Alpha-winding coil manufacturing jig and method for manufacturing alpha-winding coil

Abstract

To provide a coil with a low height and a low floor area without reducing the thickness of an electric line.SOLUTION: In an alpha-winding coil 10, an upper winding part 26, a lower winding part 28, and a connection part 30 for connecting the upper winding part 26 and the lower winding part 28 to each other in the innermost peripheral part 22 of the coil are formed by a single electric wire 20. When a cross-section of the alpha-winding coil 10 is taken at a plane including the center axis of the alpha-winding coil 10, the upper winding part 26 and the lower winding part 28 have a winding structure which forms a staggered shape in the direction from the innermost peripheral part 22 to the outermost part of the coil.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to an alpha winding coil, an alpha winding coil manufacturing jig, and an alpha winding coil manufacturing method. [Background technology]

[0002] Coils used in transformers, choke coils, etc. can be divided into coils in which the number of windings is stacked in the axial direction and coils in which the number of windings is stacked in the radial direction. An alpha winding coil is classified as the latter type of coil, but is configured so that both winding terminals can be taken out from the outer periphery. In other words, an alpha winding coil is a coil in which an upper winding section, a lower winding section, and a connecting section that connects the upper winding section and the lower winding section at the innermost periphery of the coil are made of a single electric wire, and both winding terminals can be taken out from the outer periphery (see, for example, Patent Documents 1 and 2). The alpha winding coil configured as described above is a coil in which the number of windings is overlapped in the radial direction, so that a thin coil can be configured, and it is a coil that meets the demand for a low-profile coil. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2012-114222 A [Patent Document 2] JP 2014-197600 A Summary of the Invention [Problem to be solved by the invention]

[0004] In recent years, electronic devices have become more densely packed, and coils that require less floor space are in demand, and this is also true for alpha-wound coils. Therefore, it is possible to reduce the floor space of the coil by thinning the wire to increase the number of turns per unit area. However, when the floor space of the coil is reduced by thinning the wire, the heat generated by the wire increases, and there is a problem that measures to dissipate heat and additional parts are required.

[0005] Therefore, the present invention has been made to solve the above problems, and an object of the present invention is to provide a coil that has a low height and a small floor space without thinning the electric wire. [Means for solving the problem]

[0006] (1) The alpha winding coil of the present invention is an alpha winding coil in which an upper winding section, a lower winding section, and a connecting section that connects the upper winding section and the lower winding section at the innermost portion of the coil are made of a single electric wire, and is characterized in that when the alpha winding coil is viewed in cross section on a plane including the central axis of the alpha winding coil, both the upper winding section and the lower winding section have a staggered winding structure from the innermost portion of the coil toward the outer periphery.

[0007] (2) The alpha winding coil of the present invention is the alpha winding coil described in (1) above, characterized in that, when the alpha winding coil is viewed in cross section on a plane including the central axis of the alpha winding coil, when the nth winding portion of the wire from the innermost portion of the coil toward the outer periphery is defined as the "nth winding portion", in both the upper winding portion and the lower winding portion, the position of the central axis of the "nth winding portion where n is an even number" along a direction parallel to the central axis of the alpha winding coil is biased along a direction parallel to the central axis of the alpha winding coil with respect to the position of the central axis of the "nth winding portion where n is an odd number" along a direction parallel to the central axis of the alpha winding coil.

[0008] (3) In the alpha winding coil described in (2) above, the bias direction in the upper winding portion and the bias direction in the lower winding portion may be the same direction or opposite directions.

[0009] (4) The alpha winding coil of the present invention is the alpha winding coil described in (1) above, and when the alpha winding coil is viewed in cross section on a plane including a central axis of the alpha winding coil, when the nth winding portion of the wire from the innermost portion of the coil toward the outer periphery is defined as the "nth winding portion", it is preferable that in both the upper winding section and the lower winding section, the "nth winding portion" and the "n+1th winding portion and / or the n-1th winding portion adjacent to the nth winding portion" are in contact with each other, and the "nth winding portion" and the "n+2th winding portion and / or the n-2th winding portion adjacent to the nth winding portion" are in a non-contact state.

[0010] (5) The alpha winding coil of the present invention is the alpha winding coil described in (1) above, and when the alpha winding coil is viewed in cross section on a plane including a central axis of the alpha winding coil, when the nth winding portion of the wire from the innermost peripheral portion of the coil toward the outer peripheral side is defined as the “nth winding portion”, it is also preferable that in both the upper winding section and the lower winding section, the “nth winding portion” and the “n+1th winding portion and / or the n-1th winding portion adjacent to the nth winding portion” are in contact with each other, and the “nth winding portion” and the “n+2th winding portion and / or the n-2th winding portion adjacent to the nth winding portion” are in contact with each other.

[0011] (6) In the alpha winding coil described in (1) above, it is preferable to have a winding structure stabilizing means for stabilizing the winding structure.

[0012] (7) In the alpha winding coil described in (6) above, it is preferable that the winding structure stabilizing means has a self-bonding layer formed on the outer periphery of the electric wire.

[0013] (8) The alpha winding coil manufacturing jig of the present invention is an alpha winding coil manufacturing jig for manufacturing the alpha winding coil described in (1) above, and has a bobbin structure having an upper flange, a central flange, and a lower flange. When the alpha winding coil is viewed in cross section on a plane including the central axis of the alpha winding coil, when the nth winding portion of the electric wire from the innermost portion of the coil toward the outer periphery is defined as the "nth winding portion", a "first body for winding the first winding portion" and a "second body corresponding to the second winding portion" are provided both between the upper flange and the central flange and between the lower flange and the central flange, and the central flange is provided with a notch for passing a connecting portion that connects the upper winding portion and the lower winding portion of the electric wire.

[0014] (9) The alpha winding coil manufacturing jig of the present invention is an alpha winding coil manufacturing jig described above in (8), and it is preferable that the first body has an arc-shaped recess having an inner diameter corresponding to the diameter of the electric wire in a portion that contacts the electric wire.

[0015] (10) The alpha winding coil manufacturing jig of the present invention is an alpha winding coil manufacturing jig described above in (8), and it is preferable that the distance between the upper flange portion and the central flange portion and the distance between the central flange portion and the lower flange portion are both shorter than twice the diameter of the electric wire.

[0016] (11) The alpha winding coil manufacturing jig of the present invention is the alpha winding coil manufacturing jig described above in (8), and it is preferable that the height dimension of the second body (the height dimension along the central axis of the alpha winding coil) is shorter than the diameter dimension of the electric wire.

[0017] (12) The alpha winding coil manufacturing jig of the present invention is an alpha winding coil manufacturing jig as described in (8) above, wherein the first body is positioned on the central flange side of the second body both between the upper flange and the central flange and between the lower flange and the central flange.

[0018] (13) The alpha winding coil manufacturing jig of the present invention is an alpha winding coil manufacturing jig as described in (8) above, wherein the second body is located on the central flange side of the first body both between the upper flange and the central flange and between the lower flange and the central flange.

[0019] (14) The alpha winding coil manufacturing jig of the present invention may be the alpha winding coil manufacturing jig described in (8) above, wherein, in one of the sections between the upper flange and the central flange and between the lower flange and the central flange, the first body is located on the central flange side of the second body, and in the other section, the second body is located on the central flange side of the first body.

[0020] (15) The alpha winding coil manufacturing method of the present invention is a method for manufacturing the alpha winding coil described in (1) above using the alpha winding coil manufacturing jig described in (8) above, in which after passing a portion of the electric wire that will become the connecting portion through the notch of the central flange portion, the electric wire is wound around "the first body on the upper winding portion side" and "the first body on the lower winding portion side" to perform a first turn winding process; A second turn winding step is performed by winding the electric wire using as guides "the electric wire wound around the first body on the upper winding section side in the first turn winding step and the flange portion of the upper flange portion and the central flange portion that is far from the first body on the upper winding section side" and "the electric wire wound around the first body on the lower winding section side in the first turn winding step and the flange portion of the lower flange portion and the central flange portion that is far from the first body on the lower winding section side" respectively, and the electric wire is wound around the outer periphery of the second body on the upper winding section side in the second turn winding step and the flange portion of the upper flange portion and the central flange portion that is far from the second body on the upper winding section side in the second turn winding step". a third turn winding process is performed by winding the wire using as guides "the electric wire wound around the outer periphery of the first body on the upper winding section side in the third turn winding process and the flange part of the upper flange and the central flange part that is far from the first body on the upper winding section side in the third turn winding process" and "the electric wire wound around the outer periphery of the first body on the lower winding section side in the third turn winding process and the flange part of the lower flange and the central flange part that is far from the first body on the lower winding section side in the third turn winding process" as guides, and a fourth turn winding process is performed by winding the wire using as guides "the electric wire wound around the outer periphery of the first body on the lower winding section side in the third turn winding process and the flange part of the lower flange and the central flange part that is far from the first body on the lower winding section side in the third turn winding process" and

[0021] (16) The alpha winding coil manufacturing method of the present invention is the alpha winding coil manufacturing method described in (15) above, and it is preferable that after all of the winding steps are performed, the alpha winding coil is removed from the alpha winding coil manufacturing jig. Effect of the Invention

[0022] In the alpha winding coil of the present invention, when the alpha winding coil is viewed in cross section on a plane including the central axis of the alpha winding coil, both the upper winding part and the lower winding part have a staggered winding structure from the innermost part of the coil to the outer periphery side. Therefore, according to the alpha winding coil of the present invention, the number of windings per unit area can be increased without making the wire thinner, and as a result, a coil with a low height and a small floor area can be provided.

[0023] The alpha winding coil manufacturing jig of the present invention has a bobbin structure with an upper flange, a center flange, and a lower flange, and when the alpha winding coil is viewed in cross section on a plane including the central axis of the alpha winding coil, a "first body for winding the first turn winding part" and a "second body corresponding to the second turn winding part" are provided between the upper flange and the center flange and between the lower flange and the center flange, and a notch is provided in the center flange for passing a connecting part that connects the upper winding part and the lower winding part of the electric wire. Therefore, the alpha winding coil of the present invention can be manufactured by the alpha winding coil manufacturing jig of the present invention.

[0024] In the alpha winding coil manufacturing method of the present invention, the first turn winding step to the fourth turn winding step are performed in sequence as described above, and the alpha winding coil is manufactured by repeating the winding steps in the same manner until the required number of turns is reached. Therefore, the alpha winding coil of the present invention can be manufactured by the alpha winding coil manufacturing method of the present invention. [Brief description of the drawings]

[0025] [Figure 1]FIG. 2 is an external view of an alpha winding coil 10 according to an embodiment. [Diagram 2] FIG. 2 is a cross-sectional view taken along a plane including the central axis of the alpha winding coil 10. [Diagram 3] 2 is an enlarged cross-sectional view of a main portion of a winding portion 24 of the alpha winding coil 10. FIG. [Figure 4] 2 is a cross-sectional view of the electric wire 20. FIG. [Diagram 5] FIG. 13 is a diagram for explaining an alpha winding coil manufacturing jig 40-1. [Figure 6] FIG. 1 is a front view of the alpha winding coil manufacturing jig 40-2. [Figure 7] FIG. 1 is a front view of an alpha winding coil manufacturing jig 40-3. [Figure 8] FIG. 1 is a front view of an alpha winding coil manufacturing jig 40-4. [Figure 9] FIG. 13 is a diagram for explaining a prototype model 70 of the alpha winding coil manufacturing jig 40-1. [Figure 10] FIG. 13 is a diagram showing a state in which the alpha winding coil 10 is manufactured using a prototype model 70 of the alpha winding coil manufacturing jig 40-1. [Figure 11] FIG. 13 is a diagram showing a state in which the alpha winding coil 10 is removed from the prototype model 70 of the alpha winding coil manufacturing jig 40-1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] Hereinafter, embodiments of the alpha winding coil, the alpha winding coil manufacturing jig, and the alpha winding coil manufacturing method of the present invention will be described.

[0027] FIG. 1 is an external view of an alpha winding coil 10 according to an embodiment. FIG. 1(A) is a perspective view of the alpha winding coil 10, FIG. 1(B) is a front view of the alpha winding coil 10, and FIG. 1(C) is a side view of the alpha winding coil 10. FIG. 2 is a cross-sectional view in a plane including the central axis of the alpha winding coil 10. FIG. 2(A) is a cross-sectional view of the entire alpha winding coil 10, and FIG. 2(B) is an enlarged cross-sectional view of a main part of the winding part 24 of the alpha winding coil 10. FIG. 3 is an enlarged cross-sectional view of a main part of the winding part 24 of the alpha winding coil 10. FIG. 3(A) to FIG. 3(D) are diagrams showing variations in the deviation direction of the position of the central axis of the "nth turn winding part where n is an even number" relative to the position of the central axis of the "nth turn winding part where n is an odd number". Details will be described later.

[0028] As shown in Figs. 1 to 3, the alpha winding coil 10 is an alpha winding coil including an upper winding portion 26, a lower winding portion 28, and a connecting portion 30 that connects the upper winding portion 26 and the lower winding portion 28 at the innermost circumferential portion 22 of the coil, which are configured from a single electric wire 20. When the alpha winding coil 10 is viewed in cross section on a plane including the central axis of the alpha winding coil 10, both the upper winding portion 26 and the lower winding portion 28 have a winding structure that forms a staggered shape from the innermost circumferential portion 22 of the coil toward the outer periphery. Therefore, according to the alpha winding coil 10 according to the embodiment, it is possible to increase the number of windings per unit area without thinning the electric wire 20, and as a result, it is possible to provide a coil with a low height and a small floor area.

[0029] In the alpha winding coil 10 according to the embodiment, the upper winding part 26 and the lower winding part 28 each have a staggered winding structure from the innermost circumferential part 22 of the coil toward the outer periphery, which can be rephrased as follows with reference to Fig. 2. That is, when the alpha winding coil 10 is viewed in cross section on a plane including the central axis of the alpha winding coil 10, if the nth turn winding part of the electric wire 20 from the innermost circumferential part 22 of the coil toward the outer periphery is defined as the "nth turn winding part", in both the upper winding part 26 and the lower winding part 28, the position of the central axis of the "nth turn winding part where n is an even number" along the direction parallel to the central axis of the alpha winding coil 10 is biased along the direction parallel to the central axis of the alpha winding coil 10 with respect to the position of the central axis of the "nth turn winding part where n is an odd number" along the direction parallel to the central axis of the alpha winding coil 10.

[0030] 2B, in the lower winding portion 28, the position of the central axis of the second turn winding portion of the lower stage 34 (n is 2 (even number)) is offset along a direction parallel to the central axis of the alpha winding coil 10 with respect to the position of the central axis of the first turn winding portion of the upper stage 32 (n is 1 (odd number). Similarly, the position of the central axis of the fourth turn winding portion of the lower stage 34 (n is 4 (even number)) is offset along a direction parallel to the central axis of the alpha winding coil 10 with respect to the position of the central axis of the third turn winding portion of the upper stage 32 (n is 3 (odd number). The same is true for the upper winding portion 26.

[0031] In the alpha winding coil 10 according to the embodiment, as shown in Fig. 3, the bias direction in the upper winding part 26 and the bias direction in the lower winding part 28 may be the same or opposite. That is, the winding parts of the upper winding part 26 that are odd-numbered turns and the winding parts of the upper winding part 26 that are even-numbered turns may be disposed in either the upper stage part 32 or the lower stage part 34 of the upper winding part 26, and the winding parts of the lower winding part 28 that are odd-numbered turns and the winding parts of the lower winding part 28 that are even-numbered turns may be disposed in either the upper stage part 32 or the lower stage part 34. Various winding layouts are possible.

[0032] 3A shows a state in which the windings of the upper winding portion 26 and the lower winding portion 28 are arranged symmetrically with respect to the center plane X of the upper winding portion 26 and the lower winding portion 28. In the upper winding portion 26, the winding start of the electric wire 20 is from the lower stage 34 of the upper winding portion 26. Therefore, the odd-numbered turns of the winding portion are arranged in the lower stage 34 of the upper winding portion 26, and the even-numbered turns of the winding portion are arranged in the upper stage 32 of the upper winding portion 26. Meanwhile, in the lower winding portion 28, the winding start of the electric wire 20 is from the upper stage 32 of the lower winding portion 28. Therefore, the odd-numbered turns of the winding portion are arranged in the upper stage 32 of the lower winding portion 28, and the even-numbered turns of the winding portion are arranged in the lower stage 34 of the lower winding portion 28. As a result, the winding arrangement of the upper winding portion 26 and the lower winding portion 28 is symmetrical with respect to the central plane X of the upper winding portion 26 and the lower winding portion 28.

[0033] 3(B) shows a state in which the windings of the upper winding portion 26 and the lower winding portion 28 are arranged symmetrically with respect to the center plane X of the upper winding portion 26 and the lower winding portion 28. In the upper winding portion 26, the winding start of the electric wire 20 is from the upper stage 32 of the upper winding portion 26. Therefore, the odd-numbered turns of the winding portion are arranged in the upper stage 32 of the upper winding portion 26, and the even-numbered turns of the winding portion are arranged in the lower stage 34 of the upper winding portion 26. Meanwhile, in the lower winding portion 28, the winding start of the electric wire 20 is from the lower stage 34 of the lower winding portion 28. Therefore, the odd-numbered turns of the winding portion are arranged in the upper stage 32 of the lower winding portion 28, and the even-numbered turns of the winding portion are arranged in the upper stage 32 of the lower winding portion 28. As a result, the winding arrangement of the upper winding portion 26 and the lower winding portion 28 is symmetrical with respect to the central plane X of the upper winding portion 26 and the lower winding portion 28.

[0034] 3(C) shows a state in which the windings of the upper winding portion 26 and the lower winding portion 28 are arranged in asymmetric positions with respect to the center plane X of the upper winding portion 26 and the lower winding portion 28. In the upper winding portion 26, the winding start of the electric wire 20 is from the upper stage 32 of the upper winding portion 26. Therefore, the odd-numbered turns of the winding portion are arranged in the upper stage 32 of the upper winding portion 26, and the even-numbered turns of the winding portion are arranged in the lower stage 34 of the upper winding portion 26. Similarly, in the lower winding portion 28, the winding start of the electric wire 20 is from the upper stage 32 of the lower winding portion 28. Therefore, the odd-numbered turns of the winding portion are arranged in the upper stage 32 of the lower winding portion 28, and the even-numbered turns of the winding portion are arranged in the lower stage 34 of the lower winding portion 28. As a result, the winding arrangement of upper winding portion 26 and lower winding portion 28 is asymmetric with respect to center plane X of upper winding portion 26 and lower winding portion 28.

[0035] 3(D) shows a state in which the windings of the upper winding portion 26 and the lower winding portion 28 are arranged in asymmetric positions with respect to the center plane X of the upper winding portion 26 and the lower winding portion 28. In the upper winding portion 26, the winding start of the electric wire 20 is from the lower stage 34 of the upper winding portion 26. Therefore, the odd-numbered turns of the winding portion are arranged in the lower stage 34 of the upper winding portion 26, and the even-numbered turns of the winding portion are arranged in the upper stage 32 of the upper winding portion 26. Similarly, in the lower winding portion 28, the winding start of the electric wire 20 is from the lower stage 34 of the lower winding portion 28. Therefore, the odd-numbered turns of the winding portion are arranged in the upper stage 32 of the lower winding portion 28, and the even-numbered turns of the winding portion are arranged in the upper stage 32 of the lower winding portion 28. As a result, the winding arrangement of upper winding portion 26 and lower winding portion 28 is asymmetric with respect to center plane X of upper winding portion 26 and lower winding portion 28.

[0036] In the alpha winding coil 10 according to the embodiment, as shown in FIG. 2 and FIG. 3, when the alpha winding coil 10 is viewed in cross section on a plane including the central axis of the alpha winding coil 10, when the nth winding portion of the wire 20 from the innermost coil portion 22 toward the outer periphery is defined as the "nth winding portion", in both the upper winding portion 26 and the lower winding portion 28, the "nth winding portion" and the "n+1th winding portion and / or the n-1th winding portion adjacent to the nth winding portion" are in contact with each other, and the "nth winding portion" and the "n+2th winding portion and / or the n-2th winding portion adjacent to the nth winding portion" are in a non-contact state.

[0037] 2B, when n is 1, the first turn winding portion of the upper stage 32 is in contact with the second winding portion adjacent to the first turn winding portion, and the first turn winding portion is not in contact with the third winding portion adjacent to the first turn winding portion. When n is 2, the second turn winding portion of the lower stage 34 is in contact with the first winding portion and the third winding portion adjacent to the second turn winding portion, and the second turn winding portion is not in contact with the fourth winding portion adjacent to the second turn winding portion. When n is 3, the third turn winding portion of the upper stage 32 is in contact with the second winding portion and the fourth winding portion adjacent to the third turn winding portion, and the third turn winding portion is not in contact with the first winding portion adjacent to the third turn winding portion. Furthermore, when n is 4, the fourth turn winding portion of the lower section 34 and the third winding portion adjacent to the fourth turn winding portion are in contact with each other, and the fourth turn winding portion and the second winding portion adjacent to the fourth turn winding portion are in a non-contact state.

[0038] In this way, the electric wires 20 in the upper stage 32 and the electric wires 20 in the lower stage 34 are in a non-contact state, and the electric wires 20 in the upper stage 32 and the electric wires 20 in the lower stage 34 are in a contact state. This allows the height dimension of the winding portion to be reduced. Since the electric wires 20 in the upper stage 32 and the electric wires 20 in the lower stage 34 are in a non-contact state, for example, the space between the electric wires 20 in the first turn winding portion and the third turn winding portion adjacent to each other in the upper stage 32 becomes wider, and the second turn winding portion of the lower stage 34 arranged between the electric wires 20 enters between the electric wires 20. This allows the height dimension of the winding portion 24 to be reduced, and the alpha winding coil 10 to be made low-profile.

[0039] Fig. 4 is a cross-sectional view of the electric wire 20. As shown in Fig. 4, the alpha winding coil 10 according to the embodiment has a winding structure stabilizing means for stabilizing the winding structure. The alpha winding coil 10 according to the embodiment has a self-bonding layer 36 formed on the outer periphery of the electric wire 20 as the winding structure stabilizing means.

[0040] As shown in Fig. 4, the cross section of the electric wire 20 is circular, and a self-adhesive layer 36 is formed on the outer periphery. The self-adhesive layer 36 fixes the electric wires 20 in contact with each other, stabilizing the winding structure of the upper winding portion 26 and the lower winding portion 28 of the winding portion 24. The self-adhesive layer 36 is not shown in any figures other than Fig. 4.

[0041] Next, an alpha winding coil manufacturing jig according to the embodiment will be described. 5A and 5B are diagrams for explaining the alpha winding coil manufacturing jig 40-1. Fig. 5(A) is a front view of the alpha winding coil manufacturing jig 40-1, and Fig. 5(B) is a perspective view of the alpha winding coil manufacturing jig 40-1.

[0042] The alpha winding coil manufacturing jig 40-1 for manufacturing the alpha winding coil 10 has a bobbin structure 60 equipped with an upper flange portion 42, a central flange portion 44 and a lower flange portion 46. When the alpha winding coil 10 is viewed in cross section on a plane including the central axis of the alpha winding coil 10, when the nth winding portion of the electric wire 20 from the innermost coil portion (air core portion 62 side) toward the outer periphery is defined as the "nth winding portion", a "first body 48-1, 50-1 for winding the first winding portion" and a "second body 48-2, 50-2 corresponding to the second winding portion" are provided between the upper flange portion 42 and the central flange portion 44 and between the lower flange portion 46 and the central flange portion 44. The central flange 44 is provided with a notch 52 for passing the connecting portion 30 that connects the upper winding portion 26 and the lower winding portion 28 of the electric wire 20. The electric wire 20 is wound around the notch 52 as a starting point of the winding, to form the upper winding portion 26 and the lower winding portion 28. Therefore, the alpha winding coil manufacturing jig 40-1 according to the embodiment can manufacture the alpha winding coil 10 according to the embodiment.

[0043] In the alpha winding coil manufacturing jig 40-1 for manufacturing the alpha winding coil 10, as shown in Fig. 5(A), the distance (H1+H2) between the upper flange 42 and the central flange 44 and the distance between the central flange 44 and the lower flange 46 are both shorter than twice the diameter of the electric wire 20. Therefore, both the upper winding part 26 and the lower winding part 28 have a staggered winding structure from the innermost coil part 22 toward the outer periphery, and the height of the alpha winding coil 10 is reduced.

[0044] 5(A), in the alpha winding coil manufacturing jig 40-1 for manufacturing the alpha winding coil 10, the height dimension H2 (height dimension along the central axis of the alpha winding coil 10) of the second bodies 48-2, 50-2 is shorter than the diameter of the electric wire 20. Therefore, for both the upper winding part 26 and the lower winding part 28, a staggered winding structure from the innermost periphery 22 of the coil toward the outer periphery can be effectively realized.

[0045] For example, the height dimension H1 of the first body 48-1 shown in FIG. 5(A) is the same as the diameter of the electric wire 20 as shown in FIG. 9(B) described later in order to guide the first turn winding portion of the electric wire 20. Since the odd-numbered turns and the even-numbered turns are wound in a staggered manner, the second turn winding portion of the electric wire 20 is disposed diagonally above the first turn winding portion of the electric wire 20. Therefore, the height dimension H2 of the second body 48-2 is shorter than the diameter of the electric wire 20. Also, the n+1 turn winding portion adjacent to the n-th turn winding portion is partially inserted between the n-th turn winding portion and the n+2 turn winding portion. Therefore, the distance between the upper flange 42 and the central flange 44 and the distance between the central flange 44 and the lower flange 46 are both shorter than twice the diameter of the electric wire 20.

[0046] In addition, in the alpha winding coil manufacturing jig 40-1 for manufacturing the alpha winding coil, as shown in Fig. 5(B), an air-core portion side convex portion 64 is provided on the air-core portion 62 side of the alpha winding coil manufacturing jig 40-1. This makes it possible to prevent bending of the body portion against the force applied to the air-core portion 62 side when winding the electric wire 20. In addition, the upper flange portion 42 and the lower flange portion 46 are also provided with an outer surface convex portion 66. This makes it possible to prevent bending of the upper flange portion 42 and the lower flange portion 46 against the force applied in the outer surface direction when winding the electric wire 20.

[0047] In the alpha winding coil 10 according to the embodiment, the electric wire 20 can be arranged in four different ways in the winding portion 24, as shown in Fig. 3(A) to Fig. 3(D). These electric wire 20 arrangements can be manufactured using alpha winding coil manufacturing jigs corresponding to the respective arrangements, and the alpha winding coil manufacturing jigs corresponding to the arrangements in Fig. 3(A) to Fig. 3(D) will be described below.

[0048] The alpha winding coil manufacturing jig 40-1 shown in Fig. 5(A) is a manufacturing jig for winding the electric wire 20 as shown in Fig. 3(A). Between the upper flange 42 and the central flange 44 and between the lower flange 46 and the central flange 44, the first bodies 48-1, 50-1 are located on the central flange 44 side, and the second bodies 48-2, 50-2 are located on the upper flange 42 side of the first body 48-1 between the upper flange 42 and the central flange 44, and are located on the lower flange 46 side of the first body 50-1 between the lower flange 46 and the central flange 44.

[0049] Fig. 6 is a front view of the alpha winding coil manufacturing jig 40-2. The alpha winding coil manufacturing jig 40-2 shown in Fig. 6 is a manufacturing jig for winding the electric wire 20 as shown in Fig. 3(B). Between the upper flange 42 and the central flange 44 and between the lower flange 46 and the central flange 44, the second bodies 48-2, 50-2 are located on the central flange 44 side, between the upper flange 42 and the central flange 44, the first body 48-1 is located on the upper flange 42 side of the second body 48-2, and between the lower flange 46 and the central flange 44, the first body 50-1 is located in contact with the lower flange 46 side of the second body 50-2.

[0050] Fig. 7 is a front view of the alpha winding coil manufacturing jig 40-3. The alpha winding coil manufacturing jig 40-3 shown in Fig. 7 is a manufacturing jig for winding the electric wire 20 as shown in Fig. 3(C). Between the upper flange 42 and the central flange 44, the second body 48-2 is located on the central flange 44 side, and the first body 48-1 is located on the upper flange 42 side of the second body 48-2, and between the lower flange 46 and the central flange 44, the first body 50-1 is located on the central flange 44 side, and the second body 50-2 is located on the lower flange 46 side of the first body 50-1.

[0051] Fig. 8 is a front view of the alpha winding coil manufacturing jig 40-4. The alpha winding coil manufacturing jig 40-4 shown in Fig. 8 is a manufacturing jig for winding the electric wire 20 as shown in Fig. 3(D). Between the upper flange 42 and the central flange 44, the first body 48-1 is located on the central flange 44 side, and the second body 48-2 is located on the upper flange 42 side of the first body 48-1, and between the lower flange 46 and the central flange 44, the second body 50-2 is located on the central flange 44 side, and the first body 50-1 is located on the lower flange 46 side of the second body 50-2.

[0052] 9A and 9B are diagrams for explaining a prototype model 70 of the alpha winding coil manufacturing jig 40-1. Fig. 9A is a front view of the prototype model 70, and Fig. 9B is an enlarged front view of a main part of the prototype model 70.

[0053] In the prototype model 70 of the alpha winding coil manufacturing jig 40-1, as shown in Fig. 9, the first bodies 48-1, 50-1 have an arc-shaped recess having an inner diameter corresponding to the diameter of the electric wire 20 at a portion in contact with the electric wire 20. This allows the first bodies 48-1, 50-1 to serve as a guide when winding the electric wire 20, and allows the first turn of the electric wire 20 to be wound smoothly. In addition, the second bodies 48-2, 50-2 have a tip at a position in contact with the electric wire 20, and serve as a guide for winding the electric wire 20, allowing the second turn of the electric wire 20 to be wound smoothly.

[0054] Fig. 10 is a diagram showing a state in which the alpha winding coil 10 is manufactured using a prototype model 70 of the alpha winding coil manufacturing jig 40-1. Fig. 10(A) is a front view showing the state of the first turn winding process, Fig. 10(B) is a front view showing the state of the second turn winding process, Fig. 10(C) is a front view showing the state of the third turn winding process, Fig. 10(D) is a front view showing the state of the fourth turn winding process, Fig. 10(E) is a front view showing the state of the fifth turn winding process, Fig. 10(F) is a front view showing the state of the sixth turn winding process, Fig. 10(G) is a front view showing the state of the seventh turn winding process, Fig. 10(H) is a front view showing the state of the eighth turn winding process, and Fig. 10(I) is a cross-sectional view showing the winding completion state after the eighth turn winding process is performed. 10(A) to 10(H), it appears that the lower winding part 28 has not been manufactured, but in fact, as can be seen from FIG. 10(I), the lower winding part 28 is also manufactured in the same manner as the upper winding part 26. FIG. 11 is a diagram showing a state in which the alpha winding coil 10 is removed from the prototype model 70. FIG. 11(A) is a diagram showing a state before the alpha winding coil 10 is removed, and FIG. 11(B) is a perspective view showing the alpha winding coil 10 after it has been removed from the prototype model 70.

[0055] The alpha winding coil manufacturing method according to the embodiment is a method for manufacturing an alpha winding coil 10 using a prototype model 70 of an alpha winding coil manufacturing jig, as shown in FIG.

[0056] First, the portion of the electric wire 20 that will become the connecting portion 30 is passed through the notch 52 of the central flange portion 44, and then the electric wire 20 is wound around "the first body 48-1 on the upper winding portion 26 side" and "the first body 50-1 on the lower winding portion 28 side" to perform the first turn winding process (see FIG. 10(A)).

[0057] Next, the electric wire 20 is wound using as guides "the electric wire 20 wound around the first body 48-1 on the upper winding portion 26 side in the first turn winding process, and the flange portion of the upper flange portion 42 and the central flange portion 44 that is farther from the first body 48-1 on the upper winding portion 26 side (upper flange portion 42 in the case of the embodiment)" and "the electric wire 20 wound around the first body 50-1 on the lower winding portion 28 side in the first turn winding process, and the flange portion of the lower flange portion 46 and the central flange portion 44 that is farther from the first body 50-1 on the lower winding portion 28 side (lower flange portion 46 in the case of the embodiment)" to perform the second turn winding process (see FIG. 10(B)).

[0058] Next, the electric wire 20 is wound using as guides "the electric wire 20 wound around the outer periphery of the second body 48-2 on the upper winding portion 26 side in the second turn winding process and the flange portion of the upper flange portion 42 and the central flange portion 44 that is farther from the second body 48-2 on the upper winding portion 26 side (in the case of the embodiment, the central flange portion 44)" and "the electric wire 20 wound around the outer periphery of the second body 50-2 on the lower winding portion 28 side in the second turn winding process and the flange portion of the lower flange portion 46 and the central flange portion 44 that is farther from the second body 50-2 on the lower winding portion 28 side (in the case of the embodiment, the central flange portion 44)" to perform the third turn winding process (see FIG. 10(C)).

[0059] Next, the electric wire 20 is wound using as guides "the electric wire 20 wound around the outer periphery of the first body on the upper winding portion 26 side in the third turn winding process and the flange portion of the central flange portion 44 that is farther from the first body 48-1 on the upper winding portion 26 side (upper flange portion 42 in the embodiment)" and "the electric wire 20 wound around the outer periphery of the first body 50-1 on the lower winding portion 28 side in the third turn winding process and the flange portion of the lower flange portion 46 and the central flange portion 44 that is farther from the first body 50-1 on the lower winding portion 28 side (lower flange portion 46 in the embodiment)" to perform a fourth turn winding process (see FIG. 10(D)).

[0060] In the same manner, the winding process is repeated until the required number of turns (8 turns in this embodiment) is reached (see Figs. 10(E) to 10(H)). In this manner, the alpha winding coil 10 can be manufactured using the prototype model 70 (see Fig. 10(I)).

[0061] Thereafter, as shown in FIG. 11, the alpha winding coil 10 is removed from the prototype model 70, thereby completing the alpha winding coil 10.

[0062] Each part of the prototype model 70 can be disassembled and removed individually, and the alpha winding coil 10 can be taken out in its final form after the winding of the upper and lower winding parts is completed with 8 turns. In the taken-out alpha winding coil 10, the electric wires 20 have a self-bonding layer 36, so the electric wires 20 are firmly fixed together, and the alpha winding coil 10 is completed while maintaining the wound state. Both ends of the electric wire 20 are straight and can be used as terminals.

[0063] In the alpha winding coil 10 according to the embodiment, when the alpha winding coil 10 is viewed in cross section on a plane including the central axis of the alpha winding coil 10, both the upper winding part 26 and the lower winding part 28 have a staggered winding structure from the innermost coil part 22 toward the outer periphery. Therefore, according to the alpha winding coil 10 according to the embodiment, the number of windings per unit area can be increased without thinning the electric wire 20, and as a result, a coil with a low height and a small floor area can be provided.

[0064] The alpha winding coil manufacturing jigs 40-1, 40-2, 40-3, and 40-4 according to the embodiment have a bobbin structure 60 including an upper flange 42, a central flange 44, and a lower flange 46, and when the alpha winding coil 10 is viewed in cross section on a plane including the central axis of the alpha winding coil 10, a "first body for winding the first turn winding portion" and a "second body corresponding to the second turn winding portion" are provided between the upper flange 42 and the central flange 44 and between the lower flange 46 and the central flange 44, and the central flange 44 has a notch 52 for passing the connecting portion 30 that connects the upper winding portion 26 and the lower winding portion 28 of the electric wire 20. Therefore, the alpha winding coil manufacturing jigs 40-1, 40-2, 40-3, and 40-4 according to the embodiment can manufacture the alpha winding coil 10 according to the embodiment.

[0065] In the alpha winding coil manufacturing method according to the embodiment, the first turn winding step to the fourth turn winding step are performed in sequence as described above, and the winding steps are repeated in the same manner until the required number of turns is reached to manufacture the alpha winding coil 10. Therefore, according to the alpha winding coil manufacturing method according to the embodiment, the alpha winding coil 10 of the present invention can be manufactured.

[0066] The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit and scope of the present invention. For example, the following modifications are also possible.

[0067] (1) The diameter and number of turns of the wire used in the present invention can be designed appropriately.

[0068] (2) The alpha winding coil of the present invention is not limited to a circular shape, but may be a polygonal shape.

[0069] (3) The shape of the alpha winding coil manufacturing jig of the present invention is not limited to a perfect circle, but may be an oval, an ellipse, an egg, or a polygon.

[0070] (4) The alpha winding coil of the present invention may be combined with a core.

[0071] (5) In the above embodiment, the "nth turn winding portion" and the "n+2th turn winding portion and / or the n-2th turn winding portion adjacent to the nth turn winding portion" are not in contact with each other, but the present invention is not limited to this. The present invention may be such that the "nth turn winding portion" and the "n+2th turn winding portion and / or the n-2th turn winding portion adjacent to the nth turn winding portion" are in contact with each other. In this case, the floor space of the alpha winding coil can be further reduced.

[0072] (6) In the above embodiment, the alpha winding coil 10 has a self-adhesive layer 36 formed on the outer periphery of the electric wire 20 as a winding structure stabilizing means, but the present invention is not limited to this. The alpha winding coil according to the present invention may have an adhesive layer made of an adhesive, a fixing tape, or the like as a winding structure stabilizing means. [Explanation of symbols]

[0073] 10···Alpha winding coil 20...Electric wire 22: Innermost part of coil 24 Winding section 26 Upper winding section 28 Lower winding section 30...Connection part 32 Upper section 34 Lower section 36...Self-adhesive layer 40-1, 40-2, 40-3, 40-4...Alpha winding coil manufacturing jig 42 Upper flange 44 Center flange 46 Lower flange 48-1,50-1...1st fuselage 48-2,50-2...2nd fuselage 52 Notch 60...Bobbin structure 62...Air core part 64...Air core side convex part 66...Outer surface convex part 70···Prototype model

Claims

1. An alpha winding coil in which an upper winding portion, a lower winding portion, and a connecting portion that connects the upper winding portion and the lower winding portion at an innermost circumferential portion of the coil are made of a single electric wire, An alpha winding coil characterized in that, when the alpha winding coil is viewed in cross section on a plane including the central axis of the alpha winding coil, the upper winding portion and the lower winding portion both have a staggered winding structure from the innermost portion of the coil toward the outer periphery.

2. The alpha winding coil according to claim 1, characterized in that, when the alpha winding coil is viewed in cross section on a plane including the central axis of the alpha winding coil, when the nth winding portion of the wire from the innermost portion of the coil toward the outer periphery is defined as the "nth winding portion", in both the upper winding portion and the lower winding portion, the position of the central axis of the "nth winding portion where n is an even number" along a direction parallel to the central axis of the alpha winding coil is biased along a direction parallel to the central axis of the alpha winding coil with respect to the position of the central axis of the "nth winding portion where n is an odd number" along a direction parallel to the central axis of the alpha winding coil.

3. The alpha winding coil of claim 2, wherein the bias direction of the upper winding portion and the bias direction of the lower winding portion are the same or opposite.

4. The alpha winding coil according to claim 1, characterized in that, when the alpha winding coil is viewed in cross section on a plane including a central axis of the alpha winding coil, when the nth winding portion of the wire from the innermost portion of the coil toward the outer periphery is defined as the "nth winding portion", in both the upper winding section and the lower winding section, the "nth winding portion" and the "n+1th winding portion and / or the n-1th winding portion adjacent to the nth winding portion" are in contact with each other, and the "nth winding portion" and the "n+2th winding portion and / or the n-2th winding portion adjacent to the nth winding portion" are in a non-contact state.

5. The alpha winding coil according to claim 1, characterized in that, when the alpha winding coil is viewed in cross section on a plane including the central axis of the alpha winding coil, when the nth winding portion of the wire from the innermost portion of the coil toward the outer periphery is defined as the "nth winding portion", in both the upper winding section and the lower winding section, the "nth winding portion" and the "n+1th winding portion and / or the n-1th winding portion adjacent to the nth winding portion", and the "nth winding portion" and the "n+2th winding portion and / or the n-2th winding portion adjacent to the nth winding portion" are both in contact with each other.

6. 2. The alpha winding coil of claim 1, further comprising a winding structure stabilizing means for stabilizing the winding structure.

7. The alpha winding coil according to claim 6, characterized in that the winding structure stabilizing means comprises a self-adhesive layer formed on the outer periphery of the electric wire.

8. An alpha winding coil manufacturing tool for manufacturing the alpha winding coil according to claim 1, The bobbin structure has an upper flange, a central flange, and a lower flange, When the alpha winding coil is viewed in cross section on a plane including the central axis of the alpha winding coil, the n-th winding portion of the wire from the innermost portion of the coil toward the outer periphery is defined as the "n-th winding portion." a "first body for winding a first turn winding portion" and a "second body corresponding to a second turn winding portion" are provided between the upper flange and the central flange and between the lower flange and the central flange, An alpha winding coil manufacturing jig, characterized in that the central flange portion is provided with a notch for passing a connecting portion that connects the upper winding portion and the lower winding portion of the electric wire.

9. The alpha winding coil manufacturing jig according to claim 8, wherein the first body has an arc-shaped recess having an inner diameter corresponding to a diameter of the electric wire at a portion in contact with the electric wire.

10. The alpha winding coil manufacturing jig according to claim 8, characterized in that the distance between the upper flange and the central flange and the distance between the central flange and the lower flange are both shorter than twice the diameter of the wire.

11. The alpha winding coil manufacturing jig according to claim 8, characterized in that the height dimension of the second body (the height dimension along the central axis of the alpha winding coil) is shorter than the diameter dimension of the electric wire.

12. The alpha winding coil manufacturing jig according to claim 8, characterized in that the first body is located on the central flange side of the second body both between the upper flange and the central flange and between the lower flange and the central flange.

13. The alpha winding coil manufacturing jig according to claim 8, characterized in that the second body is located on the central flange side of the first body both between the upper flange and the central flange and between the lower flange and the central flange.

14. The alpha winding coil manufacturing jig according to claim 8, characterized in that, in one of the spaces between the upper flange and the central flange and the space between the lower flange and the central flange, the first body is located on the central flange side of the second body, and in the other space between the upper flange and the central flange, the second body is located on the central flange side of the first body.

15. A method for manufacturing the alpha winding coil according to claim 1 using the alpha winding coil manufacturing jig according to claim 8, a first winding step is performed by passing a portion of the electric wire that will be the connecting portion through the notch of the central flange portion, and then winding the electric wire around "the first body on the upper winding portion side" and "the first body on the lower winding portion side", a second-turn winding step is performed by winding the electric wire using as guides "the electric wire wound around the first body on the upper winding section side in the first-turn winding step and the flange portion of the upper flange portion and the central flange portion that is farther from the first body on the upper winding section side" and "the electric wire wound around the first body on the lower winding section side in the first-turn winding step and the flange portion of the lower flange portion and the central flange portion that is farther from the first body on the lower winding section side"; a third turn winding step is performed by winding the electric wire using as guides "the electric wire wound on the outer circumferential side of the second body on the upper winding section side in the second turn winding step and the flange portion of the upper flange portion and the central flange portion that is far from the second body on the upper winding section side" and "the electric wire wound on the outer circumferential side of the second body on the lower winding section side in the second turn winding step and the flange portion of the lower flange portion and the central flange portion that is far from the second body on the lower winding section side"; a fourth-turn winding step is performed by winding the electric wire using as guides "the electric wire wound around the outer periphery of the first body on the upper winding section side in the third-turn winding step and the flange portion of the upper flange portion and the central flange portion that is far from the first body on the upper winding section side" and "the electric wire wound around the outer periphery of the first body on the lower winding section side in the third-turn winding step and the flange portion of the lower flange portion and the central flange portion that is far from the first body on the lower winding section side"; The alpha winding coil manufacturing method is characterized in that the winding process is repeated in the same manner until the required number of turns is reached to manufacture the alpha winding coil.

16. The method for manufacturing an alpha winding coil according to claim 15, characterized in that after all of the winding steps have been performed, the alpha winding coil is removed from the alpha winding coil manufacturing jig.

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