Coil manufacturing method

Abstract

To provide a manufacturing method for a coil having a larger space factor, the coil, and an electric motor.SOLUTION: A manufacturing method for a coil includes: a step of forming a winding portion which extends so as to be twisted around an axis as it goes in a direction of the axis and in which a part in an extending direction is a deformation allowing portion lower in rigidity than the other portion; a step of forming an insulating film over the extending direction of the winding portion; and a step of compressing the winding portion, on which the insulating film is formed, in the direction of the axis.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a coil. to Regarding. [Background technology]

[0002] In recent years, a technology for forming coils using a three-dimensional additive manufacturing (3D AM) device has been proposed. The technology disclosed in Patent Document 1 below is said to be capable of integrally forming the conductor that forms the coil and the insulating layer that covers the outside of the conductor by 3D AM. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-39662 Summary of the Invention [Problem to be solved by the invention]

[0004] However, when simultaneously manufacturing a conductor such as copper and an insulating layer such as ceramic, the physical properties of the materials are significantly different, making it difficult to achieve stable manufacturing. To achieve stable manufacturing, the insulating layer must be thick. As a result, there is a problem of a decrease in the space factor of the coil.

[0005] The present disclosure has been made to solve the above-mentioned problems, and provides a method for manufacturing a coil having a larger space factor. of The purpose is to provide. [Means for solving the problem]

[0006] In order to solve the above problems, a method for manufacturing a coil according to the present disclosure includes the steps of: , the outer dimensions of the spiral shaped portion as viewed from the axial direction gradually decrease,A method for manufacturing a winding portion, the winding portion having a part in an extension direction thereof as a deformable portion having lower rigidity than other parts, a method for forming an insulating film over the extension direction of the winding portion, and a method for compressing the winding portion having the insulating film formed thereon in the axial direction. and plastically deforming it to form a flat coil. and The method for manufacturing a coil according to the present disclosure includes the steps of: forming a winding portion that extends in an axial direction so as to twist around the axis, with a portion of the winding portion in the extending direction being a deformable portion that is less rigid than other portions; forming an insulating film along the extending direction of the winding portion; and compressing the winding portion with the insulating film formed thereon in the axial direction to plastically deform it; the deformable portion being a groove that extends in the axial direction from an end face of the winding portion facing the axial direction; and performing a step of providing a masking that covers the inner surface of the groove before the step of forming the insulating film; and performing a step of removing the masking after the step of forming the insulating film. The method for manufacturing a coil according to the present disclosure includes the steps of forming a winding portion that extends in an axial direction so as to twist around the axis and has a deformation-permissive portion in one portion of its extension that is less rigid than other portions, forming an insulating film along the extension direction of the winding portion, and compressing the winding portion with the insulating film formed thereon in the axial direction to plastically deform it, and after the step of forming the winding portion, a step of forming a gripping portion that protrudes from the winding portion in the axial direction is carried out. [Effects of the Invention]

[0009] According to the present disclosure, a method for manufacturing a coil having a larger space factor is of can be provided. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a cross-sectional view showing a configuration of an electric motor according to an embodiment of the present disclosure. [Figure 2] FIG. 2 is a view of a stator according to an embodiment of the present disclosure as viewed from a radial direction. [Figure 3] FIG. 1 is a perspective view illustrating a configuration of a coil intermediate according to an embodiment of the present disclosure. [Figure 4] FIG. 2 is a side view of a coil intermediate body according to an embodiment of the present disclosure. [Figure 5] FIG. 2 is an enlarged view of a main portion of a coil intermediate according to an embodiment of the present disclosure. [Figure 6] FIG. 2 is an enlarged view of a main portion of a coil according to an embodiment of the present disclosure. [Figure 7] 1 is a flowchart illustrating steps of a method for manufacturing a coil according to an embodiment of the present disclosure. [Figure 8] FIG. 10 is a side view illustrating a first modified example of a coil according to an embodiment of the present disclosure. [Figure 9] FIG. 10 is a side view illustrating a second modified example of a coil according to an embodiment of the present disclosure. [Figure 10] FIG. 10 is a side view illustrating a third modified example of a coil according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, an electric motor 1, a coil 22, and a method for manufacturing the coil 22 according to an embodiment of the present disclosure will be described with reference to FIGS.

[0012] (Motor configuration) As shown in Fig. 1, the electric motor 1 includes a rotor 10, a stator 20, and a housing 30. The rotor 10 is cylindrical and has a central axis A as its center. The rotor 10 has a permanent magnet (not shown). The rotor 10 is rotatable around the central axis A, and its shaft ends are supported by bearings or the like.

[0013] The stator 20 covers the rotor 10 from the outer periphery. The stator 20 has a stator core 21 and coils 22. The stator core 21 has a yoke 23 and teeth 24. The yoke 23 has an annular shape centered on a central axis A. The teeth 24 protrude radially inward from the inner circumferential surface of the yoke 23 and are arranged at equal intervals in the circumferential direction. In this embodiment, nine teeth 24 are provided as an example, but the number of teeth 24 may be eight or less or ten or more.

[0014] The teeth 24 have tooth bodies 25 and flanges 26. The tooth bodies 25 extend radially from the inner circumferential surface of the yoke 23. The circumferential dimension (i.e., width dimension) of the tooth bodies 25 is constant over the entire radial area. The radially inner end (tip) of the tooth bodies 25 is provided with flanges 26. The flanges 26 protrude from the tip of the tooth body 25 on both sides in the circumferential direction. The flanges 26 are provided to prevent the coils 22 attached to the tooth bodies 25 from falling off.

[0015] The space between a pair of teeth 24 adjacent to each other in the circumferential direction is called a slot 27. The coil 22 is disposed in this slot 27. The volume occupied by the coil 22 in the slot 27 may be called the space factor.

[0016] The coils 22 are formed by winding a wire for the coils 22, made of a conductive material such as copper, multiple times around each of the tooth bodies 25. When a current is supplied to the coils 22, an electromagnetic force is generated by the magnetic field generated between the permanent magnets of the rotor 10 and the coils 22 of the stator 20, and the rotor 10 is driven to rotate around the central axis A. The rotation of the rotor 10 is extracted from the shaft end and used for various purposes.

[0017] The housing 30 has a cylindrical shape centered on a central axis A, and covers the outer periphery of the stator 20. As an example, the stator 20 is fixed to the inner periphery of the housing 30 by interference fit.

[0018] (Coil configuration) As shown in Fig. 2 or 6, the coil 22 has a winding portion 41 and an insulating film 42 covering the surface of the winding portion 41. The winding portion 41 has a rectangular ring shape centered on an axis X that extends radially relative to the central axis A. The winding portion 41 has a spiral shape such that the outer dimensions, as viewed from the axis X, gradually decrease in the circumferential direction relative to the axis X. The winding portion 41 is attached to the periphery of the tooth body 25. The winding portion 41 is made of a conductive material such as copper.

[0019] Furthermore, as shown in Fig. 6, the winding portion 41 is formed with a deformable portion 43. The deformable portion 43 has lower rigidity than other portions. In this embodiment, the deformable portion 43 is formed as a slit 44 extending in the direction of the axis X from a surface of the winding portion 41 facing the direction of the axis X. A conductive material 45 (paste, etc.) is applied between the inner surfaces of the slits 44. Furthermore, a circular opening 62 is formed at the inner end of the slit 44. The opening 62 will be described later.

[0020] 2, such deformable portions 43 are formed in coil end portions 51, which are portions of coil 22 that do not overlap with tooth main body 25 when viewed from the direction of axis X (i.e., viewed from the radial direction relative to center axis A). In other words, no deformable portions 43 are formed in the portions of coil 22 that overlap with tooth main body 25.

[0021] (Coil manufacturing method) Next, a method for manufacturing coil 22 will be described with reference to Fig. 3 to Fig. 7. As shown in Fig. 7, this manufacturing method includes step S1 of forming winding portion 41, step S2 of forming gripping portion 91, step S3 of providing a mask, step S4 of forming insulating film 42, step S5 of removing the mask, step S6 of applying conductive material 45, and step S7 of compressing winding portion 41.

[0022] In step S1 of forming the winding portion 41 and step S2 of forming the gripping portion 91, a coil intermediate body 90 as shown in FIG. 3 is formed. The coil intermediate body 90 has the winding portion 41, the gripping portion 91, and a deformable portion 43. The winding portion 41 has a shape such that the winding portion 41 of the coil 22 described above is elongated in the direction of the axis X. In other words, the winding portion 41 in the coil intermediate body 90 has a helical shape that extends in a twisted manner around the axis X as it moves in the direction of the axis X. Furthermore, the opening area of ​​the annular portion formed by the winding portion 41 gradually decreases from one side to the other in the direction of the axis X.

[0023] Grip portions 91 are provided at each of the four corners of rectangular winding portion 41. Grip portions 91 are rod-shaped and protrude in the direction of axis X from winding portion 41. Grip portions 91 are provided so that an operator can grip them with a tool or with their own hand during the process of compressing winding portion 41, which will be described later.

[0024] In a region (coil end portion 51) of winding portion 41 corresponding to the end of coil 22 described above, winding portion 41 extends at an angle with respect to axis X, moving from one side along axis X to the other side along axis X as it extends. Winding portion bodies 52 are connected to both ends of coil end portion 51. Winding portion bodies 52 extend in a plane perpendicular to axis X.

[0025] 4, the winding portion 41 has grooves 60 formed as deformation-permitting portions 43 on each end surface facing the axis X. More specifically, one groove 60 is formed at the boundary between the coil end portion 51 and the winding portion main body 52. ​​The grooves 60 are formed on the end surface on the side where the angle between the inclined coil end portion 51 and the winding portion main body 52 is greater than 180° on the boundary between the inclined coil end portion 51 and the winding portion main body 52. ​​In other words, of the two angles formed by the coil end portion 51 and the winding portion main body 52, the groove 60 is formed on the side that forms the reflex angle.

[0026] 5, the groove 60 has a groove body 61 that is generally V-shaped with the distance between its inner surfaces gradually decreasing in the direction of the axis X, and a circular opening 62 provided at the bottom of the groove body 61. The opening 62 is provided to avoid stress concentration at the bottom of the groove body 61. Note that it is possible not to form the opening 62 depending on the type of material of the coil 22 and the dimensions and size of the coil 22. The formation of the deformable portion 43 makes the deformable portion 43 less rigid than other portions and therefore more likely to deform preferentially.

[0027] It is desirable to form the winding portion 41 and the gripping portion 91 integrally by, for example, three-dimensional additive manufacturing. Three-dimensional additive manufacturing is a manufacturing method in which a powdered metal material is irradiated with a high-power laser to melt and harden it, thereby obtaining layers of a predetermined shape, and this process is carried out over multiple consecutive layers. Note that it is also possible to form the winding portion 41 and the gripping portion 91 by other methods than three-dimensional additive manufacturing.

[0028] Subsequently, a masking step S3 is carried out. In this step S3, a mask made of silicon or the like is applied to the inner surface of the groove body 61. The opening 62 may or may not be masked.

[0029] Next, insulating film 42 is formed on the outer surface of winding portion 41 (step S4). In step S4, for example, winding portion 41 together with gripping portion 91 is immersed in a container storing an insulating material to form insulating film 42. Alternatively, insulating film 42 may be formed by spraying the insulating material onto winding portion 41 with a spray gun or the like.

[0030] Next, the masking is removed from the winding portion 41 on which the insulating film 42 is formed (step S5). In other words, the masking is removed from the groove 60. As a result, the metal surface of the copper or the like that constitutes the winding portion 41 is exposed on the inner surface of the groove main body 61. Next, a paste or the like made of a conductive material 45 is applied to the inner surface of the groove main body 61 (step S6).

[0031] Thereafter, the winding portion 41 is compressed from both sides in the direction of the axis X (step S7). In this step S7, it is desirable to place the coil intermediate body 90 on a workbench and apply a compressive force in the direction of the axis X to the coil intermediate body 90 by holding the gripping portion 91. This causes plastic deformation of the winding portion 41, resulting in the formation of a spiral coil 22 that spreads in a plane perpendicular to the axis X. In other words, the coil intermediate body 90, which was originally spiral, is compressed to form a flattened coil 22.

[0032] At this time, the inner surfaces of the groove bodies 61 come into contact with each other due to plastic deformation. As a result, as described above with reference to Fig. 6, the inner surfaces of the groove bodies 61 are electrically connected to each other with the conductive material 45 sandwiched therebetween. Thereafter, the gripping portion 91 is removed, completing all steps in the manufacturing method of the coil 22.

[0033] (Action and effect) When forming the coil 22 by the above-described three-dimensional additive manufacturing, it is possible to simultaneously manufacture a conductor such as copper and an insulating film 42 such as ceramic. However, since the physical properties of the conductor and the insulating film 42 differ significantly, it is difficult to achieve stable manufacturing. To achieve stable manufacturing, the thickness of the insulating layer must be increased. As a result, there is a problem that the space factor of the coil 22 decreases. Therefore, the present embodiment employs the above-described configuration and method.

[0034] According to the above method, insulating film 42 is formed on winding portion 41 that is extended and twisted around axis X. In other words, the material for forming insulating film 42 is applied to the outer surfaces of winding portion 41 while the outer surfaces are fully exposed to the outside without overlapping each other. This prevents excessive or insufficient formation of insulating film 42. This allows insulating film 42 to be finished with a thin and uniform thickness. As a result, the volume ratio of insulating film 42 to winding portion 41 decreases, and the space factor of coil 22 can be increased. In other words, the efficiency of electric motor 1 can be further improved.

[0035] Furthermore, according to the above method and configuration, because the grooves 60 are formed in the winding portion 41 as the deformable portions 43, the deformable portions 43 deform preferentially when the winding portion 41 is compressed. This allows the winding portion 41 to easily undergo plastic deformation. Conversely, if the deformable portions 43 were not formed, it would be impossible to control which parts of the winding portion 41 would undergo plastic deformation, which could result in the final coil 22 having an uneven shape. The above method reduces this possibility, making it possible to stably manufacture coils 22 with consistent shapes and quality.

[0036] Furthermore, according to the above method and configuration, a mask is applied to the inner surface of the groove 60 prior to forming the insulating film 42. Therefore, no insulating material adheres to the inner surface of the groove 60 when the insulating film 42 is formed. The mask is then removed, exposing the metal surface on the inner surface. When the winding portion 41 is compressed in this state, the inner surfaces of the grooves 60 abut against each other due to deformation. This ensures conductivity in the areas where the grooves 60 were present. In other words, it is possible to avoid a decrease in performance of the coil 22 that would be caused by forming the grooves 60.

[0037] Additionally, according to the above method and configuration, after removing the masking, conductive material 45 is applied to the inner surfaces of grooves 60. This allows conductive material 45 to be interposed between the inner surfaces when winding portion 41 is compressed and deformed. As a result, the conductivity between these inner surfaces can be further improved.

[0038] Furthermore, according to the above method and configuration, since the coil intermediate body 90 has the gripping portion 91 formed thereon, the winding portion 41 can be easily compressed in the direction of the axis X while gripping the gripping portion 91 with a tool or the like. This improves the workability and efficiency during manufacturing.

[0039] Furthermore, according to the above method, the winding portion 41 and the grip portion 91 can be manufactured more easily and in a shorter time by using three-dimensional additive manufacturing, which reduces manufacturing costs compared to when conventional manufacturing methods are used.

[0040] (Other embodiments) The embodiments of the present disclosure have been described above. However, various changes and modifications can be made to the above methods and configurations without departing from the spirit and scope of the present disclosure.

[0041] For example, in the above embodiment, an example has been described in which a groove 60 is formed as the deformable portion 43. However, the form of the deformable portion 43 is not limited to the groove 60. As a first modified example, as shown in FIG. 8 , a plurality of slits 160 may be formed as the deformable portion 43. These slits 160 penetrate the coil end portion 51 of the winding portion 41 in a direction perpendicular to the axis X and extend along the extension direction of the coil end portion 51. Furthermore, in the example of FIG. 8 , a pair of slits 160 are formed spaced apart in the direction of the axis X. With this configuration, the deformable portion 43 can be easily formed simply by forming the slits 160. Furthermore, since the above-mentioned masking step and the like are not required, the manufacturing process can be simplified.

[0042] 9, as a second modified example, deformable portion 43 may be a V-shaped through hole 260. More specifically, this through hole 260 extends in two directions that are spaced apart from each other as it moves from an apex on one side in the direction of axis X to the other side. A plurality of such through holes 260 are provided at intervals in the direction of axis X. This configuration also makes it possible to easily plastically deform winding portion 41.

[0043] 10, the deformable portion 43 may be a plurality of triangular holes 360. These holes 360 are arranged in a triangular shape overall, with the number of holes 360 gradually decreasing from one side to the other in the direction of the axis X. In other words, the side with more holes 360 is more likely to deform. This configuration also makes it possible to easily plastically deform the winding portion 41.

[0044] <Additional Notes> The manufacturing method of the coil 22, the coil 22, and the electric motor 1 described in each embodiment can be understood, for example, as follows.

[0045] (1) A method for manufacturing a coil 22 according to the first aspect includes the steps of forming a winding portion 41 that extends in a twisted manner around the axis X as it moves in the direction of the axis X and has a deformable portion 43 in a part of the extending direction that is less rigid than other parts; forming an insulating film 42 along the extending direction of the winding portion 41; and compressing the winding portion 41 with the insulating film 42 formed thereon in the direction of the axis X.

[0046] According to the above method, insulating film 42 is formed on winding portion 41 that is extended and twisted around axis X, and therefore insulating film 42 can be finished to have a thin and uniform thickness, thereby increasing the space factor of coil 22.

[0047] (2) A second aspect of the manufacturing method of the coil 22 is the manufacturing method of the coil 22 of (1), in which the deformation-permitting portion 43 is a groove 60 extending in the direction of the axis X from an end face of the winding portion 41 facing in the direction of the axis X.

[0048] According to the above method, since grooves 60 are formed as deformation-permitting portions 43, winding portion 41 can be easily plastically deformed when winding portion 41 is compressed.

[0049] (3) The manufacturing method of the coil 22 according to the third aspect is the manufacturing method of the coil 22 of (2), in which, before the step of forming the insulating film 42, a step of providing a masking to cover the inner surface of the groove 60 is carried out, and after the step of forming the insulating film 42, a step of removing the masking is carried out.

[0050] According to the above method, the inner surfaces of the grooves 60 are masked, so that no insulating material adheres to these inner surfaces when the insulating film 42 is formed. When the masking is then removed and the winding portion 41 is compressed, the inner surfaces of the grooves 60 come into contact with each other due to deformation. This ensures electrical conductivity in the areas where the grooves 60 were located.

[0051] (4) The fourth aspect of the method for manufacturing a coil 22 is the method for manufacturing a coil 22 of (3), in which after the step of removing the masking, a step of applying a conductive material 45 to the inner surface of the groove 60 is carried out.

[0052] According to the above method, after removing the masking, conductive material 45 is applied to the inner surface of groove 60, so that when winding portion 41 is compressed and deformed, the conductivity between the inner surfaces can be further increased.

[0053] (5) A fifth aspect of the manufacturing method of the coil 22 is a manufacturing method of the coil 22 of (1) or (2), wherein the deformation-permitting portion 43 is a slit 160 that extends in the extension direction of the winding portion 41 and penetrates the winding portion 41 in a direction intersecting the axis X.

[0054] According to the above method, winding portion 41 can be easily plastically deformed when compressed simply by forming slits 160 in winding portion 41. This reduces processing costs.

[0055] (6) A sixth aspect of the manufacturing method of the coil 22 is a manufacturing method of the coil 22 of (1) or (2), in which the deformable portion 43 is a plurality of holes 360 that penetrate the winding portion 41 in a direction intersecting the axis X.

[0056] According to the above method, simply by forming multiple holes 360 in winding portion 41, winding portion 41 can be easily plastically deformed when compressed. This reduces processing costs. Furthermore, since the gaps formed in winding portion 41 are smaller than when slits 160 are formed, a decrease in the space factor of coil 22 can be avoided.

[0057] (7) A method for manufacturing a coil 22 according to a seventh aspect is a method for manufacturing a coil 22 according to any one of the aspects (1) to (6), in which, after the step of forming the winding portion 41, a step of forming a gripping portion 91 protruding from the winding portion 41 in the direction of the axis X is carried out.

[0058] According to the above method, since gripping portion 91 is formed, winding portion 41 can be compressed in the direction of axis X while gripping gripping portion 91 with a tool or the like, thereby improving workability during manufacturing.

[0059] (8) The manufacturing method of the coil 22 according to the eighth aspect is a manufacturing method of the coil 22 according to any one of the aspects (1) to (7), in which in the step of forming the winding portion 41, the winding portion 41 is formed using a three-dimensional additive manufacturing method.

[0060] According to the above method, the winding portion 41 can be manufactured more easily and in a shorter time by three-dimensional additive manufacturing, thereby reducing manufacturing costs.

[0061] (9) The manufacturing method of the coil 22 according to the ninth aspect is the manufacturing method of the coil 22 of (7), in which in the step of forming the gripping portion 91, the gripping portion 91 is formed integrally with the winding portion 41 using a three-dimensional additive manufacturing method.

[0062] According to the above method, the gripping portion 91 is integrally formed in addition to the winding portion 41 by three-dimensional additive manufacturing, which further reduces the time and cost required for manufacturing.

[0063] (10) The coil 22 according to the tenth aspect has a ring shape centered on the axis X and includes a winding portion 41 that extends inwardly in the circumferential direction of the axis X, an insulating film 42 that covers the winding portion 41 from the outside, and a deformable portion 43 that is formed in a portion of the winding portion 41 in the extending direction and has lower rigidity than other portions.

[0064] According to the above configuration, since winding portion 41 is formed with deformable portion 43, insulating film 42 can be formed in a state in which winding portion 41 is stretched into a spiral shape during manufacturing of winding portion 41. This allows for the formation of a thin and uniform insulating film 42. As a result, the space factor of coil 22 can be improved.

[0065] (11) The coil 22 according to the eleventh aspect is the coil 22 of (10), wherein the deformable portion 43 is a slit 44 extending in the direction of the axis X from an end face of the winding portion 41 facing the direction of the axis X, and a conductive material 45 filled in the slit 44.

[0066] According to the above configuration, since the slits 44 are filled with the conductive material 45, the inner surfaces of the grooves 60 that were necessary during manufacturing come into contact with each other, sandwiching the conductive material 45. This ensures the conductivity of the winding portion 41.

[0067] (12) The coil 22 according to the twelfth aspect is the coil 22 of (10), wherein the deformation-permitting portion 43 is a slit 160 that extends in the extension direction of the winding portion 41 and penetrates the winding portion 41 in a direction intersecting the axis X.

[0068] According to the above configuration, winding portion 41 can be easily plastically deformed when compressed simply by forming slits 160 in winding portion 41. This reduces processing costs.

[0069] (13) The coil 22 according to a thirteenth aspect is the coil 22 of (10), wherein the deformable portion 43 is a plurality of holes 360 that penetrate the winding portion 41 in a direction intersecting the axis X.

[0070] According to the above configuration, simply by forming multiple holes 360 in winding portion 41, winding portion 41 can be easily plastically deformed when compressed. This reduces processing costs. Furthermore, since the gaps formed in winding portion 41 are smaller than when slits 160 are formed, a decrease in the space factor of coil 22 can be avoided.

[0071] (14) The electric motor 1 according to the fourteenth aspect comprises a rotor 10 rotatable around a central axis A and a stator 20 covering the rotor 10 from the outer periphery, and the stator 20 comprises a stator core 21 having an annular yoke 23 centered on the central axis A and a plurality of teeth 24 protruding from the inner periphery of the yoke 23 and arranged at intervals in the circumferential direction, and a coil 22 according to any one of the aspects (10) to (13) attached so as to cover the outer periphery of the teeth 24.

[0072] According to the above configuration, the coil 22 has a high space factor, and thus the electric motor 1 can be obtained with further improved efficiency.

[0073] (15) The coil 22 according to the fifteenth aspect is the electric motor 1 of (14), and the deformation-permitting portion 43 is provided at the end of the coil 22, which is a portion that does not overlap with the stator core 21 when viewed radially from the central axis A.

[0074] According to the above configuration, since the deformable portion 43 is provided at the end of the coil 22, it is possible to minimize the impact on the magnetic field caused by forming the deformable portion 43 in areas other than the end of the coil 22 where the magnetic flux density is high. [Explanation of symbols]

[0075] 1...Electric motor 10...Rotor 20...Stator 21... Stator core 22...Coil 23…York 24...Teeth 25...Teeth body 26...Brim 27...Slot 30…Housing 41...Winding section 42...insulating film 43...Deformation allowance section 44...Notch 45...Conductive materials 51...Coil end 52...Winding body 60...Groove 61... Groove body 62...Opening 90...Coil intermediate 91...Gripping part 160...Slit 260...Through hole 360…hole A…Central axis X…Axis line

Claims

1. forming a winding portion that extends in a twisted manner around the axis as it extends in the axial direction, has a spiral shape such that the outer dimensions as viewed from the axial direction gradually decrease, and has a deformation-permitting portion in a part of the extending direction that is lower in rigidity than other portions; forming an insulating film in the direction in which the winding portion extends; a step of compressing the winding portion on which the insulating film is formed in the axial direction to plastically deform it, thereby forming a flat coil; A method for manufacturing a coil comprising:

2. The method for manufacturing a coil according to claim 1 , wherein the deformable portion is a groove extending in the axial direction from an end face of the winding portion facing the axial direction.

3. 3. The method for manufacturing a coil according to claim 2, further comprising the steps of: providing a masking layer to cover the inner surface of the groove before the step of forming the insulating film; and removing the masking layer after the step of forming the insulating film.

4. forming a winding portion that extends in an axial direction so as to twist around the axis, and has a deformation-permitting portion in a portion of the extending direction that is lower in rigidity than other portions; forming an insulating film in the direction in which the winding portion extends; compressing the winding portion on which the insulating film is formed in the axial direction to plastically deform it; Including, the deformation-permitting portion is a groove extending in the axial direction from an end surface of the winding portion facing the axial direction, Before the step of forming the insulating film, a step of providing a mask to cover the inner surface of the groove is carried out, and after the step of forming the insulating film, a step of removing the mask is carried out. Coil manufacturing method.

5. 5. The method for manufacturing a coil according to claim 3, further comprising the step of applying a conductive material to the inner surface of the groove after the step of removing the masking.

6. The method for manufacturing a coil according to claim 1 , wherein the deformable portion is a slit that extends in the extension direction of the winding portion and penetrates the winding portion in a direction intersecting the axis.

7. The method for manufacturing a coil according to claim 1 , wherein the deformable portion is a plurality of holes that penetrate the winding portion in a direction intersecting the axis.

8. The method for manufacturing a coil according to claim 1 , further comprising the step of forming a gripping portion that protrudes from the winding portion in the axial direction after the step of forming the winding portion.

9. forming a winding portion that extends in an axial direction so as to twist around the axis, and has a deformation-permitting portion in a portion of the extending direction that is lower in rigidity than other portions; forming an insulating film in the direction in which the winding portion extends; compressing the winding portion on which the insulating film is formed in the axial direction to plastically deform it; Including, A method of manufacturing a coil, comprising the step of forming a gripping portion protruding in the axial direction from the winding portion after the step of forming the winding portion.

10. The method for manufacturing a coil according to claim 1 , wherein the step of forming the winding portion uses a three-dimensional additive manufacturing method to form the winding portion.

11. The method for manufacturing a coil according to claim 8 or 9, wherein in the step of forming the gripping portion, the gripping portion is formed integrally with the winding portion by a three-dimensional additive manufacturing method.

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