Novel coil structure and its manufacturing method

Abstract

This application relates to a novel coil structure and a method for manufacturing the same. This novel coil structure includes an inner coil, an insulating cylindrical layer, an outer coil, and a first corner ring. The inner coil is provided in a ring on the inside of the insulating cylindrical layer, and the outer coil is provided in a ring on the outside of the insulating cylindrical layer. Two first corner rings are provided, and both first corner rings are wrapped with insulating tape to form an annular structure. The two first corner rings are located at both ends of the outer coil. By providing first corner rings at both ends of the outer coil, the electric field strength at the ends of the outer coil can be reduced, improving the electrical insulation performance of this novel coil structure. Furthermore, since the first corner rings are formed by directly wrapping them with insulating tape, the phenomenon of reduced insulation performance due to the first corner rings being susceptible to moisture is avoided, making the overall electrical insulation performance of the novel coil structure relatively stable and further improving the reliability of the insulation performance.

Description

Technical Field

[0001] This application relates to the technical field of transformers, and particularly to a novel coil structure and its manufacturing method.

Background Art

[0002] In recent years, with the acceleration of urbanization in our country and the rapid development of fields such as rail transit and data centers, the demand for fireproof and explosion-proof dry-type transformers has been steadily increasing year by year. Here, the closed three-dimensional wound core dry-type transformer has advantages such as low noise, low radiation, and high fireproof and explosion-proof performance, and is widely applied.

[0003] For closed three-dimensional wound core dry-type transformers with a voltage level of 20 kV or higher, since the electric field strength at the coil end is relatively large, in order to ensure the electrical insulation performance of the product, generally, the air distance between the outer coil and the inner coil and metal parts such as the upper and lower iron yokes of the iron core is increased, so as to meet the requirements for the electrical insulation performance of such transformers. However, increasing the air insulation distance will increase the size of components such as the iron core and coil, which is disadvantageous for the transfer and installation of the transformer. Currently, in order to simultaneously meet the requirements of volume and insulation performance, engineers can achieve it by directly providing a soft corner ring of crepe paper at the coil end. However, since crepe paper is made by wrinkling insulating kraft paper as the base material, as the service life of the dry-type transformer lengthens, the corner ring made of crepe paper is more likely to receive moisture, resulting in a decrease in electrical insulation performance and a decrease in the reliability of the dry-type transformer.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Based on this, in response to the above problems, it is necessary to provide a novel coil structure and its manufacturing method, and the insulation reliability of this novel coil is high and the stability is stronger.

Means for Solving the Problems

[0005] A new type of coil structure comprising an inner coil, an insulating cylindrical layer, an outer coil, and a first corner ring, wherein the inner coil is provided in a ring on the inside of the insulating cylindrical layer, the outer coil is provided in a ring on the outside of the insulating cylindrical layer, two first corner rings are provided, and both of the first corner rings are wrapped with insulating tape to form an annular structure, and the two first corner rings are each located at both ends of the outer coil.

[0006] In the new coil structure described above, by providing first corner rings at both ends of the outer coil, the electric field strength at the ends of the outer coil can be reduced, thereby improving the electrical insulation performance of this new coil structure. Furthermore, since the first corner rings are formed by directly wrapping them with insulating tape, the phenomenon of their insulation performance degrading due to moisture exposure is avoided, making the overall electrical insulation performance of the new coil structure relatively stable and further improving the reliability of the insulation performance.

[0007] The technical proposal will be explained further below.

[0008] In one embodiment, the novel coil structure further includes a comb-shaped stay, of which a plurality of the comb-shaped stays are provided, and the plurality of the comb-shaped stays are provided on the outside of the insulating cylindrical layer along the circumferential direction of the insulating cylindrical layer, and each end of the comb-shaped stay is provided with a square ring locking groove, and the two square ring locking grooves are used to engage with the two first square rings in a one-to-one correspondence, the comb-shaped stay is provided with a plurality of comb teeth notches along its axial direction, and the plurality of comb teeth notches are all located between the two square ring locking grooves, and the outer coil includes a plurality of stacked disc-shaped coils, each of which corresponds one-to-one to the plurality of comb teeth notches, and each disc-shaped coil is locked in the corresponding comb teeth notch.

[0009] In one embodiment, the comb-shaped stay includes a first stay portion and a second stay portion, wherein a mounting groove is formed within the first stay portion, the second stay portion is provided within the mounting groove, and the second stay portion is provided at a distance from the groove wall of the mounting groove to form the square ring locking groove, and each of the comb tooth notches is provided at a distance along the axial direction of the second stay portion on the side of the second stay portion away from the first stay portion.

[0010] In one embodiment, the first corner ring includes a first cylindrical body and a first extending ring, one end of the first cylindrical body connected to the inner ring of the first extending ring and provided to form a narrow angle, and the corner ring locking groove includes a first groove body and a second groove body that communicate with each other and are provided to form a narrow angle, the first cylindrical body is locked in each of the first groove bodies, and the first extending ring is locked in each of the second groove bodies and covers the end face of the outer coil.

[0011] In one embodiment, the novel coil structure further includes a square ring support assembly, the square ring support assembly includes a first position limiting cylinder, a second position limiting cylinder, and a support ring, the first and second position limiting cylinders both located within the first groove and abutting against both sides of the first cylindrical body, and the support ring located within the second groove and supported on the side of the first extending ring facing the first cylindrical body.

[0012] In one embodiment, the novel coil structure further includes a disc-shaped coil end coil, and a plurality of such disc-shaped coil end coils are provided, and the comb-shaped stay is provided with a plurality of end coil locking grooves along its axial direction, and each of the plurality of end coil locking grooves is located between two of the square ring locking grooves, and each of the plurality of disc-shaped coil end coils engages with the plurality of end coil locking grooves in a one-to-one correspondence. and / or, the new coil structure further includes a second square ring, the second square ring includes a second cylindrical body and a second extending ring, one end of the second cylindrical body connected to the inner ring of the second extending ring and provided to form a narrow angle, the insulating cylindrical layer includes an inner insulating cylinder and an outer insulating cylinder that are sleeve-jointed, the inner coil is provided in a ring on the inside of the inner insulating cylinder, the comb-shaped stay is provided on the outside of the outer insulating cylinder, the second cylindrical body is engaged between the inner insulating cylinder and the outer insulating cylinder, the second extending ring extends toward the comb-shaped stay and covers the end face of the comb-shaped stay, and / or the new coil structure further includes end retaining rings, two of which are provided, and each end of the comb-shaped stay is further provided with a retaining ring locking groove, the retaining ring locking groove being further away from the comb tooth notch than the square ring locking groove, and the two retaining ring locking grooves each engage with the two end retaining rings in a one-to-one correspondence.

[0013] This application further provides a method for manufacturing a novel coil structure, the manufacturing method comprising the steps of winding an inner coil, assembling an insulating cylindrical layer outside the inner coil, providing each comb-shaped stay at intervals outside the insulating cylindrical layer along the circumferential direction of the insulating cylindrical layer, winding insulating tape around the outside of each comb-shaped stay and folding it back to form a first corner ring, winding an outer coil around the outside of each comb-shaped stay, and attaching a disc-shaped coil end coil and an end retaining ring on the comb-shaped stay.

[0014] In one embodiment, the step of assembling an insulating cylinder layer outside the inner coil specifically includes: bonding two pre-formed inner semi-cylinders to the outside of the inner coil to form an inner insulating cylinder; winding at least one inner insulating layer onto the outer wall of the inner insulating cylinder, offsetting the joints of the inner insulating layer and the bonding locations of the inner insulating cylinder; bonding two pre-formed outer semi-cylinders to the outside of the inner insulating layer to form an outer insulating cylinder; winding at least one outer insulating layer onto the outer wall of the outer insulating cylinder, offsetting the joints of the outer insulating layer and the bonding locations of the outer insulating cylinder.

[0015] In one embodiment, the method for manufacturing the novel coil structure further includes the steps of winding an insulating tape between the inner insulating layer and the outer insulating cylinder to form a second annular tape layer, folding one end of the second annular tape layer outward, and having the outwardly folded portion cover the end face of the outer insulating cylinder to form a second corner ring.

[0016] In one embodiment, the steps of providing each comb-shaped stay at intervals on the outside of the insulating cylindrical layer along the circumferential direction of the insulating cylindrical layer, and wrapping insulating tape around the outside of each comb-shaped stay and folding it back to form a first corner ring, specifically, the comb-shaped stay includes a first stay portion and a second stay portion, a mounting groove is formed in the first stay portion, the second stay portion is provided in the mounting groove and the second stay portion is provided at a distance from the groove wall of the mounting groove to form a corner ring locking groove, and each of the first stay portions is provided at intervals on the outside of the insulating cylindrical layer along the circumferential direction of the insulating cylindrical layer, and a first The method includes wrapping a position limiting cylinder around the first position limiting cylinder to form a first annular tape layer, wrapping a second position limiting cylinder around the outside of the first annular tape layer, attaching a plurality of pre-formed arc-shaped rings to the outside of the first annular tape layer to form a circular support ring, folding one end of the first annular tape layer outward, laying the outwardly folded portion on the support ring along the radial direction of the support ring to form a first square ring, and providing the second stay portion within the corresponding first stay portion to form the square ring locking groove, and locking the first square ring in the square ring locking groove.

[0017] The accompanying drawings, which constitute part of this application, are provided for further understanding of this application, and the exemplary embodiments and descriptions herein are for interpretation purposes only and do not constitute an unreasonable limitation of this application.

[0018] To more clearly illustrate the technical solution in the embodiments of this application, the following briefly introduces the attached drawings that need to be used in the description of the embodiments. It is self-evident that the attached drawings in the following description are only some embodiments of this application. For those skilled in the art, based on these attached drawings and without the need for creative efforts, other attached drawings can also be obtained.

[0019] Note that the attached drawings are not drawn at a scale of 1:1, and the relative dimensions of each component are only illustrated in the drawings and are not necessarily drawn at the true scale.

Brief Description of the Drawings

[0020] [Figure 1] It is a schematic structural diagram of a new coil structure and a winding mold in an embodiment of this application. [Figure 2] It is a schematic structural diagram when the new coil structure in an embodiment of this application is wound around an iron core. [Figure 3] It is a three-dimensional view of the new coil structure in an embodiment of this application. [Figure 4] It is a cross-sectional view of the new coil structure in the first embodiment of this application. [Figure 5] It is a cross-sectional view of the new coil structure in another embodiment of this application. [Figure 6] It is a schematic structural diagram of the comb-shaped stay in the new coil structure in FIG. 3. [Figure 7] It is a schematic exploded view of the structure of the comb-shaped stay in FIG. 6. [Figure 8] It is a schematic structural diagram of the first corner ring in the new coil structure in FIG. 3. [Figure 9] It is a cross-sectional structural view of the first corner ring and the corner ring support assembly in an embodiment of this application.

Modes for Carrying Out the Invention

[0021] To make the above objects, features, and advantages of the present application clearer and easier to understand, the specific embodiments of the present application will be described in detail below with reference to the accompanying drawings. In the following description, many specific details are described to fully understand the present application. However, the present application can be implemented in many ways other than those described here, and those skilled in the art can make similar improvements without departing from the spirit of the present application. Therefore, the present application is not limited by the specific embodiments disclosed below.

[0022] In the description of the present application, the orientation or positional relationship indicated by terms such as "center", "vertical direction", "horizontal direction", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial direction", "radial direction", "circumferential direction", etc. is the orientation or positional relationship shown in the accompanying drawings. It is only for the purpose of simplifying the description of the present application and does not indicate or imply that the device or element must have a specific orientation, be configured, and operated in a specific orientation. Therefore, it should not be understood as a limitation to the present application.

[0023] Note that the terms "first" and "second" are used only for the purpose of description and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, the features limited by "first" and "second" can explicitly or implicitly include at least one of these features. In the description of the present application, the meaning of the term "plurality" is at least two, for example, two, three, etc., unless specifically limited.

[0024] In this application, unless otherwise explicitly stated or limited, terms such as “attached,” “connected,” “connected,” and “fixed” should be understood in a broad sense. For example, unless otherwise explicitly limited, a connection may be fixed, detachable, integrated, mechanical, electrical, direct, indirect via an intermediary, or an internal communication between two elements or an interaction relationship between two elements. Those skilled in the art will be able to understand the specific meaning of these terms in this application depending on the specific circumstances.

[0025] In this application, unless otherwise specified or limited, similar descriptions such as the first feature being "above" or "below" the second feature may mean that the first and second features are in direct contact, or that they are indirectly in contact through an intermediate mediator. Furthermore, the statement that the first feature is "above," "above," and "above" the second feature may mean that the first feature is directly above or diagonally above the second feature, or that the horizontal height of the first feature is greater than that of the second feature. The statement that the first feature is "below," "below," and "below" the second feature may mean that the first feature is directly below or diagonally below the second feature, or that the horizontal height of the first feature is less than that of the second feature.

[0026] When an element is referred to as being "fixed" or "mounted" to another element, it may be directly positioned on the other element, or there may be a centrally positioned element. When one element is considered to be "connected" to another element, it may be directly connected to the other element, or there may be a centrally positioned element simultaneously. Where applicable, the terms "vertical," "horizontal," "up," "down," "left," "right," and similar descriptions used in this application are for illustrative purposes only and do not indicate that there are only a few embodiments.

[0027] Referring to Figures 2 to 4, one embodiment of the present application provides a novel coil structure 10 including an inner coil 110, an insulating cylindrical layer 120, an outer coil 130, and a first corner ring 140. The inner coil 110 is provided in a ring inside the insulating cylindrical layer 120, and the outer coil 130 is provided in a ring outside the insulating cylindrical layer 120. Two first corner rings 140 are provided, and both first corner rings 140 are wrapped with insulating tape to form an annular structure, and the two first corner rings 140 are located at both ends of the outer coil 130.

[0028] In the new coil structure 10 described above, by providing first corner rings 140 at both ends of the outer coil 130, the electric field strength at the ends of the outer coil 130 can be reduced, thereby improving the electrical insulation performance of this new coil structure 10. Furthermore, since the first corner rings 140 are formed by directly wrapping them with insulating tape, the phenomenon of the first corner rings 140 being susceptible to moisture and thus degrading their insulation performance can be avoided, making the overall electrical insulation performance of the new coil structure 10 relatively stable and further improving the reliability of the insulation performance.

[0029] Furthermore, the insulating tape used in this embodiment has characteristics such as strong electrical performance, high density, and excellent ductility. Because the insulating tape is easy to clean and does not accumulate ash easily, the insulating performance of the first corner ring 140 can be made relatively stable.

[0030] Referring to Figures 2 to 4 and Figure 6, in one embodiment, the novel coil structure 10 further includes comb-shaped stays 150. Multiple comb-shaped stays 150 are provided, and the multiple comb-shaped stays 150 are provided on the outside of the insulating cylindrical layer 120 along the circumferential direction of the insulating cylindrical layer 120. Each end of the comb-shaped stay 150 is provided with a square ring locking groove 153, and the two square ring locking grooves 153 are used to engage with two first square rings 140 in a one-to-one correspondence.

[0031] Specifically, as shown in Figures 3 to 7, the comb-shaped stay 150 has a plurality of comb-tooth notches 1521 along its axial direction, and all of the comb-tooth notches 1521 are located between two square ring locking grooves 153. The outer coil 130 includes a plurality of stacked disc-shaped coils 131, each of which corresponds one-to-one with a plurality of comb-tooth notches 1521, and each disc-shaped coil 131 is locked within its corresponding comb-tooth notch 1521. The comb-shaped stay 150 effectively supports the outer coil 130 and the first square ring 140, and improves the simplicity of the new coil structure 10.

[0032] In this embodiment, the comb-shaped stay 150 is made of insulating material.

[0033] Referring to Figures 6 and 7, in one embodiment, the comb-shaped stay 150 includes a first stay portion 151 and a second stay portion 152. A mounting groove 1511 is formed within the first stay portion 151, and the second stay portion 152 is provided within the mounting groove 1511, and the second stay portion is provided at a distance from the groove wall of the mounting groove 1511 to form a corner ring locking groove 153. Each comb tooth notch 1521 is provided at a distance along the axial direction of the second stay portion 152 on the side of the second stay portion 152 away from the first stay portion 151. In this way, it is easy to wind a disc-shaped coil 131 around each comb tooth notch 1521 to form an outer coil 130.

[0034] Referring to Figures 4 and 8, in one embodiment, the first corner ring 140 includes a first cylindrical body 141 and a first extending ring 142. One end of the first cylindrical body 141 is connected to the inner ring of the first extending ring 142 and is provided to form a narrow angle. The corner ring locking groove 153 includes a first groove body 1531 and a second groove body 1532 that communicate with each other and are provided to form a narrow angle. The first cylindrical body 141 is locked in each of the first groove bodies 1531, and the first extending ring 142 is locked in each of the second groove bodies 1532 and covers the end face of the outer coil 130.

[0035] In order to facilitate the installation of the first corner ring 140 into the mounting groove 1511 or removal from the mounting groove 1511, in this embodiment, as shown in Figures 6 and 7, the second stay portion 152 is detachably provided within the mounting groove 1511.

[0036] In this embodiment, the insulating tape is a thin silicone tape with strong electrical properties, high density, and excellent ductility. Since the first corner ring 140 is wrapped with the insulating tape to form a first annular tape layer with an annular structure, by folding one end of the first annular tape layer outward, the first cylindrical body 141 and the first extending ring 142, which form a narrow angle and are connected, can be formed.

[0037] Furthermore, the first annular tape layer includes at least one annular tape wrapped with a thin silicone tape. The joints between two adjacent annular tape layers are offset from each other.

[0038] Referring to Figures 4 to 9, in one embodiment, the novel coil structure 10 further includes a corner ring support assembly 160 so that the insulating tape does not deform when wrapped around each comb-shaped stay 150 and affect the insulating effect of the first corner ring 140. The corner ring support assembly 160 includes a first position limiting cylinder 161, a second position limiting cylinder 162, and a support ring 163. Both the first position limiting cylinder 161 and the second position limiting cylinder 162 are provided within the first groove 1531 and abut against both sides of the first cylindrical body 141, respectively, while the support ring 163 is provided within the second groove 1532 and is supported on the side of the first extending ring 142 facing the first cylindrical body 141.

[0039] Referring to Figures 2 to 5, in order to further improve the electric field strength at both ends of the outer coil 130 and enhance the insulation performance of this new coil structure 10, in one embodiment, the new coil structure 10 further includes disc-shaped coil end coils 170, and a plurality of disc-shaped coil end coils 170 are provided. The comb-shaped stay 150 is provided with a plurality of end coil locking grooves 1522 along its axial direction, and each of the plurality of end coil locking grooves is located between two square ring locking grooves 153. Each of the plurality of disc-shaped coil end coils 170 is engaged with one of the plurality of end coil locking grooves 1522 in a one-to-one correspondence.

[0040] In one embodiment, the multiple disc-shaped coil end coils 170 may be located between the disc-shaped coils 131, or the multiple disc-shaped coil end coils 170 may each be located at both ends of the outer coil 130, or some of the multiple disc-shaped coil end coils 170 may be located between the disc-shaped coils 131, and some of the disc-shaped coil end coils 170 may each be located at both ends of the outer coil 130.

[0041] Specifically, in this embodiment, disc-shaped coil end coils 170 are provided at both ends of the outer coil 130, and at least one disc-shaped coil end coil 170 is provided between the disc-shaped coils 131.

[0042] Referring to Figure 5, in another embodiment, the novel coil structure 10 further includes a second corner ring 180. The second corner ring 180 includes a second cylindrical body and a second extending ring, one end of the second cylindrical body connected to the inner ring of the second extending ring and positioned to form a narrow angle. The insulating cylindrical layer 120 includes an inner insulating cylinder 121 and an outer insulating cylinder 122, which are sleeve-jointed. The inner coil 110 is ring-shaped inside the inner insulating cylinder 121, and the comb-shaped stay 150 is provided outside the outer insulating cylinder 122. The second cylindrical body is engaged between the inner insulating cylinder 121 and the outer insulating cylinder 122, and the second extending ring extends toward the comb-shaped stay 150 and covers the end face of the comb-shaped stay 150.

[0043] Specifically, two second corner rings 180 are provided, and the two second corner rings 180 are located at both ends of the insulating cylindrical layer 120. In this way, the electric field strength at both ends of the outer coil 130 can be further improved, and the insulation performance of this new coil structure 10 can be enhanced.

[0044] Continuing to refer to Figures 5 to 7, in one embodiment, the new coil structure 10 further includes end retaining rings 190. Two end retaining rings 190 are provided. Retaining ring locking grooves are further provided at both ends of the comb-shaped stay 150, and the retaining ring locking grooves are further set further away from the comb tooth notches 1521 than the square ring locking grooves 153, and the two retaining ring locking grooves each engage with the two end retaining rings 190 in a one-to-one correspondence. In this way, the creepage distance between the outer coil 130 and the yoke of the iron core 20 can be further increased, improving the insulation properties of the new coil structure 10.

[0045] Furthermore, both the disc-shaped coil end coil 170 and the end retaining ring 190 are made of insulating material.

[0046] Referring to Figures 1 to 4, one embodiment of this application is: The steps include winding the inner coil 110, The steps include assembling an insulating cylindrical layer 120 outside the inner coil 110, The steps include: providing each comb-shaped stay 150 at intervals along the circumferential direction of the insulating cylindrical layer 120 on the outside of the insulating cylindrical layer 120, wrapping insulating tape around the outside of each comb-shaped stay 150 and folding it back to form the first corner ring 140; The steps include wrapping the outer coil 130 around the outside of each comb-shaped stay, The present invention further provides a method for manufacturing a novel coil structure 10, which includes the step of attaching a disc-shaped coil end coil 170 and an end retaining ring 190 on a comb-shaped stay 150.

[0047] In one embodiment, as shown in Figures 1 to 4, the step of attaching a winding die 30 to the stem of the iron core 20 before winding the inner coil 110 is further included. The winding die 30 supports the inner coil 110 to be wound.

[0048] In one embodiment, the step of assembling the insulating cylindrical layer 120 outside the inner coil 110 is, specifically, Two pre-formed inner semi-cylinders are bonded to the outside of the inner coil 110 to form the inner insulating cylinder 121, At least one layer of inner insulation is wound around the outer wall of the inner insulation cylinder 121, and the joints of the inner insulation layers and the joints of the inner insulation cylinder 121 are offset. Two pre-formed outer semi-cylinders are bonded to the outside of the inner insulating layer to form an outer insulating cylinder 122, This includes winding at least one outer insulating layer onto the outer wall of the outer insulating cylinder 122, and offsetting the joints of the outer insulating layer and the joints of the outer insulating cylinder 122.

[0049] By wrapping the inner insulating layer around the inner insulating cylinder 121 and the outer insulating layer around the outer insulating cylinder 122, the insulation reliability between the outer coil 130 and the inner coil 110 can be improved. By offsetting the joints of the inner insulating layer and the bonding points of the inner insulating cylinder 121, and offsetting the joints of the outer insulating layer and the joints of the outer insulating cylinder 122, the risk of the new coil structure 10 being damaged by leakage current from gaps or gaps in the joints can be effectively reduced, and good insulation performance of the new coil structure 10 can be ensured.

[0050] Furthermore, when multiple inner or outer insulating layers are provided, the joints between two adjacent layers are offset.

[0051] Furthermore, the two inner semi-cylinders are bonded together with insulating adhesive to form an inner insulating cylinder 121, and the two outer semi-cylinders are bonded together with insulating adhesive to form an outer insulating cylinder 122.

[0052] In one embodiment, as shown in Figure 5, the manufacturing method of the novel coil structure 10 further includes the steps of winding an insulating tape between the inner insulating layer and the outer insulating cylinder 122 to form a second annular tape layer, folding one end of the second annular tape layer outward, and covering the end face of the outer insulating cylinder 122 with the outwardly folded portion to form a second corner ring 180.

[0053] Referring to Figures 2 to 9, in one embodiment, each comb-shaped stay 150 is provided at intervals along the circumferential direction of the insulating cylindrical layer 120 on the outside of the insulating cylindrical layer 120, and the step of wrapping insulating tape around the outside of each comb-shaped stay 150 and folding it back to form the first corner ring 140 is, specifically, The comb-shaped stay 150 includes a first stay portion 151 and a second stay portion 152. A mounting groove 1511 is formed within the first stay portion 151, and the second stay portion 152 is provided within the mounting groove 1511. The second stay portion is provided at a distance from the groove wall of the mounting groove 1511 to form a corner ring locking groove 153. Each first stay portion 151 is provided on the outside of the insulating cylindrical layer 120, along the circumferential direction of the insulating cylindrical layer 120, with intervals between them. The first position limiting cylinder 161 is wrapped around the outside of each first stay portion 151, The insulating tape is wrapped around the first position limiting cylinder 161 to form a first annular tape layer, The second position limiting cylinder 162 is wrapped around the outside of the first annular tape layer, Multiple pre-formed arc-shaped rings are bonded to the outside of the first annular tape layer to form a circular support ring 163, one end of the first annular tape layer is folded outward, and the outwardly folded portion is laid on the support ring 163 along the radial direction of the support ring 163 to form the first square ring 140, This includes providing a second stay portion 152 within the corresponding first stay portion 151 to form a corner ring locking groove 153, and locking the first corner ring 140 into the corner ring locking groove 153.

[0054] In one embodiment, one end of the first annular tape layer is folded outward, and the outwardly folded portion is laid on the support ring 163 along the radial direction of the support ring 163 to form the first corner ring 140. Specifically, The steps include folding one end of the first annular tape layer outward and laying the outwardly folded portion on the support ring 163 along the radial direction of the support ring 163, The steps include extending the outwardly folded portion onto the outer ring of the support ring 163, and having the outwardly folded portion cover the outer ring of the support ring 163 to form the first corner ring 140.

[0055] In one embodiment, after attaching the disc-shaped coil end coil 170 and end retaining ring 190 on the comb-shaped stay 150, the winding mold 30 is removed, and the wound new coil structure 10 is immersed and dried.

[0056] Any combination of the technical features of the above embodiments is possible, and for the sake of simplicity, not all possible combinations of the technical features of the above embodiments are described. However, as long as these combinations of technical features are inconsistent, they should be considered to fall within the scope described herein.

[0057] The above embodiments illustrate only a few of the present invention, and their descriptions are relatively specific and detailed, but this should not be understood as limiting the scope of the patent. Those skilled in the art can make several modifications and improvements without departing from the concept of this invention, all of which fall within the scope of protection. Therefore, the scope of protection of the patent in this invention should be in accordance with the appended claims. [Explanation of Symbols]

[0058] 10: New coil structure, 110: Inner coil, 120: Insulating cylinder layer, 121: Inner insulating cylinder, 122: Outer insulating cylinder, 130: Outer coil, 131: Disc-shaped coil, 140: First corner ring, 141: First cylindrical body, 142: First extending ring, 150: Comb-shaped stay, 151: First stay section, 1511: Mounting groove, 152: Second stay section, 1521: Comb tooth notch, 1522: End coil locking groove, 153: Corner ring locking groove, 1531: First groove body, 1532: Second groove body, 160: Corner ring support assembly, 161: First position limiting cylinder, 162: Second position limiting cylinder, 163: Support ring, 170: Disc-shaped coil end coil, 180: Second corner ring, 190: End retaining ring, 20: Iron core, 30: Winding mold.

Claims

1. A novel coil structure comprising an inner coil, an insulating cylindrical layer, an outer coil, and a first corner ring, wherein the inner coil is provided in a ring on the inside of the insulating cylindrical layer, the outer coil is provided in a ring on the outside of the insulating cylindrical layer, two first corner rings are provided, and both first corner rings are wrapped with insulating tape to form an annular structure, and the two first corner rings are each located at both ends of the outer coil.

2. The novel coil structure according to claim 1, further comprising a comb-shaped stay, wherein a plurality of the comb-shaped stays are provided, and the plurality of the comb-shaped stays are provided on the outside of the insulating cylindrical layer along the circumferential direction of the insulating cylindrical layer, and each end of the comb-shaped stay is provided with a square ring locking groove, and the two square ring locking grooves are used to engage with the two first square rings in a one-to-one correspondence, the comb-shaped stay is provided with a plurality of comb tooth notches along its axial direction, and the plurality of comb tooth notches are all located between the two square ring locking grooves, and the outer coil comprises a plurality of stacked disc-shaped coils, the plurality of disc-shaped coils each correspond one-to-one to the plurality of comb tooth notches, and each disc-shaped coil is locked in the corresponding comb tooth notch.

3. The novel coil structure according to claim 2, wherein the comb-shaped stay includes a first stay portion and a second stay portion, a mounting groove is formed in the first stay portion, the second stay portion is provided in the mounting groove and the second stay portion is provided at a distance from the groove wall of the mounting groove to form the square ring locking groove, and each of the comb tooth notches is provided at a distance along the axial direction of the second stay portion on the side of the second stay portion away from the first stay portion.

4. The novel coil structure according to claim 3, characterized in that the first corner ring includes a first cylindrical body and a first extending ring, one end of the first cylindrical body is connected to the inner ring of the first extending ring and is provided to form a narrow angle, the corner ring locking groove includes a first groove body and a second groove body that communicate with each other and are provided to form a narrow angle, the first cylindrical body is locked in each of the first groove bodies, and the first extending ring is locked in each of the second groove bodies and covers the end face of the outer coil.

5. The novel coil structure according to claim 4, further comprising a square ring support assembly, the square ring support assembly comprising a first position limiting cylinder, a second position limiting cylinder, and a support ring, wherein both the first position limiting cylinder and the second position limiting cylinder are provided within the first groove body and abut against both sides of the first cylindrical body, and the support ring is provided within the second groove body and is supported on the side of the first extending ring facing the first cylindrical body.

6. The new coil structure further includes a disc-shaped coil end coil, and a plurality of such disc-shaped coil end coils are provided, and the comb-shaped stay is provided with a plurality of end coil locking grooves along its axial direction, and each of the plurality of end coil locking grooves is located between two of the square ring locking grooves, and each of the plurality of disc-shaped coil end coils engages with one-to-one with each of the plurality of end coil locking grooves. and / or the new coil structure further includes a second square ring, the second square ring includes a second cylindrical body and a second extending ring, one end of the second cylindrical body connected to the inner ring of the second extending ring and provided to form a narrow angle, the insulating cylindrical layer includes an inner insulating cylinder and an outer insulating cylinder that are sleeve-jointed, the inner coil is provided in a ring on the inside of the inner insulating cylinder, the comb-shaped stay is provided on the outside of the outer insulating cylinder, the second cylindrical body is engaged between the inner insulating cylinder and the outer insulating cylinder, the second extending ring extends toward the comb-shaped stay and covers the end face of the comb-shaped stay, The novel coil structure according to claim 2, further comprising end retaining rings, two of which are provided, and each end of the comb-shaped stay is further provided with a retaining ring locking groove, the retaining ring locking grooves being further set apart from the comb tooth notches than the square ring locking grooves, and the two retaining ring locking grooves each engaging with the two end retaining rings in a one-to-one correspondence.

7. A method for manufacturing a new type of coil structure, The steps include winding the inner coil and The steps include assembling an insulating cylindrical layer outside the inner coil, The steps include: providing each comb-shaped stay at intervals along the circumferential direction of the insulating cylindrical layer on the outside of the insulating cylindrical layer, wrapping insulating tape around the outside of each comb-shaped stay and folding it back to form a first corner ring; The steps include winding an outer coil around the outside of each of the aforementioned comb-shaped stays, A method for manufacturing a novel coil structure, characterized by including the step of attaching a disc-shaped coil end coil and an end retaining ring on the comb-shaped stay.

8. The step of assembling the insulating cylindrical layer outside the inner coil is, specifically, Two pre-formed inner semi-cylinders are bonded to the outside of the inner coil to form an inner insulating cylinder, The inner insulating layer is wound around the outer wall of the inner insulating cylinder, and the joints of the inner insulating layer and the joints of the inner insulating cylinder are offset. Two pre-formed outer semi-cylinders are bonded to the outside of the inner insulating layer to form an outer insulating cylinder, The method for manufacturing a novel coil structure according to claim 7, characterized in that it includes winding at least one outer insulating layer onto the outer wall of the outer insulating cylinder and offsetting the joint of the outer insulating layer from the joint of the outer insulating cylinder.

9. The manufacturing method for the aforementioned new coil structure is: The method for manufacturing a novel coil structure according to claim 8, further comprising the steps of winding an insulating tape between the inner insulating layer and the outer insulating cylinder to form a second annular tape layer, folding one end of the second annular tape layer outward, and having the outwardly folded portion cover the end face of the outer insulating cylinder to form a second corner ring.

10. The steps of providing each comb-shaped stay at intervals along the circumferential direction of the insulating cylindrical layer on the outside of the insulating cylindrical layer, and wrapping insulating tape around the outside of each comb-shaped stay and folding it back to form the first corner ring, specifically, The comb-shaped stay includes a first stay portion and a second stay portion, the first stay portion having a mounting groove formed within it, the second stay portion being provided within the mounting groove, and the second stay portion being provided at a distance from the groove wall of the mounting groove to form a corner ring locking groove. Each of the first stay portions is provided on the outside of the insulating cylindrical layer at intervals along the circumferential direction of the insulating cylindrical layer, The first position limiting cylinder is wrapped around the outside of each of the first stay portions, The insulating tape is wrapped around the first position limiting cylinder to form a first annular tape layer, The second position limiting cylinder is wrapped around the outside of the first annular tape layer, Multiple pre-formed arc-shaped rings are bonded to the outside of the first annular tape layer to form a circular support ring, one end of the first annular tape layer is folded outward, and the outwardly folded portion is laid on the support ring along the radial direction of the support ring to form a first angular ring, The method for manufacturing a novel coil structure according to claim 7, characterized in that the second stay portion is provided within the corresponding first stay portion to form the corner ring locking groove, and the first corner ring is locked within the corner ring locking groove.

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