Electromagnetic coil

Abstract

To provide an electromagnetic coil capable of constructing a predetermined-shaped coil assembly by combining a plurality of them and having a higher energy use efficiency as conventional one.SOLUTION: An electromagnetic coil 1 includes: two effective coil parts 20 arranged so as to be separated each other while being orthogonal to a movement direction ROT of a magnet each other; a first coil end part 30 that is positioned on one side of each of the effective coil parts and connects the two effective coil parts; and a second coil end part 40 that is positioned on the other side of each effective coil part 20. By including a middle point MD between the two effective coil parts 20, a near honeycomb structure using "a center line CL" of a line symmetry which is orthogonal to a movement direction of a magnet as a center is formed, and a step 50 is provided to near from the center line CL. Each effective coil part 20 is constructed by a coil conductor 60 formed by binding a plurality of conductive base materials 62. A wire used as each conductive base material 62 is a conductive wire containing a copper, and a mean diameter of each conductive base material is 120 μm or less.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to an air-core electromagnetic coil. [Background technology]

[0002] Electromagnetic coils used in coreless electromechanical devices are known (see, for example, Patent Document 1). Patent Document 1 describes an electromagnetic coil for configuring a cylindrical stator of a coreless motor. In this case, the magnet of the electromechanical device (here, the rotor magnet) moves circumferentially around the rotation axis (16) of the cylinder.

[0003] However, when specifically considering combining multiple electromagnetic coils to form a cylindrical coil assembly, it is not possible to actually form a cylindrical coil assembly with the hexagonal electromagnetic coil shown in Figure 5 of Patent Document 1. This is because, as shown in cross-sectional view VIII of Figure 7 of Patent Document 1, the number of windings (30) on the inner periphery side is the same as the number of windings (30) on the outer periphery side, and the length on the inner periphery side is the same as the length on the outer periphery side (in other words, the cross-sectional shape is rectangular), so even if multiple such electromagnetic coils are combined, they cannot be formed into a cylindrical shape. Even if it were possible to form such a coil assembly, it would not be a neat cylindrical coil assembly with no gaps at the joints (high energy utilization efficiency).

[0004] On the other hand, the diamond-shaped electromagnetic coil shown in FIG. 4 of Patent Document 1 may enable the cylindrical coil assembly shown in FIG. 10 of Patent Document 1 to be configured. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-230484 [Patent Document 2] International Publication No. 2018 / 139246 Summary of the Invention [Problem to be solved by the invention]

[0006] However, since each side of the rhombic electromagnetic coil is arranged diagonally with respect to the direction of movement of the magnet of the electromechanical device, the rhombic electromagnetic coil does not have any sides that are perpendicular to the direction of movement of the rotor magnet. According to Fleming's left-hand rule, when a coil current I is passed through a coil conductor in a magnetic field B (here, the magnetic field caused by the rotor magnet), a so-called Lorentz force f is generated in a direction perpendicular to both the magnetic field B and the coil current I. However, in the case of a diamond-shaped electromagnetic coil, the direction in which the coil current I flows is diagonal to the direction of movement of the rotor magnet (it is not perpendicular), so it is known that approximately 20 to 30% of the Lorentz force f is lost when generating rotational force for the rotor. As such, diamond-shaped electromagnetic coils make it difficult to configure an electromechanical device with high energy efficiency.

[0007] On the other hand, electromagnetic coils having sides perpendicular to the moving direction of the rotor magnet have also been proposed (see, for example, the electromagnetic coil described in Patent Document 2 by the same inventor). However, as shown in FIG. 2C of Patent Document 2, in conventional electromagnetic coils, the ratio of the length of the coil ends (CE1+CE2) to the overall longitudinal length (CE1+VCP+CE2) is relatively large, and therefore further improvement was expected.

[0008] The present invention has been made in consideration of the above circumstances, and aims to provide an electromagnetic coil that can be combined to form a coil assembly of a predetermined shape and has higher energy utilization efficiency than conventional coils. [Means for solving the problem]

[0009] According to one aspect of the present invention, there is provided a so-called coreless type electromagnetic coil that is arranged along the direction of movement of a magnet of an electromechanical device and has a conductive member wound around an air-core region. When viewed from above, this electromagnetic coil has two effective coil sections, each perpendicular to the direction of magnet movement and spaced apart from each other, a first coil end section located on one side of the effective coil sections in the longitudinal direction and connecting the two effective coil sections, and a second coil end section located on the other side of the effective coil sections in the longitudinal direction. The electromagnetic coil has a generally honeycomb structure that is symmetrical about a "center line" that includes the midpoint between the two effective coil sections and is perpendicular to the direction of magnet movement. When viewed along the extension direction of the effective coil sections, which is perpendicular to the direction of magnet movement, a step is provided near the center line, and at least the effective coil section is composed of a coil conductor wire made of multiple conductive substrates bundled together. The wire used as the conductive substrate is a conductive wire containing copper, and the average radius of the conductive substrate is 120 μm or less. [Effects of the Invention]

[0010] According to the present invention, it is possible to configure a coil assembly of a predetermined shape by combining a plurality of coils, and it is possible to provide an electromagnetic coil with higher energy utilization efficiency than conventional coils. [Brief explanation of the drawings]

[0011] [Figure 1] 1A and 1B are diagrams illustrating an electromagnetic coil 1 according to a first embodiment and a coil assembly 100 formed by combining a plurality of such electromagnetic coils 1. [Figure 2] 1A and 1B are diagrams shown for explaining an electromagnetic coil 1 according to a first embodiment. [Figure 3] FIG. 2 is a plan view illustrating the dimensions, angles, etc. of the electromagnetic coil 2 according to the first embodiment. [Figure 4] FIG. 2 is a perspective view of a combination of multiple electromagnetic coils 1. [Figure 5] FIG. 1 is a schematic diagram showing an experimental configuration in an experimental example. [Figure 6] 10 is a table showing experimental results in an experimental example. [Figure 7]FIG. 1 is a plan view showing a comparison of the dimensions of a conventional electromagnetic coil 9 and the electromagnetic coil 1 according to the first embodiment. [Figure 8] 10A and 10B are diagrams illustrating an electromagnetic coil 2 according to a second embodiment and a coil assembly 200 formed by combining a plurality of the electromagnetic coils 2. [Figure 9] 10 is a diagram illustrating an electromagnetic coil 3 according to a third embodiment and a coil assembly 300 formed by combining a plurality of the electromagnetic coils 3. [Figure 10] 10 is a diagram for explaining an electromagnetic coil 4 according to Modification 1. FIG. [Figure 11] FIG. 1 is a perspective view for explaining a coil assembly 400 formed by combining a plurality of electromagnetic coils 4. [Figure 12] 10 is a diagram illustrating the preparation of a coil conductor 60 (braided wire 64). FIG. [Figure 13] 10A and 10B are diagrams for explaining (a part of) the manufacturing process of the electromagnetic coil 4 according to the modified example. [Figure 14] FIG. 10 is a perspective view for explaining an electromagnetic coil 5 according to a second modification. [Figure 15] 10 is a diagram illustrating a spacer 150 according to a third modification. FIG. [Figure 16] 10 is a diagram illustrating a padding 52 according to a fourth modification. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, an embodiment of an electromagnetic coil according to the present invention will be described with reference to the drawings. Regarding the reference numerals common to the figures, the content already explained for those reference numerals can be used in the explanation of the other figures, so explanations for those figures will be omitted. Furthermore, each drawing is a schematic diagram showing an example, and does not necessarily strictly reflect the actual dimensions, proportions, etc.

[0013] [Embodiment 1] 1. Configuration of the electromagnetic coil 1 according to the first embodiment (1) Overview of the electromagnetic coil 1 and coil assembly 100 The electromagnetic coil 1 of embodiment 1 is arranged along the movement direction of the magnet of the electromechanical device, and is a so-called air-core electromagnetic coil in which a conductive member (details will be described later) is wound around the air-core region 10. In this context, "winding" includes not only winding to completely surround the air-core region 10 over 360 degrees, but also winding to surround the air-core region 10 but not completely around the air-core region 10 (not reaching 360 degrees).

[0014] The electromagnetic coil 1 can be applied to any electromechanical device that uses a so-called air-core coil. A coreless motor is one suitable application of the electromechanical device. FIG. 1(a) shows an example of a coil assembly 100 of a concentrated winding type electromagnetic coil used in a coreless motor. In the figure, the direction parallel to the rotation axis AX1 of the coreless motor is defined as the "y direction," the direction perpendicular to the rotation axis AX1 is defined as the "x direction," and the direction perpendicular to the x and y directions is defined as the "z direction." The direction perpendicular to the rotation axis AX1, starting from the rotation axis AX1, is defined as the "radial direction RD," and the direction perpendicular to the radial direction and parallel to the rotation axis AX1 is defined as the "circumferential direction CF." As shown in FIG. 1(a), the coil assembly 100 has multiple electromagnetic coils 1 (subscripted letters indicate index) arranged in a row along the direction of movement ROT of the rotor's permanent magnet (not shown) so that they are in contact with each other. As such, the electromagnetic coils 1 are suitable for use in so-called coreless motors.

[0015] Fig. 1(b) is a cross-sectional view illustrating the phase of the current supplied to the coil assembly 100 when it is operated as an electromechanical device. The hatched effective coil portions 21 and 22 in the cross section are shown as being supplied with a "first phase" current. Fig. 1(c) is a perspective view showing the state when multiple electromagnetic coils 1a, 1b, and 1c are overlapped with each other. A detailed description of Figures 1(b) and 1(c) will be given later.

[0016] (2) Basic structure of electromagnetic coil 1 Fig. 2 is a diagram for explaining the electromagnetic coil 1 according to embodiment 1. Fig. 2(a) is a plan view, Fig. 2(b) is a cross-sectional view taken along line B--B in Fig. 2(a), and Fig. 2(c) is an enlarged cross-sectional view of the cross section of the coil conductor 60 (inside the circle surrounded by the dashed line in Fig. 2(b)).

[0017] (2-1) As shown in Fig. 2(a), in a plan view, the electromagnetic coil 1 has two effective coil sections 20 that are arranged spaced apart and each perpendicular to the direction of movement of the magnet (the direction indicated by ROT in the first embodiment), a first coil end section 30 that is located on one side LD1 in the longitudinal direction LD of the effective coil sections 20 and connects the two effective coil sections 20, and a second coil end section 40 that is located on the other side LD2 in the longitudinal direction LD of the effective coil sections 20. The effective coil sections 20 extend linearly along the longitudinal direction LD. It should be noted that a plan view when "viewed from above" refers to a view that shows the electromagnetic coil when viewed in the normal direction of each effective coil section 20, first coil end section 30, and second coil end section 40 (described later) when the electromagnetic coil is continuously expanded (see Figures 2(a), 3, 7, 8(a), 9(a), etc.).

[0018] The "effective coil portion" is a portion that effectively converts energy between electrical energy and mechanical energy. Typically, it is a portion that is positioned so that its longitudinal direction LD is perpendicular to the direction of magnet movement ROT (embodiments 2 and 3) or MOV (embodiment 3). The "first coil end portion 30" and the "second coil end portion 40" can also be said to be portions that do not directly contribute to the energy conversion between electrical energy and mechanical energy.

[0019] When viewed from above, the electromagnetic coil 1 has a generally honeycomb structure that is symmetrical about a center line CL.

[0020] The electromagnetic coil 1 is hexagonal in shape and has six straight lines (sides). The first straight line section 11 and the second straight line section 12 each constitute an effective coil section, the third straight line section 13 and the fourth straight line section 14 constitute a first coil end section 30, and the fifth straight line section 15 and the sixth straight line section 16 constitute a second coil end section 40.

[0021] The term "substantially honeycomb structure" refers to a hexagonal structure that is symmetrical about a center line CL that is parallel to the effective coil portion 20, and it is sufficient for the structure to be approximately hexagonal overall. For example, the corners of the hexagon may be slightly curved, and the sides of the hexagon may not be perfectly straight. Furthermore, the second coil end portions 40 may not form complete sides of the hexagon, and may be imaginary hexagons that include non-existent sides (for example, the electromagnetic coil 4 according to Modification 1 shown in FIG. 10, which will be described later).

[0022] The "center line CL" is an imaginary line that includes the midpoint MP between the two effective coil sections 20 (21, 22) and is perpendicular to the magnet movement direction ROT. The center line CL is generally parallel to the straight portion of the effective coil section 20. It is sufficient for the "midpoint MP" included as part of the center line CL to be approximately the midpoint between the two effective coil sections 21, 22.

[0023] (2-2) As shown in Figure 2(b), when the electromagnetic coil 1 is viewed in a direction perpendicular to the magnet movement direction ROT and along the direction in which the effective coil portion extends (when viewed along the direction in which the rotation axis AX1 extends), the electromagnetic coil 1 as a whole has a split ring shape in which a circular ring centered on the rotation axis AX1 is divided so that the divided rings fall within an angle of 2π / N (described below).

[0024] When viewed in the same direction as above, the electromagnetic coil 1 has a step 50 near the center line CL. In this case, of the two effective coil sections 20, the effective coil section that is positioned closer to the side where the magnet of the electromechanical device is positioned is defined as the "first effective coil section 21," and the effective coil section that is positioned closer to the side opposite the side where the magnet is positioned is defined as the "second effective coil section 22." The first effective coil section 21 has a first surface F1 facing the magnet and closer to the magnet, and a second surface F2 opposite the first surface F1. The second effective coil section 22 has a third surface F3 on the side where the magnet is disposed and a fourth surface F4 opposite the third surface F3.

[0025] 2(b) and 9(b) (details will be described later), the step G1 between the two effective coil portions 20 (21, 22), which is defined by the step between the first surface F1 and the third surface F3, is equal to or greater than the thickness T1 of the first effective coil portion 21, which is defined by the dimension between the first surface F1 and the second surface F2. In other words, the size of the step G1 is set to be equal to or greater than the thickness T1 of the first effective coil portion 21. By setting the step G1 in this manner, the coil assembly 100 can be constructed by overlapping portions of the multiple electromagnetic coils 1 while aligning the first surfaces F1 facing the magnets on the same plane. The thickness T1 of the first effective coil portion 21 can also be referred to as the thickness of the first effective coil portion 21 in the normal direction perpendicular to the first surface F1 facing the magnet, and in the case of an electromagnetic coil that constitutes a cylindrical coil assembly, it can also be referred to as the "radial thickness" of the first effective coil portion 21.

[0026] For reference, in the drawing, symbol T2 denotes the thickness of second effective coil portion 22, which is defined as the dimension between third surface F3 and fourth surface F4, and symbol G2 denotes the step between fourth surface F4 and second surface F2. In this portion as well, the size of step G2 is set to be the same as or larger than thickness T2 of second effective coil portion 22.

[0027] When the electromagnetic coil 1 is viewed along the direction in which the rotation axis AX1 of the cylindrical coil assembly extends, the electromagnetic coil 1 has an effective coil section arranged on the inner side (second effective coil section 22 in the example of embodiment 1) and an effective coil section arranged on the outer side (first effective coil section 21) that are arranged within an angle (2π / N) obtained by dividing the mechanical angle 2π into N equal parts, where N is obtained from the equation "Pa·Pm=N". However, Pa is the number of phases when the electromechanical device is driven, Pm is the number of magnetic poles of the electromechanical device, and Pa, Pm, and N are all natural numbers.

[0028] Since the electromagnetic coil 1 constitutes a cylindrical coil assembly, the cross-section of the effective coil portion 20 (21, 22) (the cross-section when cut by a virtual plane including the magnet movement direction ROT) is substantially fan-shaped. The term "substantially fan-shaped" refers to a split ring shape assuming that an annular ring is cut along the radial direction. The cross-section of the effective coil portion 20 (21, 22) is formed so that the coil conductor 60 fits within the range of the angle θw shown in FIGS. 2(b) and 2(c). At this time, although it is difficult to confirm in the figure, the radial thickness Ti of the effective coil portion 20 arranged on the inner peripheral side centered on the rotation axis AX1 of the electromechanical device (T2 in the example of Embodiment 1) is larger than the radial thickness To of the effective coil portion arranged on the outer peripheral side (T1 in the example of Embodiment 1). That is, the relationship is To < Ti (in the example of Embodiment 1, T1 < T2).

[0029] By doing as above, a cylindrical coil assembly 100 can be configured by combining a plurality of electromagnetic coils 1.

[0030] (2-3) As shown in FIG. 2(c), in the electromagnetic coil 1, at least the effective coil portion 20 (21, 22) is constituted by a coil conductor 60 formed by bundling a plurality of conductive base materials 62. "Bundling a plurality of conductive base materials 62" can also be rephrased as twisting or / and braiding a plurality of conductive base materials 62. The wire used as the conductive base material 62 is a conductive wire containing copper, and the average radius of the conductive base material is 120 μm or less.

[0031] As described above, the electromagnetic coil 1 constitutes a cylindrical coil assembly, and the cross section of the coil conductor 60 is approximately fan-shaped, so the number of wires of the conductive substrate 62 that contact the outer periphery of the coil conductor 60 (7 in the schematic diagram of Figure 2(c)) is greater than the number of wires of the conductive substrate 62 that contact the inner periphery of the coil conductor 60 (5 in the same schematic diagram).

[0032] Furthermore, the conductive substrate 62 is preferably a bare conductor wire 61, and the coil conductor 60 is preferably a braided wire 64 in which a plurality of bare conductor wires 61 are braided. "Bare conductor wire 61" refers to a wire that is not covered with an insulating material and has a bare conductor as a conductive member. For example, "bare conductor wire 61" includes a pure "bare copper wire" made primarily of copper, a "carbon wire" made of carbon, and a "plated wire" made of bare copper wire plated with tin or nickel.

[0033] By introducing the coil conductor 60 described above into the effective coil portion 20, it is possible to reduce the generation of eddy currents, and as a result, it is possible to provide an electromagnetic coil with high energy utilization efficiency. Note that details regarding optimization of the conductive substrate 62, the type of wire material, etc. related to this will be explained separately in "2. Experimental Examples."

[0034] (3) Details of the structure of electromagnetic coil 1 FIG. 3 is a plan view for explaining the dimensions, angles, etc. of the electromagnetic coil 2 according to the first embodiment.

[0035] (3-1) Surface continuity 3, in the electromagnetic coil 1, the first surface F1 of the first effective coil portion 21 (first straight portion 11) and the surface of the third straight portion 13 constituting the first coil end portion 30 that is closer to the magnet form the same continuous surface. Similarly, the third surface F3 of the second effective coil portion 22 (second straight portion 12) and the surface of the fourth straight portion 14 constituting the first coil end portion 30 that is closer to the magnet form the same continuous surface. Therefore, the step 50 is formed near the corner where the third straight portion 13 and the fourth straight portion 14 of the first coil end portion 30 join together.

[0036] The electromagnetic coil 1 according to the first embodiment is a hexagonal coil with all sides closed, and so a step 50 is also provided in the second coil end portion 40. That is, the first surface F1 of the first effective coil portion 21 (first straight portion 11) and the surface of the fifth straight portion 15 constituting the second coil end portion 40 closer to the magnet form a continuous, identical surface, and the third surface F3 of the second effective coil portion 22 (second straight portion 12) and the surface of the sixth straight portion 16 constituting the second coil end portion 40 closer to the magnet form a continuous, identical surface, and a step 50 is similarly formed near the corner where the fifth straight portion 15 and the sixth straight portion 16 of the second coil end portion 40 meet.

[0037] Next, the electromagnetic coil 1 has the following relationship, for example, so that a coil assembly of a predetermined shape can be configured by combining a plurality of electromagnetic coils as shown in FIG. 1(c).

[0038] (3-2) Widths W1 and W2 of the effective coil portion 20 and width AC of the air-core region 10 The electromagnetic coil 1 according to the first embodiment is an electromagnetic coil 1 for three-phase driving. For this reason, two effective coil portions 21 are accommodated within the width AC of the air-core region 10 of the electromagnetic coil 1 (see FIG. 3). In general, when the width of the first effective coil portion 21 is W1, the distance between the first effective coil portion 21 and the second effective coil portion 22 (in other words, the width of the air-core region 10) is AC, and the number of phases when the electromechanical device is driven is Pa, there is a relationship AC≧(Pa−1)×W1. In other words, the air-core region 10 is set so that (number of phases−1) effective coil portions 21 fit within its width AC.

[0039] (3-3) Consistency between outer and inner peripheral shapes The shape of the outer periphery including sides S1, S5, S4, etc. and the shape of the inner periphery including sides S2, S6, S3, etc. have a predetermined relationship so that they match when a plurality of electromagnetic coils 1 are combined. When the length of the outer periphery S1 of the first straight portion 11 constituting the first effective coil portion 21 is L1o and the length of the inner periphery S2 of the first straight portion 11 is L1i, the relationship L1o≦L1i holds. In this case, the outer periphery S1 and the inner periphery S2 are approximately parallel to each other. Furthermore, when the angle formed between the outer periphery S1 and the outer periphery S5 of the third straight portion 13 is defined as θ1, and the angle formed between the inner periphery S2 and the inner periphery S6 of the third straight portion 13 is defined as θ2, the relationship θ1≦θ2 holds. Furthermore, although not necessarily required, when the width of the third straight portion 13 constituting the first coil end portion 30 is W3, the length of the inner periphery of the fourth straight portion 14 is L4, and the number of phases when the electromechanical device is driven is Pa, the relationship L4 ≥ (Pa - 1) × W3 is satisfied. Furthermore, the outer periphery S5 and inner periphery S6 of the third straight portion may be set to be approximately parallel.

[0040] FIG. 4 is a perspective view of a combination of a plurality of electromagnetic coils 1. For example, when electromagnetic coil 1b is overlapped with electromagnetic coil 1a as shown in Figure 4, since L1o ≤ L1i, the outer perimeter S1 of electromagnetic coil 1b is contained within the length L1i of the inner perimeter S2 of electromagnetic coil 1a without being interfered with by the third straight portion 13 or the fifth straight portion 15 of electromagnetic coil 1a. Also, since θ1 ≤ θ2 of electromagnetic coil 1, the angle defining θ1 of electromagnetic coil 1b can be abutted against the angle defining θ2 of electromagnetic coil 1a. For these reasons, S1 of electromagnetic coil 1b can be aligned with S2 of electromagnetic coil 1a without any gap.

[0041] (3-4) The electromagnetic coil 1 is configured so that the effective coil portion of the “other electromagnetic coil” to which a second phase current is supplied is fitted into the air-core region of the “one electromagnetic coil” to which a first phase current is supplied. Here, the "first phase" may be, for example, the U phase when the electromechanical device is excited and driven by a three-phase (U, V, W) drive voltage or drive current. In this case, the "second phase" may be the V phase or the W phase. The electromagnetic coil 1 according to the first embodiment is an electromagnetic coil 1 for three-phase drive. Therefore, as shown in Fig. 1(b), in the outer layer, an effective coil portion 21b of electromagnetic coil 1b to which a V-phase (second phase) current is supplied and an effective coil portion 21c of electromagnetic coil 1c to which a W-phase (another second phase) current is supplied are fitted into the air-core region (region sandwiched between effective coil portion 21a and effective coil portion 22a) of electromagnetic coil 1a (one electromagnetic coil) to which a U-phase (first phase) current is supplied (see also Fig. 4 in addition to Fig. 1(b)). Similarly, in the inner layer, an effective coil portion 22y (V-phase) and an effective coil portion 22z (W-phase) are fitted.

[0042] 2. Experimental Example The inventors conducted an experiment on the generation of eddy currents due to the movement of magnets in an electromechanical device, and found that eddy currents We have gained new knowledge about coils that suppress the generation of noise, which we will explain below.

[0043] (1) Experimental configuration FIG. 5 is a schematic diagram showing the experimental setup in the experimental example. In order to reproduce the movement of a magnet in an electromechanical device, a pendulum-shaped experimental jig was constructed as shown in Fig. 5. Specifically, permanent magnets MGa and MGb were disposed on one end 710b of a rod 710 via a fixing member 720 (reference numeral 730 indicates the pair of permanent magnets MGa and MGb), and the other end 710a of the rod 710 was fixed to a rotation axis AX2. The other end 710a of the rod 710 was connected to a bearing shaft so that it could rotate with a low coefficient of friction. In addition, a sample (referred to as Sample in the figure) was placed directly below the rotation axis AX2. The sample was fixed on the top surface of a sample fixing stage 740 made of a non-magnetic material, and a gap G was set between the level of the top surface of the sample and the permanent magnet pair 730 disposed at the tip of the pendulum, so that the sample and the permanent magnet pair 730 did not come into spatial contact with each other.

[0044] (2) Samples and experimental methods (2-1) Sample The sample was basically assumed to be an electromagnetic coil, but more specifically, various candidate materials for the "conductive member (e.g., conductive substrate 62, coil conductor 60, first end member 130 and second end member 140 described below)" were assumed, and these samples were used in the experiment. More specifically, the materials shown in the second column of the table in Fig. 6 (described below) were shaped into a rectangular shape of 30 mm x 10 mm in plan view, and each was prepared as a sample.

[0045] (2-2) Experimental method First, a sample corresponding to the experiment number is placed on the sample fixing stage 740. At that time, the position of the sample fixing stage 740 is adjusted so that the gap G is approximately 1 mm regardless of the experiment number. Next, the permanent magnet pair 730 is raised to the position shown by the solid line in FIG. 8 so that the height of the center of the permanent magnet pair 730 coincides with the height of the rotation axis AX2 (ie, so that the rod 710 is horizontal). The pendulum is then released. As a result, the permanent magnet pair 730 begins to move in the direction of arrow C0 in Figure 8, vibrating back and forth, alternately moving in the directions of arrows C1 and C2 directly above the sample. This vibration dampens and eventually stops due to resistance between the pendulum and the air, as well as losses caused by eddy currents generated when the permanent magnet pair 730 passes near the sample. Experimental data is obtained by observing this vibration. The observations are the number of times the pendulum vibrates (the number of times it takes for the pendulum to stop; hereafter simply referred to as the number of vibrations) and the duration of vibration (the time required for the pendulum to stop; hereafter simply referred to as the vibration duration). Under the assumption that the greater the number of vibrations and / or the vibration duration, the less loss due to eddy currents will be generated. Note that although the samples in Experiments 6 and 7 were not conductor wires, these were also observed for comparison. Experiments 1 to 7 were conducted using the above experimental method.

[0046] (3) Experimental results FIG. 6 is a table showing the experimental results of the experimental example. As shown in Figure 6, for Experiments 2, 4, and 5, in which the average radius of the conductive substrate (conductor portion) was 100 μm or less, the number of reciprocating motions and vibration time were relatively large, and the generation of eddy currents was small. Furthermore, when the average radius of the conductive substrate (conductor portion) was 50 μm or less, the generation of eddy currents was even smaller. Furthermore, for Experiments 4 and 5, which were braided wires in which multiple bare conductor wires were braided, the number of reciprocating motions and vibration time were relatively large, and the generation of eddy currents was small. Furthermore, for the magnet wire of Experiment 2 (in which an insulating coating was previously applied to the conductive portion, which is the conductive substrate), the number of reciprocating motions and vibration time were relatively large, and the generation of eddy currents was small. Furthermore, for the plated copper wire of Experiment 3, the number of reciprocating motions and vibration time were relatively large, and the generation of eddy currents was small.

[0047] (4) Discussion (4-1) From the above experimental results, it became clear that when constructing the electromagnetic coil 1 according to embodiment 1, the average radius of the conductive substrate 62 is preferably 120 μm or less, more preferably 100 μm or less, and even more preferably 50 μm or less (Experiment Nos. 2, 4, and 5). (4-2) When constructing the electromagnetic coil 1, under the conditions of (1) above, it was found that it is more preferable for the coil conductor 60 to be a braided wire 64 in which multiple bare conductor wires 61 are braided (Experiment Nos. 4 and 5). (4-3) When constructing the electromagnetic coil 1, under the conditions of (1) above, it was found that it is more preferable for the coil conductor 60 to be made of a "magnet wire" in which an insulating coating has been applied to a conductive substrate 62 in advance (Experiment No. 2). (4-4) It was also found that the conductive substrate 62 can be suitably a nickel-plated wire made by plating a copper wire with nickel or a tin-plated wire made by plating a copper wire with tin (Experiment No. 3). From the above, it has been experimentally confirmed that the generation of eddy currents can be reduced by adopting a conductive substrate 62 and a coil conductor 60 that satisfy any one or a combination of the above (4-1) to (4-4).

[0048] 3. Effects of the electromagnetic coil 1 according to the first embodiment The electromagnetic coil 1 according to the first embodiment has a generally honeycomb structure that is symmetrical about a "center line CL" that includes the midpoint MP between two effective coil portions 20 and is perpendicular to the magnet movement direction ROT, and a step 50 is provided near the center line CL. This configuration allows regions that are relatively lowered by the step 50 (specifically, in the first embodiment, the effective coil portion 22 on the inner periphery and the fourth straight portion 14 of the first coil end portion 30 and the sixth straight portion 16 of the second coil end portion 40 that are integrated therewith) to be aligned with regions that are relatively higher by the step 50 of adjacent electromagnetic coils (specifically, in the first embodiment, the effective coil portion 21 on the outer periphery and the third straight portion 13 of the first coil end portion 30 and the fifth straight portion 15 of the second coil end portion 40 that are integrated therewith), allowing multiple of these electromagnetic coils 1 to be repeatedly combined adjacently. Therefore, in the first embodiment, a cylindrical coil assembly 100 can be configured.

[0049] Furthermore, the electromagnetic coil 1 is configured to ensure that the effective coil section 20 is positioned perpendicular to the direction of magnet movement ROT. As a result, the direction of the drive current I flowing through the coil conductor 60 of the effective coil section 20 is perpendicular to the direction of the magnetic field B (magnetic lines of force) generated by the magnet, and compared to the conventional diamond-shaped electromagnetic coil (Patent Document 1), it can generate Lorentz force f more efficiently (100% contribution due to perpendicularity) and contribute to the rotational force of the rotor. Therefore, this electromagnetic coil has higher energy utilization efficiency than conventional ones.

[0050] Furthermore, since the electromagnetic coil 1 has a hexagonal, approximately honeycomb structure when viewed in a plane, the length of the effective coil portion 20 relative to the overall length can be made larger than that of the conventional trapezoidal-shaped electromagnetic coil 9 (Patent Document 2), as shown in Figure 7. 7 is a plan view showing a comparison of the dimensions of a conventional electromagnetic coil 9 and the electromagnetic coil 1 according to embodiment 1. As shown in the figure, the ratio of the length of the effective coil portion in the electromagnetic coil 9 is VCP / (CE1+CE2+VCP), and the ratio of the length of the effective coil portion 20 (21, 22) in the electromagnetic coil 1 is L1 / (L2+L3). In other words, when attempting to provide electromagnetic coils of the same length, the electromagnetic coil 1 according to embodiment 1 can ensure a larger ratio of the length of the effective coil portion compared to the conventional electromagnetic coil 9. In this way, the electromagnetic coil 1 according to the first embodiment can relatively increase the "effective coil portion," which is the portion that directly contributes to energy conversion. Conversely, the coil end portion that does not directly contribute to energy conversion can be made smaller, thereby reducing the wiring length, and therefore the resistance value of the entire electromagnetic coil can also be reduced. As a result, the electromagnetic coil has higher energy utilization efficiency than conventional electromagnetic coils.

[0051] Furthermore, in the electromagnetic coil 1, the effective coil portion 20 is configured with a coil conductor 60 formed by bundling together a plurality of conductive substrates 62, and the wire used as the conductive substrate 62 is a conductive wire containing copper, and the average radius of the conductive substrate is 120 μm or less. This configuration can further reduce the generation of eddy currents. This is because, as verified in the [Experimental Example], in the effective coil portion, which is susceptible to the influence of magnet movement, the generation of eddy currents can be expected to be reduced by using the coil conductor of the above-mentioned nature, rather than using a solid conductive material made of metal (e.g., copper plate). In this way, the energy loss due to eddy current can be suppressed, and the electromagnetic coil 1 according to the first embodiment is an electromagnetic coil with higher energy utilization efficiency than conventional electromagnetic coils.

[0052] Furthermore, in the electromagnetic coil 1 according to the first embodiment, the cross section of the effective coil portion 20 (21, 22) is substantially sector-shaped, the radial thickness Ti of the effective coil portion located on the inner periphery is greater than the radial thickness To of the effective coil portion located on the outer periphery, the width AC of the air-core region 10 and the width W1 of the effective coil portion 20 have the relationship AC≧(Pa−1)×W1, and the effective coil portion located on the inner periphery and the effective coil portion located on the outer periphery are arranged within an angle (2π / N) obtained by dividing a mechanical angle 2π into N equal parts, where N is obtained from the equation “Pa·Pm=N.” Therefore, a cylindrical coil assembly 100 can be configured. Furthermore, since the first embodiment is structured to accommodate a phase number Pa=3, an electromagnetic coil 1 suitable for a cylindrical (rotary) electromechanical device for three-phase drive can be provided.

[0053] [Embodiment 2] FIG. 8 is a diagram illustrating an electromagnetic coil 2 according to a second embodiment and a coil assembly 200 configured by combining a plurality of such electromagnetic coils 2. FIG. 8(a) is a plan view, and FIG. 8(b) is a DD cross-sectional view of FIG. 8(a). FIG. 8(c) is a perspective view showing a state in which a plurality of electromagnetic coils 2a, 2b, and 2c are stacked one on top of the other. FIG. 8(d) is a perspective view of the coil assembly 200, and FIG. 8(e) is a cross-sectional view illustrating the phase of the current supplied to the coil assembly 200 when it is operated as an electromechanical device.

[0054] The electromagnetic coil 2 according to the second embodiment basically has the same configuration as the electromagnetic coil 1 according to the first embodiment, but differs in that it is an electromagnetic coil used in an electromechanical device that is driven in two phases.

[0055] That is, in the electromagnetic coil 2 according to the second embodiment, the width AC of the air-core region 10 is set to a width that can accommodate one effective coil portion 20 of another electromagnetic coil 2, as shown in FIG. 8(a). With this configuration, as shown in FIG. 8(e), in the outer layer, the effective coil portion 21b of the electromagnetic coil 2b to which a B-phase (second phase) current is supplied is fitted into the air-core region (region sandwiched between the effective coil portion 21a and the effective coil portion 22a) of the electromagnetic coil 2a (one electromagnetic coil) to which an A-phase (first phase) current is supplied (see also FIG. 8(c)). Similarly, in the inner layer, the effective coil portion 22z (B-phase) is fitted. Therefore, according to the second embodiment, it is possible to provide an electromagnetic coil 2 suitable for a cylindrical (rotary) electromechanical device for two-phase drive.

[0056] The electromagnetic coil 2 according to the second embodiment has a configuration basically similar to that of the electromagnetic coil 1 according to the first embodiment, except that it is an electromagnetic coil used in a two-phase driven electromechanical device. Therefore, it similarly has the corresponding effects of the electromagnetic coil 1 according to the first embodiment.

[0057] [Embodiment 3] 9A and 9B are diagrams illustrating an electromagnetic coil 3 according to a third embodiment and a coil assembly 300 configured by combining a plurality of the electromagnetic coils 3. Fig. 9A is a plan view, and Fig. 9B is an E-E cross-sectional view of Fig. 9A. Fig. 9C is a perspective view of the coil assembly 300, and Fig. 9D is a cross-sectional view illustrating the phase of the current supplied to the coil assembly 300 when it is driven as an electromechanical device.

[0058] The electromagnetic coil 3 of embodiment 3 basically has the same configuration as the electromagnetic coil 2 of embodiment 2, but differs in that it is an electromagnetic coil used in a so-called linear electromechanical device equipped with a mover (not shown) that moves linearly, i.e., it constitutes a planar coil assembly.

[0059] The electromagnetic coil 2 according to the second embodiment described above has a split ring shape when viewed along the direction in which the rotation axis AX1 extends. On the other hand, as shown in Fig. 9(b), the electromagnetic coil 3 according to the third embodiment has a linear shape extending in a direction parallel to the direction of movement MOV of the magnet. The first surface F1 constituting the first effective coil portion 21 and the third surface constituting the second effective coil portion 22 are substantially flat surfaces parallel to the direction of movement MOV of the magnet.

[0060] Furthermore, the thicknesses T1 and T2 of the two mutually separated effective coil portions 20 (21, 22) in the direction perpendicular to the plane are approximately equal to each other.

[0061] As configured as described above, by combining multiple electromagnetic coils 3, a linear coil assembly 300 can be formed on a plane, extending in a straight line along the direction of magnet movement MOV (see Figure 9(c)).

[0062] Since the electromagnetic coil 3 is an electromagnetic coil for two-phase drive, as shown in Fig. 9(d), in the layer closer to the magnet, the effective coil portion 21b of the electromagnetic coil 3b to which a B-phase (second phase) current is supplied is fitted into the air-core region (region sandwiched between the effective coil portion 21a and the effective coil portion 22a) of the electromagnetic coil 3a (one electromagnetic coil) to which an A-phase (first phase) current is supplied (see also Fig. 9(c)). Similarly, in the layer opposite to the side where the magnet is arranged, an effective coil portion 22z (B-phase) is fitted.

[0063] Although an electromagnetic coil for two-phase drive has been described as an example here, the electromagnetic coil 3 according to the third embodiment is not limited to this. It can also be configured as an electromagnetic coil for three-phase drive.

[0064] The electromagnetic coil 3 according to embodiment 3 has a configuration basically similar to that of the electromagnetic coil 1 according to embodiment 1 and the electromagnetic coil 2 according to embodiment 2, except that it is an electromagnetic coil used in a linear electromechanical device. Therefore, it similarly has the corresponding effects of the effects of the electromagnetic coil 1 and the electromagnetic coil 2.

[0065] [Application example] The electromagnetic coils obtained in the embodiments described so far can be applied to various product fields. For example, the electromagnetic coil 1 according to embodiment 1 and the electromagnetic coil 2 according to embodiment 2 can be applied to a motor equipped with a rotor, a generator equipped with a rotor, an actuator equipped with a rotor, etc. Furthermore, the electromagnetic coil 3 according to embodiment 3 can be applied to a linear motor equipped with a mover, etc.

[0066] [Variations] Although the present invention has been described based on the above embodiment, the present invention is not limited to the above embodiment and can be embodied in various forms without departing from the spirit of the present invention, and for example, the following modifications are also possible.

[0067] 1. Making the coil end part a solid conductive material (Variation 1) FIG. 10 is a diagram for explaining an electromagnetic coil 4 according to Modification 1. FIG. 10(a) is a plan view, FIG. 8(b) is a diagram viewed from the side where the second coil end portion 40 is arranged, and FIG. 10(c) is a cross-sectional view of the coil conductor 60 constituting the effective coil portion 20 (21, 21) when cut along the arrow H shown in FIG. 10(a). FIG. 11 is a perspective view for explaining a coil assembly 400 formed by combining a plurality of electromagnetic coils 4. FIG. 11 is a perspective view for explaining a coil assembly 400 formed by combining a plurality of electromagnetic coils 4.

[0068] (1) Configuration of the electromagnetic coil 4 according to Modification 1 In each embodiment, the description has been given assuming that the effective coil portion 20 (21, 22), the first coil end portion 30, and the second coil end portion 40 are entirely formed using the same material (coil conductor 60), but the present invention is not limited to this. For example, as shown in Figures 10(a) and 10(b), in an electromagnetic coil 4 according to variant example 1, the first coil end portion 30 may be formed by a first end member 130 made of a solid conductive material, and the second coil end portion 40 may be formed by a second end member 140 made of a solid conductive material (variant example 1).

[0069] (2) First end member 130 The first end member 130 is made of a solid conductive material. A "solid conductive material" is a variation of the term "conductive member" and refers to a conductive member that is a single solid body, rather than a bundle of wires. For example, it may be made of a metal containing copper and cast or forged into a predetermined shape. It may also be a copper plate (a rolled metal containing copper) pressed into a predetermined shape. It is preferable that the solid conductive material be made of a material that contains at least copper or carbon.

[0070] The first end member 130 is connected to one end (LD1 side) of the one coil conductor 601 and the other coil conductor 602 that respectively constitute the two effective coil portions 21, 22, and electrically connects the one coil conductor 601 and the other coil conductor 602. The first end member 130 is provided with an opening 131 that can receive and fit the one end sides 60a of the coil conductors 601, 602 (see also Figure 13(b)).

[0071] (3) Second end member 140 The second end member 140 is made of a solid conductive material similar to that described above. The second end member 140 is connected to the other end (LD2 side) of one coil conductor 601 and the other coil conductor 602 that respectively constitute the two effective coil portions 21 and 22. The second end member 140 is provided with an opening 141 that can receive and fit the other end 60b of the coil conductors 601 and 602. In addition, the second end member 140 is provided with a circuit connection terminal 105 (see also Figure 13(b)).

[0072] (4) Coil wire 60 The coil conductors 601, 602 constituting the effective coil portions 21, 22 are made of a braided wire 64 formed by braiding a plurality of bare conductor wires 61. Specifically, as shown in Fig. 10(c), for example, the coil conductors 601, 602 are made of a braided wire 64 formed by braiding three sets of twisted wires 63, each of which is made of six bare conductor wires 61 twisted together as an intermediate material. The coil conductor 60 that constitutes the effective coil portion 20 (21, 22) is made of a material that contains at least copper or carbon.

[0073] (5) Insulation An insulating layer 106 is provided on at least the surface of the braided wire 64. The insulating layer 106 may be made of any insulating material. For example, the insulating layer in at least the effective coil portion 20 may be made of an insulating layer 107 formed by solidifying a water-soluble material that has permeated the conductive substrate 62. This insulating layer 107 is preferably an electrodeposited insulating coating formed around the conductive substrate 62. In other words, the insulating layer 107 is an "electrodeposited insulating coating" obtained by electrodeposition coating on the conductive substrate 62. The electrodeposited insulating coating as the insulating layer 107 coats the conductive substrate 62, is made of an insulating material, and has an insulating function. The above explanations regarding (4) the coil conductor 60 and (5) the insulation can be applied to each embodiment.

[0074] The second coil end portion 40 is provided with a circuit connection terminal 105 coupled or connected to the second end member 140 (see Figure 10(a)), and the electromagnetic coil 4 is provided with an insulating layer on the entire surface other than the circuit connection terminal 105 (the entire surface of all areas except the portion of the circuit connection terminal 105).

[0075] (6) Manufacturing method of electromagnetic coil 4 (6-1) Braided wire preparation process 12A and 12B are diagrams illustrating the preparation of the coil conductor 60 (braided wire 64). Fig. 12A is a cross-sectional view of the twisted wire 63 or the braided wire 64 cut along a plane perpendicular to the longitudinal direction. In the braided wire preparation process, first, six bare conductor wires 61 serving as conductive substrates 62 are twisted together to form a stranded wire 63, which is used as the intermediate material (see FIG. 12(a)(i)). Next, three sets of such stranded wires 63 are gathered together and braided together to form a braided wire 64 (see FIG. 12(a)(ii)). At this stage, the braided wire 64 may be lightly formed by, for example, pressing the entire periphery from the outside. The braided wire 64 thus prepared is prepared as a substantially plate-shaped coil conductor 60 having a predetermined thickness, as shown in the perspective view of FIG. 12(b).

[0076] (6-2) Braided wire forming process 13A and 13B are diagrams for explaining (a part of) the manufacturing process of the electromagnetic coil 4 according to the modified example. Fig. 13A is a perspective view for explaining the braided wire forming process. In the braided wire forming process, first, the braided wire 64 is adjusted to a predetermined length by cutting or the like (see the left diagram in FIG. 13(a)). Next, the outer diameter of both ends of the braided wire 64 is reduced by compressing the periphery from the outside over a predetermined length at one end side 60a and the other end side 60b (see the right diagram in FIG. 13(a)). This allows both ends of the braided wire 64 to be inserted into the opening 131 of the first end member 130 and the opening 141 of the second end member 140.

[0077] (6-3) End member and coil conductor connection process FIG. 13(b) is a perspective view for explaining the step of connecting the end member and the coil conductor. In the end member and coil conductor connecting process, first, for the first end member 130, one end sides 60a of the coil conductors 601, 602 (braided wire 64), which have been flattened to reduce their outer dimensions in the braided wire forming process, are inserted into the openings 131 of the first end member 130 and fitted into the overlapping portions of the coil conductors and the first end member. For the second end member 140, the other end sides 60b of the coil conductors 601, 602 (braided wire 64) are similarly inserted from the openings 141 of the second end member 140 and fitted into the overlapping portions. Next, the fitted first end member 130 and the coil conductors 601, 602, and the second end member 140 and the coil conductors 601, 602 are firmly connected to each other. The connection may be performed by crimping. For example, crimping is performed by applying pressure from the outside of the first end member 130 using a crimping tool or the like to a predetermined portion located within the overlapping portion of the first end member 130, thereby plastically deforming the overlapping portion of the first end member 130. As a result, the inner wall of the opening 131 of the first end member 130 firmly presses against the outer peripheries of the coil conductors 601, 602. As a result, the first end member 130 is firmly fixed to the coil conductors 601, 602 in close contact and electrically connected to them. After the above-described crimping and fixing, a further step may be taken to join and fix the first end member 130 and the coil conductor wires 601, 602 together using a conductive material such as solder.

[0078] (6-4) Insulation layer formation process The insulating layer forming step is a step of providing insulating layer 106 at least on the surface of the region (portion) other than circuit connection terminal 105. Note that the surface of circuit connection terminal 105 is masked in advance.

[0079] Although not shown in the drawings, the insulating layer forming process preferably involves a permeation step in which a water-soluble material using an insulating solute is permeated into at least the coil conductor 60, and a solidification step in which the permeated water-soluble material is solidified, in this order. In this case, it is preferable to use a water-soluble material that has both insulating and adhesive properties. In the permeation step, a process of adhering the water-soluble material to the surfaces of the first end member 130 and the second end member 140 (excluding the portions that have been masked in advance) may also be carried out.

[0080] The insulating layer forming process may be performed, for example, as follows. A thermosetting resin solution is filled into a liquid tank or container (hereinafter simply referred to as the liquid tank), and the (assembled) electromagnetic coil, which has undergone the end member and coil conductor connecting process, is placed into the liquid tank. This causes the water-soluble material to penetrate (permeate) between the multiple conductive substrates 62 that make up the coil conductor 60. At this time, the water-soluble material also adheres to the surfaces of the first end member 130 and the second end member 140 (excluding the masked portions). With the water-soluble material thus adhered to the periphery of the conductive substrates 62, etc., the coil conductor 60, the first end member 130, and the second end member 140 (subjects to be coated) are then removed from the liquid tank. The object to which the water-soluble material is adhered is then heated, solidifying the material derived from the water-soluble material adhered to the periphery of the object.

[0081] The penetration and solidification of the water-soluble material is preferably carried out by so-called electrodeposition insulating coating.

[0082] By carrying out the above steps, the electromagnetic coil 4 according to Modification 1 shown in Fig. 13(c) can be obtained. The electromagnetic coil 4 is a so-called single-turn electromagnetic coil in which the conductive member surrounds the air-core region 10 for approximately 3 / 4 of the turn.

[0083] The method for preparing the coil conductor 60, the method for connecting the end members, etc. are also detailed in Japanese Patent Application No. 2020-147041, a previous application filed by the same inventor. Therefore, the content of the previous application can be incorporated into this application and used by reference as an explanation in this application.

[0084] (7) Effects of the electromagnetic coil 4 according to the first modification (7-1) In the electromagnetic coil 4, the first coil end portion 30 and the second coil end portion 40 are configured by the first end member 130 and the second end member 140 made of solid conductive material, rather than by members using wire. Therefore, the first coil end portion 30 and the second coil end portion 40 can be wound around the air-core region 10 while changing direction at an acute angle from the longitudinal direction LD of the effective coil portion 20. As a result, the dimension of the coil end portion in the longitudinal direction LD can be made smaller. This allows the ratio of the length of the effective coil portion 20 to the overall length to be relatively increased. Conversely, the coil end portion that does not directly contribute to energy conversion can be made smaller, thereby reducing the wiring length, thereby also reducing the resistance value of the entire electromagnetic coil. Therefore, an electromagnetic coil can be obtained that can produce high torque and has high energy utilization efficiency.

[0085] Furthermore, assuming that the same length of the effective coil portion 20 is ensured, a smaller coil assembly can be constructed than in the case of a coil end portion made of wire. Furthermore, because the first end member 130 and the second end member 140 are made of solid conductive material, i.e., they are not twisted or braided, problems of wire breakage and wire diameter distortion when attempting to bend the wire at an acute angle do not occur. Furthermore, even when the specifications of an electromechanical device require the formation of an electromagnetic coil with a three-dimensionally complex shape or a shape with irregularities, such requirements can be met by preparing solid conductive material formed into an appropriate shape.

[0086] 2. Making the coil end part a solid conductive material (Variation 2) Furthermore, the number of turns of the coil may be greater than that of the electromagnetic coil 4 according to the first modification (second modification). Fig. 14 is a perspective view shown to explain the electromagnetic coil 5 according to Modification 2. Fig. 14(a) is an exploded view of the electromagnetic coil 5, and Fig. 14(b) is a view of the electromagnetic coil 5 after assembly is complete. For components that have the same basic configuration and features as those in Modification 1, the explanation of the components in Modification 1 will be used with the reference numerals 130 and 140 in the explanation of Modification 1 replaced with 230 and 240, respectively, and explanations thereof will be omitted here.

[0087] The electromagnetic coil 5 according to the second modification basically has the same configuration as the electromagnetic coil 4 according to the first modification, but differs from the electromagnetic coil 4 according to the first modification in the number of turns of the coil. That is, as shown in FIG. 14, the electromagnetic coil 5 is wound approximately twice to surround the air-core region 10, with the "conductive member" connected in order from the upper left side to the second end member 2401, the coil conductor 601, the first end member 2301, the coil conductor 603, the second end member 2402, the coil conductor 602, the first end member 2302, the coil conductor 604, and the second end member 2403.

[0088] The electromagnetic coil 5 according to the second modification has an increased number of turns, making it possible to configure an electromechanical device with even higher torque.

[0089] 3. Making the coil end part a solid conductive material (Variation 3) Fig. 15 is a diagram illustrating a spacer 150 of Modification 3. Fig. 15(a) shows a plan view of the spacer 150 before it is attached to the braided wire 64, and Fig. 15(b) shows a side view of the same. Fig. 15(c) shows a plan view of the spacer 150 when it is attached to the braided wire 64.

[0090] In the electromagnetic coil 4 according to variant 1 and the electromagnetic coil 5 according to variant 2, a spacer 150 made of metal or the like may be attached to the end of the coil conductor 60, and one end side 60a and the other end side 60b of the coil conductor 60 may be indirectly coupled and connected to the first end members 130, 230 and the second end members 140, 240 via the spacer 150 (variation 3).

[0091] In addition, in the manufacturing method of the electromagnetic coil (not shown) according to the third modification, a new spacer mounting step is required. That is, as shown in Figures 15(a) and 15(b), after the braided wire forming process is performed, spacers 150 are attached to one end side 60a and the other end side 60b of the coil conductor 60. Specifically, the spacers 150 are inserted into one end side 60a and the other end side 60b of the coil conductor 60, respectively, and fixed by applying pressure from the outside of each spacer 150 using a crimping tool or the like to "crimp" them. Also, instead of or in addition to "crimping," fixing by welding or fixing with a conductive adhesive may be performed. In either case, after fixing, the state shown in Figure 15(c) is achieved.

[0092] Thereafter, in the same manner as the end member and coil conductor connection process shown in Figures 13(b) and 14(a) described above, the ends of the coil conductor 60 to which the spacer 150 is attached are inserted into the openings of the first end member and the second end member, respectively, to obtain the electromagnetic coil (not shown) relating to variant example 3.

[0093] When a braided wire 64 is used as the coil conductor 60, for example, it is possible to directly insert and fit the end of the braided wire 64 into the opening of the first end member, but this may cause fraying, fluffing, etc. of the conductive substrate 62 (wire material) at the end of the braided wire 64. On the other hand, by introducing the spacer 150 of Modification 3, it is possible to couple and connect to the first end member and the second end member without the above-mentioned fraying, fluffing, etc., resulting in an electromagnetic coil with even higher connection reliability.

[0094] 4. Pad 52 for reducing the step 50 (Variation 4) Fig. 16 is a diagram illustrating the build-up 52 of Modified Example 4. Fig. 16(a) is a diagram of a coil assembly (part) using the electromagnetic coil 3 of Embodiment 3, and Fig. 16(b) is a diagram of an electromagnetic coil 3b (part) when viewed along arrow J in Fig. 16(a). Fig. 16(c) is a diagram of a coil assembly (part) using an electromagnetic coil 3' as a modified example, and Fig. 16(d) is a diagram of an electromagnetic coil 3b' (part) when viewed along arrow K in Fig. 16(c).

[0095] When the electromagnetic coils in each of the above-described embodiments and modified examples are viewed in a plane, as shown in Figure 16(a), in the region RG1 on the same surface as the second effective coil portion of the electromagnetic coil (the inner row or the lower row) where the same surface as the first effective coil portion of the adjacent electromagnetic coil (the outer row or the upper row) does not overlap, a partial hole (depression) is formed in the first side surface on which the magnet of the electromechanical device is arranged.

[0096] Therefore, as shown in FIG. 16(c) and FIG. 16(d), a build-up 52 may be provided in the region RG1 to reduce the inclination of the step 50 (Modification 4). By providing padding 52 in this region RG1, the partial depression is alleviated, and the first-side surface on which the magnet of the electromechanical device is disposed can be made an entirely smooth surface. Note that, although an example of the third embodiment is illustrated and described here, padding can be similarly applied to the depression in the other embodiments.

[0097] 5. Other Variations (1) In the above-described embodiments and modifications, a braided wire 64 formed by braiding a plurality of bare conductor wires 61 has been described as an example of the coil conductor wire 60. However, the present invention is not limited to this. For example, the conductive substrate 62 may be an enameled wire, and the coil conductor wire 60 may be a "litz wire" formed by twisting a plurality of enameled wires.

[0098] (2) In the above-described embodiments and modifications, the insulating layer 106 is described as being composed of the insulating layer 107 formed by solidifying a water-soluble material that has permeated the periphery of the conductive substrate 62. However, the present invention is not limited to this. For example, the insulating layer 106 may be an insulating coating film formed around the periphery of the conductive substrate.

[0099] (3) The drawings used in the explanations of the above-mentioned first and second embodiments and each of the modified examples show a so-called outer rotor type in which the magnet of the electromechanical device moves outside the cylindrical coil assemblies 100 and 200. However, the present invention is not limited to this. The present invention can also be applied to a so-called interrotor type electromechanical device in which the magnet moves inside the cylindrical coil assemblies 100 and 200. Similarly, with regard to the linear electromechanical device described in the third embodiment, the present invention is not limited to a type in which the magnet (mover) moves on the upper side of the coil assembly 300 in the drawing, but can also be applied to an electromechanical device in which the magnet (mover) moves on the lower side. [Explanation of symbols]

[0100] 1, 1a, 1b, 1c, 2, 2a, 2b, 2c, 3, 3a, 3b, 3c, 4, 5, 9... electromagnetic coil, 10... air-core region, 11... first straight section, 12... second straight section, 13... third straight section, 14... fourth straight section, 15... fifth straight section, 16... sixth straight section, 20... effective coil section, 21, 21a, 21b, 21c... first effective coil section, 22, 22a, 22y, 22z... second effective coil section, 30... first coil end section, 40... second coil end section, 50... step, 52... padding, 60... coil conductor, 60a... one end side (of the coil conductor), 60b... (coil) other end side of the coil conductor, 61...bare conductor wire, 62...conductive substrate, 63...stranded wire, 64...braided wire, 100, 200, 300, 400...coil assembly, 105...circuit connection terminal, 106...insulating layer, 107...insulating layer formed by solidifying a water-soluble material, 130, 230...first end member, 131...opening (of the first end member), 140, 240...second end member, 141...opening (of the second end member), 150...spacer, 710...rod, 710a...other end side, 710b...one end side, 720...fixing member, 730...permanent magnet pair, 740...sample fixing stage

Claims

1. An electromagnetic coil arranged along a moving direction of a magnet of an electromechanical device, the electromagnetic coil being formed by winding a conductive member around an air-core region, The electromagnetic coil constitutes a cylindrical coil assembly, When viewed in plan, the magnet has two effective coil sections that are spaced apart and perpendicular to the direction of movement of the magnet, a first coil end section that is located on one side of the effective coil sections in the longitudinal direction and connects the effective coil sections, and a second coil end section that is located on the other side of the effective coil sections in the longitudinal direction, The magnet has a generally honeycomb structure that is symmetrical about a "center line" that includes the midpoint between the two effective coil portions and is perpendicular to the direction of movement of the magnet, a step is provided near the center line when viewed in a direction perpendicular to the moving direction of the magnet and along the extending direction of the effective coil portion, one of the two effective coil sections is an effective coil section that is arranged on the inner periphery side around a rotation axis AX1 of the electromechanical device, and the other is an effective coil section that is arranged on the outer periphery side around the rotation axis AX1, the first coil end portion has an outer peripheral surface connecting the step between an outer peripheral surface of the effective coil portion arranged on the inner peripheral side and an outer peripheral surface of the effective coil portion arranged on the outer peripheral side, and an inner peripheral surface connecting the step between an inner peripheral surface of the effective coil portion arranged on the inner peripheral side and an inner peripheral surface of the effective coil portion arranged on the outer peripheral side, When viewed in a direction perpendicular to the direction of movement of the magnet and along the direction in which the effective coil section extends, the outer peripheral surface connecting the steps is disposed such that a normal line to the cylindrical shape, the normal line being centered on the rotation axis AX1 and passing through the midpoint, is located on one side of a center of a width of the outer peripheral surface connecting the steps in the circumferential direction of the cylindrical shape, an inner peripheral surface connecting the steps is disposed such that the normal line is located on the other side, opposite to the one side, with respect to the center of the width of the inner peripheral surface connecting the steps in the circumferential direction of the cylindrical shape, At least the effective coil portion is configured by a coil conductor formed by bundling a plurality of conductive substrates, The wire used as the conductive substrate is a conductive wire containing copper, and the average The radius is 120 μm or less. An electromagnetic coil characterized by:

2. 2. The electromagnetic coil according to claim 1, the conductive substrate is a bare conductor wire; the coil conductor wire is a braided wire formed by braiding a plurality of the bare conductor wires, An electromagnetic coil characterized by:

3. 3. The electromagnetic coil according to claim 1, When the effective coil section of the two effective coil sections that is closer to the side where the magnet of the electromechanical device is arranged is defined as a first effective coil section, and the effective coil section that is closer to the side opposite to the side where the magnet is arranged is defined as a second effective coil section, the first effective coil section has a first surface F1 facing the magnet and closer to the magnet, and a second surface F2 opposite the first surface F1, and the second effective coil section has a third surface F3 on the side where the magnet is disposed, and a fourth surface F4 opposite the third surface F3, a step between the two effective coil sections, defined by a step between the first surface F1 and the third surface F3, is equal to or greater than a thickness of the first effective coil section, defined by a dimension between the first surface F1 and the second surface F2; An electromagnetic coil characterized by:

4. The electromagnetic coil according to any one of claims 1 to 3, The cross section of the effective coil portion is substantially fan-shaped, a radial thickness Ti of the effective coil portion arranged on the inner circumferential side is greater than a radial thickness To of the effective coil portion arranged on the outer circumferential side, When viewed along the direction in which the rotation axis AX1 extends, the effective coil portion arranged on the inner circumferential side and the effective coil portion arranged on the outer circumferential side are arranged within an angle obtained by equally dividing a mechanical angle 2π into N, where N is obtained from the equation "Pa·Pm=N". An electromagnetic coil characterized by: Here, Pa is the number of phases when the electromechanical device is driven, Pm is the number of magnetic poles of the electromechanical device, and Pa, Pm, and N are all natural numbers.

5. The electromagnetic coil according to any one of claims 1 to 4, The effective coil portion of the "another electromagnetic coil" to which a second phase current is supplied is configured to be fitted into the air-core region of the "one electromagnetic coil" to which a first phase current is supplied. An electromagnetic coil characterized by:

6. The electromagnetic coil according to any one of claims 1 to 5, the coil conductor constituting the effective coil portion is a braided wire formed by braiding a plurality of bare conductor wires, the first coil end portion is formed by a first end member made of a solid conductive material, the first end member is coupled to one end of each of the first coil conductor wire and the second coil conductor wire that respectively constitute the two effective coil portions, and electrically connects the first coil conductor wire and the second coil conductor wire, the second coil end portion is constituted by a second end member made of a solid conductive material, the second end member is connected to the other end side of each of the first coil conductor and the second coil conductor, which respectively constitute the two effective coil portions; An electromagnetic coil characterized by:

7. 7. The electromagnetic coil according to claim 6, A circuit connection terminal is disposed in the second coil end portion and is coupled or connected to the second end member, The electromagnetic coil is provided with an insulating layer on the entire surface thereof except for the circuit connection terminals. An electromagnetic coil characterized by:

8. 8. The electromagnetic coil according to claim 6 or 7, the solid conductive material is made of a material containing at least copper or carbon, The coil conductor constituting the effective coil portion is made of a material containing at least copper or carbon. An electromagnetic coil characterized by:

9. The electromagnetic coil according to any one of claims 6 to 8, An electromagnetic coil, characterized in that a spacer is attached to an end of the coil conductor, and the end of the coil conductor is connected to the first end member and the second end member.

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