Alpha-winding coil with bobbin and method for manufacturing alpha-winding coil with bobbin

Abstract

To provide a coil with a low height and a low floor area without reducing an electric line.SOLUTION: An alpha-winding coil 10 with a bobbin includes: a bobbin 60 having an upper flange part 42, a lower flange part 46, a center flange part 44 with a notch part 52, an upper body part 23 between the upper flange part 42 and the center flange part 44, and a lower flange part 30 located between the lower flange part 46 and the center flange part 44; and an alpha-winding coil formed in which an upper winding part 26 wound around the upper body part 23 of the bobbin 60, a lower winding part 28 wound around the lower body part 30 of the bobbin 60, and a connection part 22 for connecting the upper winding part 26 and the lower winding part 28 in the innermost peripheral part of the coil are formed by a single electric wire 20. When a cross-section of the alpha-winding coil is taken at a plane including the center axis of the alpha-winding coil, 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 part to the outermost part of the coil.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an alpha-wound coil with a bobbin and a method for manufacturing an alpha-wound coil with a bobbin. [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 occupy less floor space than before are in demand, and this is also the case with 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 it may become necessary to devise a heat dissipation measure or to use additional parts.

[0005] In order to solve the above problems, the present invention aims to provide a coil with a low height and a small floor space without thinning the electric wire. Another aim of the present invention is to provide a method for manufacturing the alpha winding coil with a bobbin of the present invention. [Means for solving the problem]

[0006] (1) The alpha winding coil with a bobbin of the present invention comprises a bobbin having an upper flange, a lower flange, and a central flange with a notch formed from the outer periphery to the inner periphery, an upper body portion located between the upper flange and the central flange, and a lower body portion located between the lower flange and the central flange, and an alpha winding coil having an upper winding portion wound around the upper body portion of the bobbin, a lower winding portion wound around the lower body portion of the bobbin, and a connecting portion connecting the upper winding portion and the lower winding portion at the innermost periphery of the coil, the connecting portion being composed of a single electric wire, and 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 portion and the lower winding portion have a staggered winding structure from the innermost periphery of the coil toward the outer periphery.

[0007] (2) The alpha winding coil with a bobbin of the present invention is the alpha winding coil with a bobbin 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 with a bobbin 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 with a bobbin of the present invention is the alpha winding coil with a bobbin described in (1) above, and 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", it is preferable that in both the upper winding portion and the lower winding portion, 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 with a bobbin of the present invention is the alpha winding coil with a bobbin described in (1) above, and 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", 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", 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.

[0011] (6) The alpha winding coil with a bobbin of the present invention is the alpha winding coil with a bobbin described in (1) above, and preferably has a winding structure stabilizing means for stabilizing the winding structure.

[0012] (7) The alpha winding coil with a bobbin of the present invention is the alpha winding coil with a bobbin described above in (6), and preferably has a self-fusing layer formed on the outer periphery of the electric wire as the winding structure stabilizing means.

[0013] (8) The alpha winding coil with a bobbin of the present invention is the alpha winding coil with a bobbin described in (1) above, and 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," it is preferable that the upper body and the lower body include a first body around which the first winding portion of the electric wire is wound and a second body corresponding to the second winding portion of the electric wire.

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

[0015] (10) The alpha winding coil with a bobbin of the present invention is an alpha winding coil with a bobbin as described in (8) above, 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 with a bobbin of the present invention is the alpha winding coil with a bobbin described in (8) above, 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 with a bobbin of the present invention is the alpha winding coil with a bobbin described in (1) above, and it is preferable that the bobbin has a hollow core portion along the central axis of the alpha winding coil and has a first warping prevention means along the hollow core portion.

[0018] (13) The alpha winding coil with a bobbin of the present invention is the alpha winding coil with a bobbin described in (12) above, and it is preferable that the bobbin has, as the first warping prevention means, a plurality of linear protrusions formed along the central axis of the alpha winding coil and protruding toward the hollow core portion.

[0019] (14) The alpha winding coil with a bobbin of the present invention is the alpha winding coil with a bobbin described in (1) above, and it is preferable that both the upper flange portion and the lower flange portion have a second warp prevention means on their outer surfaces.

[0020] (15) The alpha winding coil with a bobbin of the present invention is an alpha winding coil with a bobbin as described in (14) above, and it is preferable that the second warping prevention means is a plurality of linear protrusions formed from the inner circumference toward the outer circumference.

[0021] (16) The alpha winding coil with a bobbin of the present invention is an alpha winding coil with a bobbin as described in (8) above, wherein 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.

[0022] (17) The alpha winding coil with a bobbin of the present invention is an alpha winding coil with a bobbin 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.

[0023] (18) The alpha winding coil with a bobbin of the present invention is an alpha winding coil with a bobbin as described in (8) above, wherein, in one of the areas between the upper flange and the central flange and the area 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 area, the second body is located on the central flange side of the first body.

[0024] (19) The manufacturing method of the alpha winding coil with a bobbin of the present invention is a manufacturing method of the alpha winding coil with a bobbin described in (8) above, comprising the steps of: preparing the bobbin having the upper flange, the lower flange, the central flange in which the notch is formed from the outer periphery to the inner periphery, the upper body portion located between the upper flange and the central flange, and the lower body portion located between the lower flange and the central flange; and preparing one electric wire that is the base of the alpha winding coil; and forming a bobbin having the upper flange, the lower flange, and the central flange in which the notch is formed from the outer periphery to the inner periphery. After passing the portion of the electric wire that will become the connecting portion, a first turn winding process is performed by winding the electric wire "around the first body on the upper winding section side" and "around the first body on the lower winding section side", and the electric wire is wound around "the electric wire wound around the first body on the upper winding section side in the first turn winding process, 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 process, and the flange portion of the lower flange portion and the central flange portion that is farther from the first body on the upper winding section side in the first turn winding process" and "the electric wire wound around the first body on the lower winding section side in the first turn winding process, a second winding step is performed by winding the electric wire using as a guide "the electric wire wound around the outer periphery of the second body on the upper winding section side and the flange portion of the upper flange and the central flange portion that is far from the second body on the upper winding section side in the second turn winding step" and "the electric wire wound around the outer periphery of the second body on the lower winding section side and the flange portion of the lower flange and the central flange portion that is far from the second body on the lower winding section side in the second turn winding step" a third turn winding process is performed by winding the electric wire using as a guide "the electric wire wound around the outer circumferential side of the first body on the upper winding section side in the third turn winding process 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 in the third turn winding process" and "the electric wire wound around the outer circumferential side of the first body on the lower winding section side in the third turn winding process 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 in the third turn winding process" as guides, and a fourth turn winding process is performed by winding the electric wire using as a guide "the electric wire wound around the outer circumferential side of the first body on the upper winding section side in the third turn winding process 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 in the third turn winding process" andThe method is characterized in that the alpha-wound coil with bobbin is manufactured by repeating the winding process until the required number of turns is reached. Effect of the Invention

[0025] In the alpha winding coil with a bobbin 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 with a bobbin of the present invention, it is possible to increase the number of windings per unit area without thinning the electric wire, and as a result, it is possible to provide a coil with a low height and a small floor area.

[0026] In the manufacturing method of the alpha winding coil with a bobbin 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 with a bobbin is manufactured by repeating the winding steps in the same manner until the required number of turns is reached. Therefore, the manufacturing method of the alpha winding coil with a bobbin of the present invention can manufacture the alpha winding coil with a bobbin of the present invention. [Brief description of the drawings]

[0027] [Figure 1] 1 is an external view of an alpha winding coil 10 with a bobbin according to an embodiment. FIG. [Diagram 2] 1 is a cross-sectional view taken along a plane including the central axis of the alpha winding coil 12. FIG. [Diagram 3] 2 is an enlarged cross-sectional view of a main portion of a winding portion 24 of the alpha winding coil 12. FIG. [Figure 4] FIG. [Diagram 5] 2 is an enlarged view showing the vicinity of an upper body portion 23 and a lower body portion 30 of a bobbin 60. FIG. [Figure 6] FIG. [Figure 7] FIG. 2 is a front view of the bobbin structure 60-1. [Figure 8] FIG. 2 is a front view of the bobbin structure 60-2. [Figure 9] FIG. 2 is a front view of the bobbin structure 60-3. [Figure 10] FIG. 1 is a front view of the bobbin structure 60-4. [Figure 11] FIG. 1 is a diagram showing how a bobbin-attached alpha-wound coil 10 is manufactured using a bobbin 60 having a bobbin structure 60-1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] Hereinafter, an embodiment of the alpha winding coil with a bobbin and the method for manufacturing the alpha winding coil with a bobbin of the present invention will be described.

[0029] FIG. 1 is an external view of an alpha winding coil 10 with a bobbin according to an embodiment. FIG. 1(A) is a perspective view of the alpha winding coil 10 with a bobbin, FIG. 1(B) is a cross-sectional view of the alpha winding coil 10 with a bobbin along a plane including a straight line AA in FIG. 1(A) and a central axis of the alpha winding coil 12 (not shown), and FIG. 1(C) is a front view of the alpha winding coil 10 with a bobbin. FIG. 2 is a cross-sectional view in a plane including the central axis of the alpha winding coil 12. FIG. 2(A) is a cross-sectional view of the entire alpha winding coil 12, and FIG. 2(B) is an enlarged cross-sectional view of a main part of the winding part 24 of the alpha winding coil 12. FIG. 3 is an enlarged cross-sectional view of a main part of the winding part 24 of the alpha winding coil 12. FIG. 3(A) to FIG. 3(D) are diagrams showing variations in the direction of deviation of the central axis of the "nth winding part where n is an even number" relative to the central axis of the "nth winding part where n is an odd number". Details will be described later.

[0030] As shown in Fig. 1 to Fig. 3, the alpha winding coil 10 with a bobbin includes a bobbin 60 having an upper flange 42, a lower flange 46, a central flange 44 with a notch 52 formed from the outer periphery to the inner periphery, an upper body 23 located between the upper flange 42 and the central flange 44, and a lower body 30 located between the lower flange 46 and the central flange 44, an upper winding part 26 wound around the upper body 23 of the bobbin 60, a lower winding part 28 wound around the lower body 30 of the bobbin 60, and a connecting part 22 connecting the upper winding part 26 and the lower winding part 28 at the innermost periphery of the coil, the connecting part 22 being made of a single electric wire 20. The connecting part 22 connects the upper winding part 26 and the lower winding part 28 through the notch 52. When the alpha winding coil 12 is viewed in cross section on a plane including the central axis of the alpha winding coil 12, both the upper winding portion 26 and the lower winding portion 28 have a staggered winding structure from the innermost periphery of the coil toward the outer periphery. Therefore, according to the alpha winding coil 10 with a bobbin 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 low floor area can be provided. In addition, according to the alpha winding coil 10 with a bobbin according to the embodiment, since it includes a bobbin 60, it is possible to increase the structural stability of the alpha winding coil 12.

[0031] In the alpha winding coil 10 with a bobbin according to the embodiment, the upper winding part 26 and the lower winding part 28 each have a staggered winding structure from the innermost periphery 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 12 is viewed in cross section on a plane including the central axis of the alpha winding coil 12, if the nth turn winding part of the electric wire 20 from the innermost periphery 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 a direction parallel to the central axis of the alpha winding coil 12 is biased along a direction parallel to the central axis of the alpha winding coil 12 with respect to the position of the central axis of the "nth turn winding part where n is an odd number" along a direction parallel to the central axis of the alpha winding coil 12.

[0032] 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 12 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.

[0033] In the alpha winding coil 12 in the embodiment, as shown in Fig. 3, the bias direction in the upper winding portion 26 and the bias direction in the lower winding portion 28 may be the same or opposite. That is, the winding portion of the upper winding portion 26 that is an odd number of turns and the winding portion of the upper winding portion 26 that is an even number of turns may be disposed in either the upper stage portion 32 or the lower stage portion 34 of the upper winding portion 26, and the winding portion of the lower winding portion 28 that is an odd number of turns and the winding portion of the lower winding portion 28 that is an even number of turns may be disposed in either the upper stage portion 32 or the lower stage portion 34. Various winding layouts are possible.

[0034] 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 mid-plane X between 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 midplane X between the upper winding portion 26 and the lower winding portion 28.

[0035] 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 mid-plane X between 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 midplane X between the upper winding portion 26 and the lower winding portion 28.

[0036] 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 mid-plane X between 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 midplane X between upper winding portion 26 and lower winding portion 28.

[0037] 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 mid-plane X between 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 midplane X between upper winding portion 26 and lower winding portion 28.

[0038] In the alpha winding coil 12 of the embodiment, as shown in Figs. 2 and 3, when the alpha winding coil 12 is viewed in cross section on a plane including the central axis of the alpha winding coil 12, when the nth winding portion of the wire 20 from the innermost portion of the coil 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.

[0039] 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.

[0040] 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 section 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 section 24 to be reduced, and the height of the alpha winding coil 10 with bobbin can be reduced.

[0041] Fig. 4 is a cross-sectional view of the electric wire 20. The alpha winding coil 10 with a bobbin according to the embodiment has a winding structure stabilizing means for stabilizing the winding structure, as shown in Fig. 4. The alpha winding coil 10 with a bobbin 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.

[0042] 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.

[0043] Next, the bobbin 60 in the bobbin-attached alpha winding coil 10 according to the embodiment will be described in detail. Fig. 5 is an enlarged view of the vicinity of the upper body portion 23 and the lower body portion 30 of the bobbin 60. Fig. 5(A) is a view showing a state in which the electric wire 20 is not wound, and Fig. 5(B) is a view showing a state in which the first turn winding portion and the second turn winding portion of the electric wire 20 are wound. In Fig. 5(B), the electric wire 20 is shown in cross section. Fig. 6 is a perspective view of the bobbin 60.

[0044] In the alpha winding coil 10 with a bobbin according to the embodiment, when the alpha winding coil 12 is viewed in cross section on a plane including the central axis of the alpha winding coil 12, when the n-th winding portion of the electric wire 20 from the innermost circumferential portion of the coil toward the outer circumferential side is defined as the "n-th winding portion," the upper body 23 and the lower body 30 include first bodies 48-1, 50-1 around which the first winding portion of the electric wire 20 is wound, and second bodies 48-2, 50-2 corresponding to the second winding portion of the electric wire 20. Therefore, according to the alpha winding coil 10 with a bobbin according to the embodiment, the alpha winding coil 12 can be formed by winding the electric wire 20 around the bobbin 60.

[0045] 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, allowing the first turn of the electric wire 20 to be wound smoothly. 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.

[0046] In the alpha winding coil 10 with a bobbin according to the embodiment, 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 part of the coil toward the outer periphery, and the height of the alpha winding coil 10 with a bobbin is reduced.

[0047] 5(A), in the alpha winding coil 10 with a bobbin according to the embodiment, the height H2 (height along the central axis of the alpha winding coil 12) 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 portion of the coil toward the outer periphery can be effectively realized.

[0048] 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. 5(B) 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.

[0049] In the bobbin-attached alpha winding coil 10 according to the embodiment, as shown in Fig. 6, the bobbin 60 has an air-core portion 62 along the central axis of the alpha winding coil 12, and has a first warping prevention means 64 along the air-core portion 62. This makes it possible to prevent bending of the body against the force acting on the air-core portion 62 when winding the electric wire 20. The "air-core portion" refers to a hollow through opening in the center of the bobbin.

[0050] The bobbin 60 has, as the first warp prevention means 64, a plurality of linear protrusions formed along the central axis of the alpha winding coil 12 and protruding toward the air-core portion 62. The linear protrusions are reinforcing means for preventing bending of the body, and thus can more reliably prevent bending of the body against the force applied to the air-core portion 62 when winding the electric wire 20.

[0051] In the alpha winding coil 10 with a bobbin according to the embodiment, both the upper flange 42 and the lower flange 46 have a second warp prevention means 66 on the outer surface, as shown in Fig. 6. This makes it possible to prevent bending of the upper flange 42 and the lower flange 46 against the force applied in the direction of the outer surface when winding the electric wire 20.

[0052] The second warp prevention means 66 is a plurality of linear protrusions formed from the inner periphery toward the outer periphery. The linear protrusions are reinforcing means for preventing bending of the upper flange 42 and the lower flange 46, and thus it is possible to more reliably prevent bending of the upper flange 42 and the lower flange 46 against the force applied in the outer surface direction when the electric wire 20 is wound.

[0053] In the alpha winding coil 10 with a bobbin according to the embodiment, the electric wire 20 can be arranged in four different ways in the winding section 24, as shown in Fig. 3(A) to Fig. 3(D). These electric wire 20 arrangements can be manufactured using the corresponding bobbins 60. The structure (bobbin structure) of the bobbin 60 in the alpha winding coil 10 with a bobbin corresponding to the arrangements in Fig. 3(A) to Fig. 3(D) will be described below.

[0054] Fig. 7 is a front view of a bobbin structure 60-1. The bobbin structure 60-1 shown in Fig. 7 is a bobbin structure around which the electric wire 20 of Fig. 3(A) is wound. Between the upper flange 42 and the central flange 44 and between the lower flange 46 and the central flange 44, the first body 48-1, 50-1 is located on the central flange 44 side, between the upper flange 42 and the central flange 44, 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 lower flange 46 side of the first body 50-1.

[0055] Fig. 8 is a front view of a bobbin structure 60-2. The bobbin structure 60-2 shown in Fig. 8 is a bobbin structure around which the electric wire 20 of Fig. 3(B) is wound. 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 on the lower flange 46 side of the second body 50-2.

[0056] Fig. 9 is a front view of a bobbin structure 60-3. The bobbin structure 60-3 shown in Fig. 9 is a bobbin structure around which the electric wire 20 of Fig. 3(C) is wound. 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.

[0057] Fig. 10 is a front view of a bobbin structure 60-4. The bobbin structure 60-4 shown in Fig. 10 is a bobbin structure around which the electric wire 20 of Fig. 3(D) is wound. 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.

[0058] Next, a method for manufacturing an alpha winding coil with a bobbin according to the embodiment will be described. Fig. 11 is a diagram showing a state in which a bobbin-attached alpha winding coil 10 is manufactured using a bobbin 60 having a bobbin structure 60-1. Fig. 11(A) is a front view showing the state of the first turn winding process, Fig. 11(B) is a front view showing the state of the second turn winding process, Fig. 11(C) is a front view showing the state of the third turn winding process, Fig. 11(D) is a front view showing the state of the fourth turn winding process, Fig. 11(E) is a front view showing the state of the fifth turn winding process, Fig. 11(F) is a front view showing the state of the sixth turn winding process, Fig. 11(G) is a front view showing the state of the seventh turn winding process, Fig. 11(H) is a front view showing the state of the eighth turn winding process, and Fig. 11(I) is a cross-sectional view showing the winding completion state after the eighth turn winding process is performed. 11(A) to 11(H), it appears that the lower winding portion 28 has not been manufactured, but in reality, the lower winding portion 28 is manufactured in the same manner as the upper winding portion 26.

[0059] The manufacturing method of the alpha winding coil with a bobbin according to the embodiment is a method for manufacturing the alpha winding coil with a bobbin 10, as shown in Fig. 11. First, a bobbin 60 having an upper flange 42, a lower flange 46, a central flange 44 in which a notch 52 is formed from the outer periphery to the inner periphery, an upper body 23 located between the upper flange 42 and the central flange 44, and a lower body 30 located between the lower flange 46 and the central flange 44, and one electric wire 20 which is the base of the alpha winding coil 12 are prepared. In the embodiment, a bobbin 60 having a bobbin structure 60-1 is prepared.

[0060] Next, the portion of the electric wire 20 that will become the connecting portion 22 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 "around the first body 50-1 on the lower winding portion 28 side" to perform the first turn winding process (see FIG. 11(A)).

[0061] 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. 11(B)).

[0062] 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. 11(C)).

[0063] Next, the electric wire 20 is wound using as guides "the electric wire 20 wound around the outer periphery of the first body 48-1 on the upper winding portion 26 side in the third turn winding process and the flange portion of the upper flange portion 42 and the central flange portion 44 that is farthest 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 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 farthest 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 a fourth turn winding process (see FIG. 11(D)).

[0064] The winding process is repeated in the same manner until the required number of turns (8 turns in this embodiment) is reached (see Figs. 11(E) to 11(H)). In this manner, the alpha winding coil 10 with a bobbin can be manufactured (see Fig. 11(I)). In the alpha winding coil 10 with a bobbin, 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 with a bobbin is completed while maintaining the wound state. Both ends of the electric wire 20 are straight and can be used as terminals.

[0065] In the alpha winding coil 10 with a bobbin according to the embodiment, when the alpha winding coil 12 is viewed in cross section on a plane including the central axis of the alpha winding coil 12, both the upper winding portion 26 and the lower winding portion 28 have a staggered winding structure from the innermost portion of the coil toward the outer periphery. Therefore, according to the alpha winding coil 10 with a bobbin 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 low floor area.

[0066] In the manufacturing method of the alpha winding coil with a bobbin according to the embodiment, the first turn winding process to the fourth turn winding process are performed in sequence as described above, and the winding processes are repeated in the same manner until the required number of turns is reached to manufacture the alpha winding coil with a bobbin 10. Therefore, according to the manufacturing method of the alpha winding coil with a bobbin according to the embodiment, the alpha winding coil with a bobbin 10 according to the embodiment can be manufactured.

[0067] 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.

[0068] (1) The diameter and number of turns of the wire used in the present invention can be designed appropriately.

[0069] (2) The shape of the alpha winding coil in the alpha winding coil with bobbin of the present invention is not limited to a perfect circle, but may be an oval, an ellipse, an egg, or a polygon.

[0070] (3) The bobbin in the alpha winding coil with bobbin of the present invention is not limited to a perfect circle, but may be an oval, an ellipse, an egg, or a polygon.

[0071] (4) A core may be combined with the alpha-wound coil with bobbin of the present invention.

[0072] (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 one in which 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 with a bobbin can be further reduced.

[0073] (6) In the above embodiment, the alpha winding coil with a bobbin 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 with a bobbin 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.

[0074] (7) In the above embodiment, the bobbin 60 has the first warp prevention means 64 and the second warp prevention means 66 which are a plurality of linear protrusions, but the present invention is not limited to this. The first warp prevention means and the second warp prevention means in the bobbin are not limited to linear protrusions, and may have any shape that can prevent bending of the body, upper flange, lower flange, etc. Also, the bobbin does not have to have one or both of the first warp prevention means and the second warp prevention means. [Explanation of symbols]

[0075] 10···Alpha wound coil with bobbin 12. Alpha winding coil 20...Electric wire 22...Connection part 23 Upper body 24 Winding section 26 Upper winding section 28 Lower winding section 30 Lower body 32 Upper section 34 Lower section 36...Self-adhesive layer 42 Upper flange 44 Central flange 46 Lower flange 48-1,50-1...1st fuselage 48-2,50-2...2nd fuselage 52 Notch 60...Bobbin 60-1, 60-2, 60-3, 60-4...Bobbin structure 62...Air core part 64...First warpage prevention method 66...Second warp prevention method

Claims

1. a bobbin having an upper flange, a lower flange, a central flange having a notch formed from an outer periphery to an inner periphery, an upper body portion located between the upper flange and the central flange, and a lower body portion located between the lower flange and the central flange; an alpha winding coil including an upper winding portion wound around the upper body of the bobbin, a lower winding portion wound around the lower body of the bobbin, and a connecting portion connecting the upper winding portion and the lower winding portion at an innermost periphery of the coil, the connecting portion being made of a single electric wire; An alpha winding coil with a bobbin, 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. 2. The alpha winding coil with a bobbin 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. 3. The alpha winding coil with bobbin according to 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 to each other.

4. The alpha winding coil with a bobbin 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" 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 with a bobbin 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 with bobbin according to claim 1, further comprising a winding structure stabilizing means for stabilizing the winding structure.

7. 7. The alpha winding coil with bobbin 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. 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." 2. The alpha-wound coil with bobbin according to claim 1, wherein the upper body portion and the lower body portion include a first body around which a first turn of the electric wire is wound and a second body corresponding to a second turn of the electric wire.

9. The alpha winding coil with a bobbin 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 with bobbin 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 with a bobbin 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. 2. The alpha winding coil with bobbin according to claim 1, wherein the bobbin has a hollow core along a central axis of the alpha winding coil and a first warping prevention means along the hollow core.

13. The bobbin has a plurality of linear protrusions formed along the central axis of the alpha winding coil and protruding toward the hollow core portion as the first warping prevention means.

14. 2. The alpha-wound coil with bobbin according to claim 1, wherein both the upper flange portion and the lower flange portion have a second warp prevention means on an outer surface thereof.

15. The alpha winding coil with bobbin according to claim 14, wherein the second warp prevention means is a plurality of linear protrusions formed from the inner periphery toward the outer periphery.

16. The alpha-wound coil with bobbin 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.

17. The alpha-wound coil with bobbin 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.

18. The alpha-wound coil with a bobbin according to claim 8, characterized in that, in one of the areas between the upper flange and the central flange and the area 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 area, the second body is located on the central flange side of the first body.

19. A method for manufacturing an alpha-wound coil with a bobbin according to claim 8, comprising the steps of: a bobbin having the upper flange, the lower flange, the central flange in which the notch is formed from the outer periphery to the inner periphery, the upper body portion located between the upper flange and the central flange, and the lower body portion located between the lower flange and the central flange; and a single electric wire that is a base of the alpha winding coil; 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 method for manufacturing an alpha-wound coil with a bobbin is characterized in that the winding process is repeated in the same manner until the required number of turns is reached, thereby manufacturing the alpha-wound coil with a bobbin.

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