Coil, motor and manufacturing method

Abstract

The purpose of the present disclosure is to provide a coil that can suppress quality deterioration, a motor, and a manufacturing method. A coil (1) is an edgewise coil (1) comprising a conducting wire (3) and a coating film (5) that covers the conducting wire (3). The conducting wire (3) includes curved sections (4), which are portions of the conducting wire (3) where the same are curved. The coating film (5) includes a first coating film (L1) that covers portions, of the conducting wire (3), different from the curved sections (4), and a second coating film (L2) that covers at least portions in the curved sections (4) where tensile force (T1) is generated. The coating film (5) has, between the first coating film (L1) and the second coating film (L2), boundaries (B1) lying in a direction intersecting the direction in which the tensile force (T1) is generated.

Description

[Technical field]

[0001] The present disclosure relates generally to coils, motors, and manufacturing methods, and more particularly to coils having wire and coating, motors, and manufacturing methods. [Background technology]

[0002] The rotor is provided with a stator core having a number of concave slots and a number of convex magnetic poles alternately arranged in the circumferential direction, and a magnet wire having a rectangular cross section and an insulating coating formed on the outer peripheral surface of the metal wire. The spacing between both side surfaces of the slot is formed so as to decrease from the bottom of the slot toward the tip opening. The magnet wire is wound around the magnetic poles and inserted into the slot in a laminated state. The width of the magnet wire is arranged to decrease continuously or stepwise from the bottom of the slot toward the tip opening.

[0003] On the other hand, when making an edgewise coil by bending a coated rectangular wire, if the corner of the bent part is bent too sharply, the coating on the outer part of the bent part may be damaged. If the coating is damaged, the quality of the coil may be reduced. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2007-317636 A Summary of the Invention

[0005] The present disclosure has been made in consideration of the above-mentioned problems, and has an object to provide a coil, a motor, and a manufacturing method that can suppress deterioration in quality.

[0006] A coil according to one embodiment of the present disclosure is an edgewise coil, comprising a conductor and a coating that coats the conductor. The conductor includes a bent portion where the conductor is bent. The coating includes a first coating that coats a portion of the conductor other than the bent portion, and a second coating that coats at least a portion of the bent portion where tension is generated. The coating has a boundary between the first coating and the second coating in a direction that intersects with the direction in which tension is generated.

[0007] A motor according to one aspect of the present disclosure includes the coil and a stator on which the coil is mounted.

[0008] A manufacturing method according to one embodiment of the present disclosure is a method for manufacturing the edgewise coil, and includes a process of winding the conductor wire with the first coating to form the edgewise coil, and a process of forming the second coating on the bent portion where the conductor wire is bent. [Brief description of the drawings]

[0009] [Figure 1] Fig. 1A is a diagram for explaining an outline of an edgewise coil according to embodiment 1. Fig. 1B is a diagram for explaining a state before a bent portion of the edgewise coil is repaired with a second coating. Fig. 1C is a diagram for explaining a state after the bent portion of the edgewise coil is repaired. [Diagram 2] FIG. 2 is a diagram illustrating a manufacturing process according to the first embodiment. [Diagram 3] Fig. 3A is a diagram for explaining a portion of the edgewise coil according to the second embodiment where bending processing is to be performed, Fig. 3B is a diagram for explaining repair of the bent portion of the edgewise coil, and Fig. 3C is a diagram for explaining the state of the edgewise coil after the bent portion has been repaired. [Figure 4] Fig. 4A is a diagram for explaining a portion of the edgewise coil according to the third embodiment where bending processing is to be performed, Fig. 4B is a diagram for explaining repair of the bent portion of the edgewise coil, and Fig. 4C is a diagram for explaining the state of the edgewise coil after the bent portion has been repaired. [Diagram 5] Fig. 5A is a side view of a motor using an edgewise coil according to Modification 2. Fig. 5B is a top view of the motor using the edgewise coil according to Modification 2. [Figure 6] Fig. 6A is a diagram for explaining the above-mentioned edgewise coil with a fixed width, and Fig. 6B is a diagram for explaining the above-mentioned edgewise coil with a variable width. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The embodiments and modifications described below are merely examples of the present disclosure, and the present disclosure is not limited to the embodiments and modifications. Various modifications other than these embodiments and modifications are possible according to the design, etc., as long as they do not deviate from the technical idea of ​​the present disclosure.

[0011] (Embodiment 1) Hereinafter, a coil 1, a motor 2, and a manufacturing method according to this embodiment will be described with reference to FIGS. 1A to 6B.

[0012] (1) Overview The coil 1 of the present embodiment 1 is an edgewise coil, for example. In the following description, the coil 1 will be described as an edgewise coil 1. The coil 1 of the present embodiment 1 is an edgewise coil 1, and includes a conductor 3 and a coating 5 that coats the conductor 3. The conductor 3 includes a bent portion 4 that is a bent portion. The coating 5 includes a first coating L1 that coats a portion 6 of the conductor 3 that is different from the bent portion 4, and a second coating L2 that coats at least a portion of the bent portion 4 where tension T1 is generated. The coating 5 has a boundary B1 between the first coating L1 and the second coating L2 in a direction that intersects with the direction in which tension T1 is generated.

[0013] Here, tension T1 is a force that pulls the unbent conductor 3 in both directions from the bent portion 4 of the conductor 3, and is a force that is generated by bending the conductor 3. The tension T1 is generated along the conductor 3 (see FIG. 1B). The generation of tension T1 may damage the first coating L1 on the wide angle β side (outside, see FIG. 1B) of the bent portion 4.

[0014] The edgewise coil 1 is formed by bending a conductor wire 3, which is called a rectangular wire. The conductor wire 3 is covered in advance with a first coating L1, which is an insulating coating. In other words, before the bent portion 4 is formed, the conductor wire 3 is covered in advance with the first coating L1, which is an insulating coating.

[0015] The edgewise coil 1 includes a conductor 3, a first coating L1 that was originally attached to the conductor 3, and a second coating L2 that repairs a specific portion D1 where the first coating L1 may be damaged.

[0016] On the other hand, in the edgewise coil 1 of the present embodiment 1, by bending the conductor 3, the conductor 3 (bent portion 4) includes a specific portion D1 where tension is generated. At the specific portion D1, the first coating L1 may be damaged or will be damaged due to the generated tension. Therefore, the conductor 3 (bent portion 4) is repaired by covering the specific portion D1 where tension is generated with the second coating L2. By repairing the specific portion D1 of the insulating coating (first coating L1) of the edgewise coil 1, the insulating performance of the edgewise coil 1 is maintained.

[0017] According to the first embodiment, the specific portion D1 of the bent portion 4 of the edgewise coil 1 using the conductor wire 3 is repaired with the second coating L2, so that the insulating performance of the edgewise coil 1 can be maintained.

[0018] (2) Composition A description will be given of the configuration of the edgewise coil 1 of the present embodiment 1. As shown in Figures 1A, 1B, and 1C, the edgewise coil 1 includes a conductive wire 3, a first coating L1, a second coating L2, and a boundary B1.

[0019] FIG. 1A shows a schematic diagram of an edgewise coil 1. As shown in FIG. 1A, the edgewise coil 1 includes a conductor 3, which is a rectangular wire. The conductor 3 includes a bent portion 4, which is a portion where the conductor 3 is bent. The conductor 3 is, for example, a flat rectangular wire with a rectangular cross section, and is covered with a first coating L1, which is an insulating coating. The core material of the conductor 3 is, for example, a copper material, and has electrical conductivity. The bent portion 4 is a portion where the conductor 3 is processed and bent. When the conductor 3 covered with the first coating L1 is bent, as shown in FIG. 1B, the first coating L1 may be damaged in the outer portion of the bent portion 4. Here, the outer side of the bent portion 4 refers to the portion located outside the bent portion 4 when viewed from the center of the edgewise coil 1 around which the conductor 3 is wound.

[0020] As a result of the bending process, tension T1 is generated in the outer portion of the bent portion 4. The tension T1 is generated along the conductor 3. The generation of tension T1 generates tensile stress in the outer portion of the conductor 3, and there is a possibility that the first coating L1 will peel off at the specific portion D1.

[0021] 1A shows a configuration in which the edgewise coil 1 has a fixed width, but the present invention is not limited to this configuration. The width of the conductor 3 may be processed to form a variable width edgewise coil.

[0022] As shown in Fig. 1C, the edgewise coil 1 of the present embodiment 1 has a second coating L2 for repairing a specific portion D1 in addition to a first coating L1 used for coating. The first coating L1 and the second coating L2 may be made of the same material or different materials. In the present embodiment 1, the first coating L1 and the second coating L2 are described as being made of the same material.

[0023] When the first coating L1 and the second coating L2 are made of the same material, examples of the first coating L1 and the second coating L2 include polyurethane, polyamide, polyester, ester imide, amide imide, and polyimide. Methods for forming the first coating L1 and the second coating L2 include coating, impregnation, dripping, electrostatic coating, spray coating, electrodeposition coating, powder coating, and film / tape application. The coating formation methods for the first coating L1 and the second coating L2 may be different.

[0024] As shown in FIG. 1B, a boundary B1 is formed at the boundary between the first coating L1 that was originally formed and the second coating L2 that was formed as a repair. The boundary B1 is a boundary surface that is formed whether the first coating L1 and the second coating L2 are made of the same material or different materials. For example, before the bent portion 4 is formed, the first coating L1 is formed by electrocoating on the entire surface of the conductor 3, so the boundary B1 is not formed. When the bent portion 4 is formed and the second coating L2 is formed in a portion of the bent portion 4 where the first coating L1 may be damaged, the boundary B1 is formed between the first coating L1 and the second coating L2. Specifically, the boundary B1 is formed in a direction that intersects with the direction in which the tension T1 is generated.

[0025] At the boundary B1, there are the second coating L2 on the bent portion 4 side of the boundary B1 and the first coating L1 which is the coating that originally covered the conductor wire 3, which is the base material, and the second coating L2 has an overlapping portion 7 where the second coating L2 overlaps at least a portion of the first coating L1. At the overlapping portion 7, as shown in Fig. 1C, the first coating L1 and the second coating L2 overlap each other.

[0026] The boundary B1 in the present embodiment 1 has a boundary B4 between the first coating L1 and the second coating L2 that is separate from the boundary B1 and follows the shape of the bent portion 4. The specific portion D1 of the first coating L1 that may be damaged is formed in a part of the width direction of the conductor 3 at the bent portion 4, and the boundary B1 is not formed over the entire periphery in the width direction. This is because, in the present embodiment 1, the second coating L2 repairs the specific portion D1 of the first coating L1 that may be damaged.

[0027] (3) Manufacturing method A method for manufacturing the edgewise coil 1 of the first embodiment will be described with reference to FIG.

[0028] The manufacturing method of the edgewise coil 1 includes an edgewise coil forming process (step S1) and a coating forming process (step S2). In the edgewise coil forming process, the edgewise coil 1 is formed by winding the conductor 3 on which the first coating L1 is formed. In the coating forming process, a second coating L2 is formed on the bent portion 4 of the conductor 3.

[0029] The manufacturing method of the edgewise coil 1 of the present embodiment 1 includes a process of forming the edgewise coil 1 by bending the conductor wire 3 with the first coating L1. By bending the conductor wire 3 with the first coating L1, the first coating L1 at the edge portion (bent portion 4) formed on the edgewise coil 1 may be damaged. For this reason, the manufacturing method of the edgewise coil 1 includes a process of covering the specific portion D1 of the first coating L1 that may be damaged with the second coating L2. As described above, the first coating L1 and the second coating L2 may be made of the same material or different materials. In the present embodiment 1, the first coating L1 and the second coating L2 are made of the same material, and the second coating L2 is formed by electrostatic coating using polyurethane. Electrostatic coating is a method in which a grounded coating object is used as a positive electrode and a paint spraying device is used as a negative electrode, a high voltage is directly applied between the two electrodes to form an electrostatic field between the two electrodes, and fine particles of the paint are negatively charged to form a coating. In this embodiment 1, the edgewise coil 1 is grounded as the positive electrode, the spray paint device is the negative electrode, and a high voltage is applied between the two electrodes to form an electrostatic field between the two electrodes. Polyurethane paint particles are negatively charged and sprayed to form a second coating L2 on a specific portion D1 of the first coating L1. In this embodiment 1, the first coating L1 and the second coating L2 are both polyurethane, but as described above, a boundary B1 is formed between the portion of the first coating L1 that may be damaged and the second coating L2 newly formed by electrostatic painting.

[0030] As described above, the deterioration of the insulating performance due to damage to the first coating L1 occurring at the bent portion 4 of the edgewise coil 1 can be suppressed by forming the second coating L2.

[0031] (4) Advantages The coil 1 is an edgewise coil 1 and includes a conductor 3 and a coating 5 that coats the conductor 3. The conductor 3 includes a bent portion 4 where the conductor 3 is bent. The coating 5 includes a first coating L1 that coats a portion 6 of the conductor 3 that is different from the bent portion, and a second coating L2 that coats at least a portion of the bent portion 4 where tension T1 is generated. The coating 5 has a boundary B1 between the first coating L1 and the second coating L2 in a direction that intersects with the direction in which tension T1 is generated.

[0032] According to this configuration, the coating 5 has a boundary B1 between the first coating L1 and the second coating L2 in a direction intersecting with the direction in which the tension T1 is generated, and therefore it can be seen that the bent portion 4 is repaired by the second coating L2.

[0033] Since tension T1 occurs in the bent portion 4, there is a possibility that the coating covering the bent portion 4 may be damaged. Therefore, by repairing the bent portion 4 with the second coating L2, it is possible to suppress the deterioration of the insulating performance of the coating 5. As a result, it is possible to suppress the deterioration of the quality of the coil 1. Therefore, it is possible to provide a coil 1 in which the portion of the first coating L1 that may be damaged is repaired with the second coating L2, which is an insulating coating.

[0034] (5) Variations The following are examples of modified examples. The modified examples described below can be applied in appropriate combination with the above-described embodiment.

[0035] (5-1) Variation 1 In the first embodiment, the first coating L1 and the second coating L2 are both made of the same material, polyurethane, but are not limited to this. The first coating L1 and the second coating L2 may be made of different materials.

[0036] When the first coating L1 and the second coating L2 are made of different materials, the first coating L1 is made of the above-mentioned material or a combination of the above-mentioned materials, and the second coating L2 is made of, for example, fluororesin, polyethylene terephthalate (PET), aromatic polyester (LCP), polyether ether ketone (PEEK), polyphenylene sulfide (PPS), aromatic polyamide, epoxy, and acrylic. The second coating L2 can be formed by the above-mentioned forming methods. In addition to these, varnish such as unsaturated polyester can be formed as the second coating L2 by coating, impregnation, or dripping. A heat-shrinkable tube such as fluororesin can be formed as the second coating L2 by heat shrinking. Also, mica can be formed as the second coating L2 by attaching a film or tape.

[0037] In this modified example 1, as an example in which the first coating L1 and the second coating L2 are made of different materials, a case in which the first coating L1 is polyurethane and the second coating L2 is PEEK will be described. The edgewise coil 1 is formed in a state in which the first coating L1 is coated with polyurethane. In this case, the first coating L1 may be damaged at the bent portion 4, resulting in a decrease in insulation performance. For this reason, in this modified example 1, in order to suppress the decrease in insulation performance, PEEK, which is different from the first coating L1, is formed as the second coating L2 by spray coating. In the spray coating of PEEK, fine powder of PEEK resin is dispersed in water, sprayed with an air spray device, and then baked to form a film. This completes the formation of the PEEK film as the second coating L2. The second coating L2 is formed by spray coating on the first coating L1 and on the specific portion D1 of the first coating L1. That is, the boundary B1 is formed between the first coating L1 and the second coating L2, and similarly to the first embodiment, the first coating L1 and the second coating L2 also overlap each other.

[0038] (5-2) Variation 2 The edgewise coil 1 in which the specific portion D1 of the first coating L1 of the bent portion 4 is repaired with the second coating L2 can be combined with a stator 14 on which the edgewise coil 1 is mounted and applied to a motor 2, as shown in Figures 5A and 5B. A side view of the motor 2 having the edgewise coil 1 is shown in Figure 5A, and a top view of the motor 2 is shown in Figure 5B.

[0039] The motor 2 includes an edgewise coil 1, a shaft 11, a bearing 12, a rotor 13, a stator 14, a terminal member 15, and a bearing 18.

[0040] In the edgewise coil 1, after the conductor wire 3 is bent, a specific portion D1 of the first coating L1 at the bent portion 4 that may be damaged is repaired with the second coating L2. Therefore, deterioration of the insulation performance of the edgewise coil 1 caused by bending the conductor wire 3 is suppressed.

[0041] Each element of the motor 2 will be described. The shaft 11 transmits rotational power. The bearing 12 and the bearing 18 rotatably support the shaft 11. As shown in FIG. 5B, FIG. 6A, and FIG. 6B, the rotor 13 includes the shaft 11 and a plurality of (12 in FIG. 6A and FIG. 6B) permanent magnets 17. The rotor 13 is rotatable relative to the stator 14, and rotates due to a magnetic field generated by a current flowing through the edgewise coils 1 of the stator 14. That is, the rotor 13 has the permanent magnets 17, and rotates due to a magnetic field generated by the permanent magnets 17 and a magnetic field generated by a current flowing through the edgewise coils 1 of the stator 14, and transmits the generated torque to the shaft 11. The stator 14 has a plurality of teeth 16. A plurality of edgewise coils 1 are wound around the plurality of teeth 16 via insulators. The terminal members 15 are a plurality of (three in FIG. 5B) terminal members connected to a switching circuit (not shown).

[0042] In the motor 2, the edgewise coil 1 is attached to the stator 14. A method of winding the conductive wire 3 to form the edgewise coil 1 will be described using the 12-pole, 18-slot edgewise coil 1 shown in Figs. 6A and 6B.

[0043] The edgewise coil 1 can be formed by winding the conductor 3 either in a fixed width manner as shown in Fig. 6A or in a variable width manner as shown in Fig. 6B. In the fixed width manner, the width at which the conductor 3 is wound is fixed, while in the variable width manner, the width at which the conductor 3 is wound is variable. By fabricating the edgewise coil 1 by bending a rectangular wire (conductor 3) that has been processed in width, it is possible to improve the space factor within the slot and manufacture a motor 2 that can efficiently obtain large rotational torque. Here, width processing refers to processing the width of the conductor 3 in order to adjust the width of the edgewise coil 1 so as to increase the space factor.

[0044] As described above, by repairing the second coating L2, which is an insulating coating, in the portion where the first coating L1 is likely to be damaged, it is possible to provide a motor 2 in which deterioration in quality is suppressed.

[0045] (Embodiment 2) The second embodiment differs from the first embodiment in that the first coating L1 of the portion (bend 4) that will become the corner, i.e., the edge, of the edgewise coil 1 is removed in advance. In the second embodiment, as shown in Fig. 3A, the first coating L1 of the bend 4 that will become the edge of the conductor 3 is removed in advance. The portion of the conductor 3 that corresponds to the bend 4 is designated as a specific portion D2.

[0046] When bending is performed, tension T1 acts on the specific portion D2. As shown in FIG. 3B, tension T1 is generated along the shape of the bent portion 4. Therefore, the first coating L1 on the specific portion D2 may be damaged, as in the first embodiment. Therefore, by removing the first coating L1 on the specific portion D2 in advance, the influence of tension T1 can be suppressed.

[0047] 3B, the specific portion D2 is bent to form the bent portion 4. This results in an edgewise coil 1 that does not have the first coating L1 at the edge portion (bent portion 4). Since the specific portion D2 is formed from the first coating L1 of the bent portion 4 having been removed in advance, the effect of the tension T1 generated by bending the conductor 3 on the first coating can be suppressed.

[0048] As shown in FIG. 3C, a second coating L2 is formed on a bent portion 4 that does not have a first coating L1, and a coating 5 is formed by the original first coating L1 and the second coating L2, thereby suppressing deterioration in the insulating performance of the first coating L1.

[0049] By removing the first coating L1 in advance at the bent portion 4, the possibility of damage such as peeling off of the first coating L1 occurring when bending the conductor 3 to form the bent portion 4 is suppressed in advance, and by forming the second coating L2 after forming the bent portion 4, stable first coating L1 and second coating L2 can be formed.

[0050] Specifically, the first coating L1, which is the original coating, can be made of the same material and manufactured by the same method as in embodiment 1. The second coating L2 can be made of the same material and manufactured by the same method as in embodiment 1.

[0051] As an example, a case where the second coating L2, which is the second coating, is formed by electrochemical coating will be described. First, the first coating L1 is removed from the conductor 3 at a portion that will become the bent portion 4. Next, the conductor 3 is shaped to become the edgewise coil 1. In this case, the area where the first coating L1 has been removed corresponds to the bent portion 4 of the edgewise coil 1, and the first coating L1 has been removed at the bent portion 4. The second coating L2 is formed by electrochemical coating in the area where the first coating L1 has been removed. In electrochemical coating, an object to be electrochemically coated and an electrode are placed in the electrochemical paint to generate a potential, and the coating components are electrophoresed, so that the coating is deposited on the surface of the object to be electrochemically coated. In this case, the first coating L1 of the conductor 3 is removed in advance, and the base material of the conductor 3 is exposed, so that the first coating L1 plays the role of an electrode in electrochemical coating, and electrochemical coating can be performed on the bent portion 4 from which the first coating L1 has been removed in advance. The edgewise coil 1 is completed by forming a second coating L2 on the bent portion 4 of the conductor wire 3 from which the first coating L1 has been previously removed.

[0052] By forming the second coating L2 on the bent portion 4 from which the first coating L1 has been previously removed, a boundary B2 is formed at both ends of the bent portion 4, as shown in Fig. 3B. At the boundary B2, the first coating L1 overlaps at least a portion of the second coating L2. In other words, there is an overlap between the first coating L1 and the second coating L2.

[0053] The second coating L2 covers the entire circumference of the bent portion 4. This is because the first coating L1 of the conductor 3 at the portion corresponding to the bent portion 4 (specific portion D2) is removed in advance, and the boundary B2 is formed in a manner different from the first embodiment in which only the specific portion D1 of the first coating L1, which may be damaged, is repaired with the second coating L2.

[0054] (Embodiment 3) The edgewise coil 1 of the third embodiment is different from the first and second embodiments in that a heat-shrinkable tube L3 made of, for example, fluororesin is used as the second coating L2.

[0055] As shown in FIG. 4A, before forming the edgewise coil 1, the heat-shrinkable tube L3 as the second coating L2 is placed at the portion of the conductor 3 that is to be formed as the bent portion 4 (the portion D3 to be formed), and then the edgewise coil 1 is formed.

[0056] 4B, when the conductor 3 with the first coating L1 is bent to form the bent portion 4, a tension T1 is generated in the bent portion 4. The tension T1 acts to pull both ends of the bent portion 4 in the direction from the bent portion 4 to the conductor 3 with the first coating L1. Therefore, at the bent portion 4, the first coating L1 may be damaged by the tension T1.

[0057] As shown in Fig. 4B, after the edgewise coil 1 is formed, heat is applied to shrink the heat shrink tube L3, and damage to the first coating L1 of the bent portion 4 is repaired as shown in Fig. 4C. Here, when a plurality of portions (pre-formed portions D3) are provided to be formed as the bent portion 4, a plurality of heat shrink tubes L3 corresponding one-to-one to the plurality of pre-formed portions D3 are arranged at the corresponding pre-formed portions D3.

[0058] The first coating L1 is repaired with the heat shrink tube L3 by repairing the second coating L2, which is made of a different material from the first coating L1, around the entire circumference of the conductor 3 and the bent portion 4, in a direction perpendicular to the longitudinal direction of the conductor 3.

[0059] 4C, a boundary B3 is formed between the bent portion 4 and the conductor 3. At the boundary B3, the first coating L1 and the heat shrink tube L3 overlap (overlap portion 7). The boundary B3 is formed over the entire periphery of the conductor 3 in the width direction, similar to the second embodiment.

[0060] (Other variations) The following are examples of modified examples. The modified examples described below can be applied in appropriate combination with the above-described embodiments.

[0061] In the second modification, the motor 2 is configured to use the edgewise coil 1 with a variable width as shown in Fig. 6B, but is not limited to this configuration. It may be configured to use the edgewise coil 1 with a fixed width as shown in Fig. 6A.

[0062] In the third embodiment, the first coating L1 is repaired by using the heat shrink tube L3 made of a material different from that of the first coating L1 over the entire circumference of the conductor 3, but the present invention is not limited to this configuration. For example, a specific portion D1 of the first coating L1 may be wrapped with insulating tape (not shown).

[0063] (summary) As described above, the coil (1) according to the first embodiment is an edgewise coil (1) including a conductor wire (3) and a coating (5) coating the conductor wire (3). The conductor wire (3) includes a bent portion (4) where the conductor wire (3) is bent. The coating (5) includes a first coating (L1) coating a portion (6) of the conductor wire (3) different from the bent portion (4), and a second coating (L2) coating at least a portion of the bent portion (4) where tension (T1) is generated. The coating (5) has boundaries (B1, B2, B3) between the first coating (L1) and the second coating (L2) in a direction intersecting with the direction in which tension is generated.

[0064] According to this configuration, the coil (1) can be provided with a repaired coating (5) by having a first coating (L1) that covers a portion (6) different from the bent portion (4) and a second coating (L2) that covers a portion where tension (T1) occurs. By covering the bent portion (4) with the second coating (L2), boundaries (B1, B2, B3) are formed. In addition, since tension (T1) occurs in the bent portion (4), if the first coating (L1) is formed in advance in the portion where the bent portion (4) is to be formed, the first coating (L1) formed in that portion may be damaged. Therefore, by repairing the portion of the first coating (L1) that may be damaged with the second coating (L2), it is possible to suppress deterioration of the insulation performance, that is, to suppress deterioration of the quality of the coating (5).

[0065] In the coil (1) according to the second embodiment, in the first embodiment, the first coating (L1) and the second coating (L2) are formed from the same material.

[0066] According to this configuration, since the first coating (L1) and the second coating (L2) are formed from the same material, no additional material is generated, and the cost of repairing the first coating (L1) can be reduced while suppressing the deterioration of the insulating performance of the coating (5).

[0067] In the coil (1) according to the third embodiment, in the first embodiment, the first coating (L1) and the second coating (L2) are formed from different materials.

[0068] According to this configuration, the first coating (L1) and the second coating (L2) are formed from different materials, which broadens the options for materials and manufacturing methods available for repair.

[0069] In the coil (1) according to the fourth aspect, in any of the first to third aspects, there is a boundary (B4) between the first coating (L1) and the second coating (L2) that follows the shape of the bent portion (4) and is different from the boundary (B1).

[0070] According to this configuration, a boundary (B4) different from the boundary (B1) that follows the shape of the bent portion (4) is provided between the first coating (L1) and the second coating (L2), and the second coating (L2) repairs a part of the conductor (3). Therefore, the second coating (L2) repairs a portion of the first coating (L1) that may be damaged, and the cost of repairing the first coating (L1) can be reduced while suppressing deterioration of the insulating performance of the coating (5).

[0071] In the coil (1) according to the fifth embodiment, in any one of the first to third embodiments, the second coating (L2) covers the entire circumference of the bent portion (4).

[0072] According to this configuration, the second coating (L2) covers the entire circumference of the bent portion (4), thereby making it possible to perform stable repair and suppress deterioration of the insulating performance of the coating (5), i.e., suppress deterioration of quality.

[0073] In the coil (1) according to the sixth aspect, in any one of the first to fifth aspects, the first coating (L1) overlaps with at least a part of the second coating (L2) across the boundary (B1, B2, B3).

[0074] According to this configuration, since the first coating (L1) and the second coating (L2) overlap each other, it is possible to suppress deterioration of the insulating performance at the boundaries (B1, B2, B3), that is, it is possible to suppress deterioration of the quality.

[0075] A motor (2) according to a seventh aspect includes the coil (1) according to any one of the first to sixth aspects and a stator (14) on which the coil is mounted.

[0076] According to this configuration, in the edgewise coil (1) produced by bending the conductor wire (3), a specific portion (D1) of the first coating (L1), which is the original insulating coating, is repaired with the second coating (L2), thereby providing a motor (2) in which deterioration of the insulating performance of the coating (5) of the coil (1) is suppressed. In other words, deterioration of quality can be suppressed.

[0077] The manufacturing method according to the eighth aspect is a manufacturing method for an edgewise coil (1), and includes a process of winding a conductor wire (3) having a first coating (L1) to form the edgewise coil (1), and a process of forming a second coating (L2) on a bent portion (4) of the conductor wire (3).

[0078] This method includes a process of forming an edgewise coil (1) by bending a conductor wire (3) with a first coating (L1) and a process of forming a second coating (L2), which is an insulating coating, on the bent portion (4), thereby making it possible to provide an edgewise coil (1) in which deterioration of insulation performance is suppressed. In other words, deterioration of quality can be suppressed. [Explanation of symbols]

[0079] 1 coil, edgewise coil 2 Motors 3 conductors 4 Bending section 5 Coating 6 Different parts 7 Overlap 14 Stator L1 1st coating L2 2nd coating B1,B2,B3,B4 boundary T1 tension

Claims

1. An edgewise coil, A conducting wire, a coating covering the conductor; The conductor includes a bent portion at which the conductor is bent, the coating includes a first coating that coats a portion of the conductor other than the bent portion, and a second coating that coats at least a portion of the bent portion where tension is generated, the coating has a boundary between the first coating and the second coating in a direction intersecting a direction in which the tension is generated, The first coating and the second coating are formed from the same material. coil.

2. a boundary between the first coating and the second coating that follows the shape of the bent portion and is different from the boundary; The coil according to claim 1 .

3. The second coating covers the entire circumference of the bent portion. The coil according to claim 1 .

4. The first coating overlaps at least a portion of the second coating. A coil according to any one of claims 1 to 3.

5. A coil according to any one of claims 1 to 4; A stator on which the coil is mounted. Motor.

6. A method for manufacturing an edgewise coil, comprising the steps of: winding the conductor with the first coating to form an edgewise coil; and forming a second coating on the bent portion of the conductor. The first coating and the second coating are formed of the same material. Manufacturing method.

Images