the paint. This improves the conductivity of the wire 2 in both winding portions 12, thereby eliminating the need for a metal sheet and reducing the thickness of the winding base 1. Furthermore, after the wire 2 forms the coil at the winding post 13, the positioning hole 15 can preferably be sealed by means such as potting, so that the coil winding S can be tightly held in place by a clamp during the surface mount technology (SMT) process on the circuit board without air leakage.

[0033] In summary, the coil winding of the present invention is integrally formed by injection molding of the winding base and the winding post, and the wire can be wound around the winding post to form a coil. Therefore, it is easy to form a coil winding in a motor to provide current magnetic effect to generate a magnetic field. In addition, after the wire is wound by the two winding parts, a conductive part can be formed to allow current to flow. The metal sheet can be omitted, thereby reducing the thickness of the winding base and the molding steps, which can achieve the effect of simplifying the process and reducing manufacturing costs.

[0034] Although the present invention has been disclosed using the above preferred embodiments, it is not intended to limit the present invention. Any modifications and alterations made by those skilled in the art to the above embodiments without departing from the spirit and scope of the present invention shall still fall within the technical scope protected by the present invention. Therefore, the protection scope of the present invention shall include all changes within the meaning and equivalent scope of the appended claims.

Claims

1. A coil winding, characterized in that, include: A winding base has at least one plate having a winding surface, a winding post located on the winding surface, the winding post and the at least one plate being integrally injection molded; the at least one plate having two winding portions located at opposite ends of the at least one plate, the two winding portions and the at least one plate being integrally injection molded so that the two winding portions and the at least one plate are made of the same material; and A wire is wound around the winding post to form a coil, with both ends of the wire wound around the two winding portions.

2. The coil winding as described in claim 1, characterized in that, The winding base is made of heat-resistant material.

3. The coil winding as described in claim 1, characterized in that, Each winding portion has an enlarged diameter end, and there is a winding section between the enlarged diameter end and the at least one plate body. The inlet end and outlet end of the wire are wound around the two winding sections.

4. The coil winding as described in claim 1, characterized in that, The at least one plate has a wire receiving groove recessed in the winding surface, a first end of the wire receiving groove adjacent to the winding post, a second end of the wire receiving groove connected to one of the winding portions, and the wire portion located in the wire receiving groove.

5. The coil winding as described in claim 4, characterized in that, The width of the groove gradually decreases from the second end toward the first end.

6. The coil winding as described in claim 4, characterized in that, The depth of the groove from the opening to the bottom of the groove gradually narrows towards the first end near the first end.

7. The coil winding as described in claim 1, characterized in that, The winding post has an end face, and a positioning hole extends through the end face of the winding post and the at least one plate.

8. The coil winding as described in claim 1, characterized in that, The winding base has two plates located at opposite ends of the winding post.

9. A method for forming a coil winding, characterized in that, include: A winding base is injection molded, the winding base having a plate having a winding surface and a winding post located on the winding surface; and A wire is wound around the winding post to form a coil.

10. The method for forming a coil winding as described in claim 9, characterized in that, The plate has two winding sections located at opposite ends of the plate. After the wire is wound around one of the winding sections, it is wrapped around the winding post to form the coil, and then wound around the other winding section.

11. The method for forming a coil winding as described in claim 10, characterized in that, A conductive material is applied to the wire body of the two winding sections.

12. The method for forming a coil winding as described in claim 11, characterized in that, The conductive material is applied to the wire body of the two winding sections after the paint is removed.

13. The method for forming a coil winding as described in claim 12, characterized in that, Two winding portions of the conductive material each form a conductive portion.

14. The method for forming a coil winding as described in claim 9, characterized in that, A positioning hole extends through the end face of the winding post and the plate. A winding machine's working shaft is inserted into the positioning hole. The winding machine then winds the wire around the winding post to form the coil, and finally closes the positioning hole.

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