Coil structure, linear motor, and method for manufacturing a coil structure

Abstract

To provide a coil structure which generates high thrust per volume in a compact and simple design, a linear motor and a manufacturing method for the coil structure.SOLUTION: A coil structure 30 comprising a rectangular air-core coil which is a single layer in an axial direction comprises a first coil set 31 including two first coil pairs 31A in which two air-core coils of which the winding directions are opposite to each other are laminated in the axial direction. Both ends of each first coil pair 31A in a length direction are bent in the same direction in the axial direction. The two first coil pairs 31A are laminated in the axial direction in such a manner that the bending directions of both ends are mutually opposed. A second coil set 32 is provided in which two second coil pairs 32B are laminated in the axial direction, each having two air-core coils with opposite winding directions laminated in the axial direction, as well as long side parts 321 and 322 and short side parts 323 and 324 provided on the same plane. The two second coil sets 32 are juxtaposed in parallel in the axial direction.SELECTED DRAWING: Figure 4

Description

Technical Field

[0003]

[0001] The present invention relates to a coil structure, a linear motor, and a method for manufacturing a coil structure.

Background Art

[0002] In recent years, linear motors using flat air-core coils have become widespread. For example, Patent Document 1 discloses a linear motor in which a plurality of air-core coils that are single-layer in the axial direction are arranged while being partially overlapped.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Patent Document 1 describes a linear motor in which a plurality of air-core coils are partially overlapped. However, since such air-core coils are single-layer, high thrust cannot be expected. Further, Patent Document 1 also discloses a linear motor in which air-core coils of different shapes are stacked four-fold for high thrust. However, for stacking four-fold, a plurality of types of air-core coils having different sizes and shapes are required, and the structure is complicated.

[0005] The present invention has been made in view of such circumstances, and an object thereof is to provide a coil structure, a linear motor, and a method for manufacturing a coil structure that can increase the generated thrust per unit volume with a compact and simple structure.

Means for Solving the Problems

[0006] The coil structure according to the present invention is a coil structure having a rectangular air-core coil that is a single layer in the axial direction, comprising a first coil set having two first coil pairs in which two air-core coils with opposite winding directions are stacked in the axial direction, the ends of each first coil pair in the longitudinal direction are bent in the same direction in the axial direction, the two first coil pairs are stacked in the axial direction such that the bending directions of the ends of each are in opposite directions, and comprising a second coil set having two second coil pairs stacked in the axial direction, each having a long side and a short side that are arranged on the same plane, the two second coil sets are arranged side by side with their axial directions parallel, one long side of each of the two second coil sets is positioned inside the first coil set, the end of one long side is interposed between the short sides of the two first coil pairs, and the long sides of the two first coil pairs are shorter than those of the second coil pairs.

[0007] In the present invention, the first coil set has two pairs of first coils, the two pairs of first coils are stacked in the axial direction such that the bending directions of both ends of each are in opposite directions, the adjacent long sides of the two parallel second coil sets are positioned inside the first coil set, the end of one of the long sides is interposed between the short sides of the two pairs of first coils, and the long sides of the two pairs of first coils are shorter than those of the second coil pair, thus the thrust generated per unit volume can be increased while simplifying the structure.

[0008] The coil structure according to the present invention has, in each first coil pair, two long sides and two short sides connecting the ends of the two long sides, and both ends of the two long sides are bent in the axial direction within a range of 15° to 35°.

[0009] In the present invention, both ends of the two long sides of the first coil pair are bent in the axial direction of the first coil pair within a range of 15° to 35°. This prevents defects such as scratches from occurring in the first coil pair during press working due to an excessively large bending angle, while preventing a reduction in the area of ​​the laminated portion when the two first coil pairs are laminated due to an excessively small bending angle, thereby preventing a reduction in the strength of the first coil set.

[0010] In the coil structure according to the present invention, each air-core coil of the first and second coil pairs has an inner lead wire and an outer lead wire, and the connection portion between the inner lead wires of the second coil pair is provided between the long side of the first coil set and the other long side of the second coil set.

[0011] In the present invention, the connection portion between the inner lead wires of the second coil pair is provided between the long side of the first coil set and the other long side of the second coil set, thereby improving the insulation of such connection portion.

[0012] In the coil structure according to the present invention, in the first and second coil pairs, the outer lead wire of one of the two air-core coils and the outer lead wire of the other air-core coil are provided on different long sides.

[0013] In the present invention, the two outer lead wires of the first coil pair are provided on different long sides of the first coil pair, and the two outer lead wires of the second coil pair are provided on different long sides of the second coil pair. Therefore, in the case of wiring, the coil structure and the outer lead wires do not overlap in the axial direction, and the thickness of the coil structure can be prevented from increasing.

[0014] The linear motor according to the present invention comprises one of the above-described coil structures and magnets arranged on both sides of the coil structure so as to face each other in the axial direction of the first coil set.

[0015] As described above, the present invention uses a coil structure that is compact and simple in structure, which makes it possible to make the linear motor more compact and improve the thrust generated per unit volume.

[0016] The present invention relates to a method for manufacturing a coil structure having a rectangular air-core coil that is a single layer in the axial direction, wherein two air-core coils with opposite winding directions are stacked in the axial direction, and both ends of the air-core coils in the longitudinal direction are bent in the same direction in the axial direction to generate a first coil pair, two air-core coils with opposite winding directions are stacked in the axial direction to generate a second coil pair in which the long side and short side are provided on the same plane and the long side is longer than that of the first coil pair, two second coil pairs are stacked in the axial direction to generate a second coil set, the two second coil sets are placed side by side with their axial directions parallel, and the two first coil sets are stacked in the axial direction such that the bending directions of both ends of each are opposite to each other and the end of one of the long sides is interposed between the short sides of the two first coil pairs to generate a first coil set.

[0017] In this invention, two air-core coils are stacked so that their winding directions are opposite, and both ends of the air-core coils in the longitudinal direction are bent in the same direction in the axial direction to generate a first coil pair. By stacking the two air-core coils in the axial direction so that their winding directions are opposite, a second coil pair is generated in which the long side and short side are located on the same plane, and the long side is longer than that of the first coil pair. Two of the second coil pairs are stacked in the axial direction to generate a second coil set. The two second coil sets are placed side by side with their axial directions parallel, and the two first coil pairs are stacked in the axial direction such that the bending directions of both ends of each are opposite to each other, and the end of one of the long sides is interposed between the short sides of the two first coil pairs to generate a first coil set. [Effects of the Invention]

[0018] According to the present invention, a coil structure, a linear motor, and a method for manufacturing the coil structure can be provided, which are compact, have a simple structure, and have a high thrust per unit volume.

Brief Description of the Drawings

Embodiments for Carrying Out the Invention

[0020] Hereinafter, a coil structure and a linear motor according to an embodiment of the present invention will be described in detail based on the drawings.

[0021] (Embodiment 1) ​​​​​​​​​​​​​​Figure 1 is a perspective view showing the external appearance of a linear motor 100 according to an embodiment of the present invention. The linear motor 100 is, for example, a coil-movable linear motor and comprises a stator 10 and a movable element 20. The movable element 20 is connected to a power supply (not shown).

[0022] The stator 10 has a pair of rectangular flat plate-shaped yokes 11 and an intervening portion 12 interposed between the pair of yokes 11, connecting both ends of the yokes 11. The intervening portion 12 is located on the short side of the yokes 11. The intervening portion 12 causes the yokes 11 to face each other at a predetermined distance apart, and a movable element 20 is interposed between the pair of yokes 11. The movable element 20 is movable in the opposite direction of the long sides of the yokes 11 (in the direction of the arrows in Figure 1). That is, the arrows in Figure 1 indicate the direction of movement of the movable element 20.

[0023] Each yoke 11 has a rectangular flat plate shape and is made of a magnetic material such as iron. The intervening part 12 is made of a non-magnetic material such as resin or a magnetic material such as iron. The intervening part 12 is, for example, screwed to the yoke 11.

[0024] Figure 2 is a schematic cross-sectional view taken along the line II-II in Figure 1. For convenience, the movable element 20 is omitted from the diagram in Figure 2. Each yoke 11 has a magnet unit 13 attached to its inner surface. The magnet unit 13 is positioned between the yoke 11 and the movable element 20. In other words, the movable element 20 is interposed between a pair of magnet units 13.

[0025] The magnet unit 13 has a plurality of permanent magnets 131. Each permanent magnet 131 has a rectangular bar shape extending in the longitudinal direction of the yoke 11, and the plurality of permanent magnets 131 are arranged in parallel at equal intervals in the direction of movement of the movable element 20.

[0026] The pair of magnet units 13 form an alternating magnetic field. More specifically, each permanent magnet 131 has its magnetic poles facing the opposite direction of the pair of magnet units 13, and in the opposite direction, the magnetic poles of the permanent magnets 131 are reversed, as are the magnetic poles of adjacent permanent magnets 131.

[0027] Figure 3 is a perspective view showing the movable element 20 of the linear motor 100 in this embodiment. The movable element 20 includes a coil structure 30 consisting of a plurality of stacked air-core coils, and a clamping member 40 that clamps the coil structure 30. The clamping member 40 clamps the coil structure 30 from both sides in the axial direction of the air-core coils of the coil structure 30.

[0028] The clamping member 40 has a rectangular flat plate shape and has a pair of opposing contact portions 41 and a gusset portion 42 connecting the pair of contact portions 41. That is, one adjacent short side of the pair of contact portions 41 is connected by the gusset portion 42. The gusset portion 42 has an elongated rectangular plate shape with a length approximately the same as the width dimension of the contact portions 41. The pair of contact portions 41 and the gusset portion 42 are integrally formed and are made of, for example, carbon fiber reinforced plastic (CFRP).

[0029] Furthermore, a spacing portion 43 is provided between the pair of contact portions 41, extending from approximately the midpoint of the length of the contact portion 41 to the shorter side of the other contact portion 41. The spacing portion 43 is a rectangular plate shape with a thickness approximately the same as the width dimension of the gusset portion 42, and is attached to the contact portions 41 by screws or adhesive to maintain the spacing between the contact portions 41. The spacing portion 43 is made of, for example, glass fiber reinforced plastic (GFRP).

[0030] With the above configuration, a gap is formed in the clamping member 40 between the contact portions 41 and between the gusset portion 42 and the spacing portion 43, and the coil structure 30 is interposed in this gap. The gusset portion 42 prevents the coil structure 30 from coming off, and an insulating sheet (not shown) made of GFRP or the like may be interposed between the contact portion 41 and the coil structure 30.

[0031] Figure 4 is a perspective view showing the coil structure 30 of the linear motor 100 of this embodiment, and Figure 5 is a view taken along the VV line in Figure 4. In Figure 5, for convenience, the inner and outer lead wires of the first coil set 31 and the second coil set 32 ​​are omitted from the illustration.

[0032] The coil structure 30 comprises one first coil set 31 and two second coil sets 32. Both the first coil set 31 and the second coil sets 32 are roughly rectangular in shape, have the same width, and the length of the first coil set 31 is shorter than that of the second coil sets.

[0033] Each second coil set 32 ​​is a hollow rectangle comprising two long sides 321, 322 and two short sides 323, 324. In the second coil set 32, the two long sides 321, 322 have the same width dimension and are formed separated by a distance equivalent to the sum of the width dimensions of the long sides 321, 322.

[0034] The first coil set 31, like the second coil set 32, is a hollow rectangle and comprises two long sides 311 and 312 and two short sides 313 and 314. In the first coil set 31, the two long sides 311 and 312 have the same width dimension and are formed separated by a distance equivalent to the sum of the width dimensions of the long sides 311 and 312.

[0035] The first coil set 31 and the two second coil sets 32 are arranged so that their lengths are parallel, and the first coil set 31 partially overlaps with the two second coil sets 32.

[0036] The second coil set 32 ​​has two stacked second coil pairs 32B. Figure 6 is a perspective view showing the second coil pair 32B of the linear motor 100 of this embodiment, and Figure 7 is an explanatory diagram illustrating the manufacturing method of the second coil pair 32B of the linear motor 100 of this embodiment. In Figure 7, the solid arrows indicate the winding direction.

[0037] The second coil pair 32B is a hollow rectangle comprising two long sides 321B, 322B and two short sides 323B, 324B. The two long sides 321B, 322B and the two short sides 323B, 324B are located on the same plane.

[0038] Furthermore, the second coil pair 32B is formed by stacking two rectangular air-core coils 300B, each a single layer in the axial direction, in the axial direction with their winding directions opposite to each other. That is, as shown in Figure 7, one of the two air-core coils 300B with the same winding direction is reversed and stacked coaxially with the other.

[0039] Each air-core coil 300B is formed by winding, for example, a strip of conductor flat wire measuring 0.835 × 0.6 mm (including a case where conductor flat wire measuring 0.835 × 0.3 mm is doubled) 15 times in a direction perpendicular to the axial direction. The flat wires are wound so that they overlap in the thickness direction. That is, the air-core coil 300B is single-layered in the axial direction and multi-layered in the direction perpendicular to the axial direction, with both end faces in the axial direction being substantially flat. Such flat wires are wound with a thermosetting resin adhesive, such as epoxy resin, applied to their outer surfaces. The adhesive hardens at room temperature or by heating. This maintains the shape of the air-core coil 300B, and in the second coil pair 32B and the second coil set 32, the air-core coils 300B stacked in the axial direction are fixed together. In Figures 4-7, for convenience, the axial end faces (multilayered coils) of the air-core coil 300B are roughly shown.

[0040] The air-core coil 300B has an inner lead wire 325B and an outer lead wire 326B. The inner lead wire 325B is drawn from the inside of the short side of the air-core coil 300B and is positioned offset from the center in the width direction of the air-core coil 300B towards the long side. The outer lead wire 326B is drawn from one of the long sides of the outermost layer of the air-core coil 300B.

[0041] As described above, the second coil pair 32B is formed by stacking two air-core coils 300B on the coaxial axis with one of them inverted. Therefore, in the second coil pair 32B, the outer lead wires 326B of each air-core coil 300B are drawn out from the outer surfaces of different long sides 321B and 322B, respectively. In this case, the inner lead wires 325B are connected to each other by, for example, soldering to form a connection 327B, and are positioned offset from the center in the width direction of the second coil pair 32B, closer to the long side 322B.

[0042] Each second coil set 32 ​​is formed by stacking two pairs of second coils 32B coaxially. In other words, the second coil set 32 ​​has four air-core coils 300B stacked in the axial direction. In this case, the second coil set 32 ​​has two connecting parts 327B, one of which is located closer to the short side 324, and the other connecting part 327B is located closer to the short side 323.

[0043] The first coil set 31 has two stacked first coil pairs 31A. Figure 8 is a perspective view showing the first coil pairs 31A of the linear motor 100 of this embodiment, and Figure 9 is a view taken along the line IX-IX in Figure 8. In Figure 9, the leader lines are omitted for convenience.

[0044] The first coil pair 31A is a hollow rectangle comprising two long sides 311A, 312A and two short sides 313A, 314A. Furthermore, the first coil pair 31A is formed by stacking two rectangular air-core coils 300A, each a single layer in the axial direction, in the same way as the second coil pair 32B, with their winding directions opposite to each other. That is, one of the two air-core coils 300A with the same winding direction is reversed and stacked coaxially with the other. The first coil pair 31A has the same shape as the second coil pair 32B, except for the bent portion 318A described later, which has a shorter long side.

[0045] Each air-core coil 300A has substantially the same shape as the air-core coil 300B, except that its long side is shorter. It has an inner lead wire 315A and an outer lead wire 316A. The inner lead wire 315A is drawn from the inside of the short side of the air-core coil 300A and is positioned offset from the center in the width direction of the air-core coil 300A towards the long side. The outer lead wire 316A is drawn from one of the long sides of the outermost layer of the air-core coil 300A. In Figure 8, for convenience, the axial end face (multilayered coil) of the air-core coil 300A is substantially shown.

[0046] As described above, the first coil pair 31A is constructed by inverting one of the two air-core coils 300A and stacking it coaxially with the other. Therefore, in the first coil pair 31A, the outer lead wires 316A of each air-core coil 300A are drawn out from the outer surfaces of different long sides 311A ​​and 312A, respectively. In this case, the inner lead wires 315A are connected to each other, for example, by soldering to form a connection portion 317A, and are positioned offset from the center in the width direction of the first coil pair 31A, closer to the long side portion 312A.

[0047] Furthermore, the first coil pair 31A is curved by press working at both ends in the longitudinal direction. After such press working, the length of the first coil pair 31A in the longitudinal direction is shorter than that of the second coil pair 32B. As a result, in the first coil pair 31A, bent portions 318A are formed at both ends of the two long sides 311A ​​and 312A. As described above, except for the bent portions 318A and the shorter long sides, the first coil pair 31A has substantially the same shape as the second coil pair 32B. The bent portion 318A is bent, for example, in the axial direction within a range of 15° to 35°. That is, each bent portion 318A is formed at an angle within a range of 15° to 35° with respect to the direction perpendicular to the axial direction of the first coil pair 31A. If the bending angle of the bent portion 318A exceeds 35°, defects such as scratches may occur on the first coil pair 31A during press working. If the bending angle of the bent portion 318A is less than 15°, the portion formed at an angle (inclined portion) on the long side portions 311A ​​and 312A becomes wider, and when the two first coil pairs 31A are stacked and fixed with adhesive, the contact area between the two first coil pairs 31A becomes smaller, thus reducing the strength of the first coil set 31.

[0048] The first coil set 31 is formed by stacking two first coil pairs 31A coaxially. In other words, the first coil set 31 has four air-core coils 300A stacked in the axial direction. In this case, the bending direction of the bent portion 318A of one of the two first coil pairs 31A is opposite to the bending direction of the bent portion 318A of the other first coil pair 31A. Therefore, in the first coil set 31, gaps are formed between the short sides 313 and between the short sides 314 of the two first coil pairs 31A.

[0049] In the coil structure 30, two second coil sets 32 are arranged side by side with their axial directions parallel and their respective long sides 321 adjacent to each other. The long sides 321 of the two second coil sets 32 are positioned inside the first coil set 31. In this case, the long sides 321 of the two second coil sets 32 and the long side 311 of the first coil set 31 are flush with each other in the portion excluding the bent portion 318A of the first coil pair 31A.

[0050] Furthermore, one end of the long side portion 321 of the two second coil sets 32 is interposed in the gap between the short side portions 313 of the two first coil pairs 31A. Also, the other end of the long side portion 321 of the two second coil sets 32 is interposed in the gap between the short side portions 314 of the two first coil pairs 31A.

[0051] In this configuration, the connecting portion 327B of the two second coil sets 32 is positioned in the space between the long side portion 311 of the first coil set 31 and the long side portion 322 of the second coil set 32, and between the long side portion 312 of the first coil set 31 and the long side portion 322 of the second coil set 32.

[0052] In the linear motor 100 of Embodiment 1 having this configuration, when the coil structure 30 is energized, a thrust is generated in a direction that crosses the alternating magnetic field formed between the pair of magnet units 13 (hereinafter referred to as the direction of movement) based on Fleming's left-hand rule, pushing the coil structure 30 in the direction of movement. As a result, the movable element 20 moves (see arrow in Figure 1).

[0053] In the linear motor 100 of this embodiment, as described above, the first coil set 31 and the two second coil sets 32 of the coil structure 30 are both made up of four-layer air-core coils 300A and 300B. Furthermore, the long sides 321 of the two second coil sets 32 are arranged flush with the inside of the first coil set 31. In addition, the ends of the long sides 321 of the two second coil sets 32 are interposed in the gaps between the short sides 313 and 314 of the two first coil pairs 31A. Thus, the thrust generated per unit volume can be increased with a compact and simple structure.

[0054] Furthermore, in the linear motor 100 of this embodiment, as described above, the connection portion 327B between the inner lead wires 325B of the two air-core coils 300B is located between the long side portion 311 of the first coil set 31 and the long side portion 322 of the second coil set 32, and between the long side portion 312 of the first coil set 31 and the long side portion 322 of the second coil set 32 ​​(see Figure 4). Therefore, the linear motor 100 can be made more compact, and the insulation of the connection portion 327B can be improved.

[0055] Furthermore, in the linear motor 100 of this embodiment, as described above, in the first coil pair 31A, the outer lead wires 316A of each air-core coil 300A are drawn out from the outermost layer, from mutually different long sides 311A ​​and 312A, respectively. Also, in the second coil pair 32B, the outer lead wires 326B of each air-core coil 300B are drawn out from the outermost layer, from mutually different long sides 321B and 322B, respectively. Therefore, when wiring the outer lead wires 316A and 326B, the coil structure 30 and the outer lead wires 316A and 326B do not overlap in the axial direction, thus preventing the thickness of the coil structure 30 from increasing.

[0056] In the above explanation, the linear motor 100 was described using the example where the first coil pair 31A consists of two air-core coils 300A and the second coil pair 32B consists of two air-core coils 300B, but it is not limited to this. The first coil pair 31A may consist of three or more air-core coils 300A, and the second coil pair 32B may consist of three or more air-core coils 300B.

[0057] (Embodiment 2) The coil structure 30 according to Embodiment 1 can also be applied to a linear motor having a U-shaped yoke in cross-section. This will be explained in detail below.

[0058] Figure 10 is a perspective view showing the external appearance of the linear motor 100 according to Embodiment 2. The linear motor 100 is a coil-movable type linear motor, similar to that in Embodiment 1, and comprises a stator 10 and a movable element 20. The movable element 20 is connected to a power supply (not shown).

[0059] The stator 10 has a pair of rectangular flat yoke plates 11 and a connecting portion 12A that connects one end of the yoke plates 11. The connecting portion 12A is provided on one long side of the yoke plate 11. That is, the connecting portion 12A is in the shape of a strip of the same length as the yoke plate 11 and connects one long side of one yoke plate 11 to one long side of the other yoke plate 11. The connecting portion 12A causes the yoke plates 11 to be positioned opposite each other at a predetermined distance apart, and a gap is formed between the yoke plates 11. The pair of yoke plates 11 are open on the three sides other than the aforementioned long side. A movable element 20 is interposed in the gap between the pair of yoke plates 11. The movable element 20 is movable in the opposite directions of the two short sides of the yoke 11 (in the direction of the arrows in Figure 10). That is, the direction of the arrows in Figure 10 indicates the direction of movement of the movable element 20.

[0060] Each yoke plate 11 is made of a magnetic material such as iron, and the connecting portion 12A is also made of a magnetic material such as iron, similar to the yoke plate 11. The pair of yoke plates 11 and the connecting portion 12A are, for example, integrally formed and have a U-shape in cross-section.

[0061] Each yoke plate 11 has a magnet unit 13 (a row of magnets) attached to its inner surface. That is, the magnet unit 13 is positioned between the yoke plate 11 and the movable element 20. In other words, the movable element 20 is interposed between a pair of opposing magnet units 13.

[0062] Each magnet unit 13 has multiple permanent magnets 131. Each permanent magnet 131 has a rectangular bar shape extending in the width direction of the yoke plate 11, and the multiple permanent magnets 131 are arranged in parallel at equal intervals in the direction of movement of the movable element 20. The magnet unit 13 has already been described in Embodiment 1, so a detailed explanation will be omitted.

[0063] The movable element 20 comprises a rectangular thick plate-shaped intervening portion 50 located between a pair of yoke plates 11, and a holding portion 21 that holds one end of the intervening portion 50 in the longitudinal direction. The movable element 20 is movable in the direction in which the multiple permanent magnets 131 are arranged side by side.

[0064] As described above, the intervening portion 50 of the movable element 20 is interposed between a pair of magnet units 13 and includes a coil structure 30. More specifically, the intervening portion 50 is formed by molding the coil structure 30 using a molding material such as epoxy resin or glass fiber reinforced engineering plastic (PPS). The intervening portion 50 has a rectangular plate shape corresponding to the shape of the coil structure 30. That is, the stacking direction of the air-core coils of the coil structure 30 is the thickness direction of the intervening portion 50, the length direction of the coil structure 30 is the length direction of the intervening portion 50, and the width direction of the coil structure 30 is the width direction of the intervening portion 50. The thickness of the intervening portion 50 is thinner than the distance between the magnet units 13.

[0065] In the linear motor 100 of Embodiment 2 having such a configuration, when the coil structure 30 is energized, a thrust is generated in a direction that crosses the alternating magnetic field formed between the pair of magnet units 13 based on Fleming's left-hand rule, similar to Embodiment 1, pushing the coil structure 30 in the direction of movement. As a result, the movable element 20 moves.

[0066] (Embodiment 3) The above explanation has used the case where the movable element 20 has one coil structure 30 as an example, but the present invention is not limited to this. The movable element 20 may be configured to have multiple coil structures 30. The following explanation will be given in detail using the case where the movable element 20 has three coil structures 30 as an example.

[0067] Figure 11 is an illustrative diagram illustrating a case in which the movable element 20 of the linear motor 100 according to Embodiment 3 has a plurality of coil structures 30. In the example in Figure 11, the movable element 20 has three coil structures 30X, 30Y, and 30Z. For convenience, the holding part 21 is not shown in Figure 11. Also, below, the three coil structures 30X, 30Y, and 30Z will be simply referred to as coil structure 30.

[0068] The three coil structures 30X, 30Y, and 30Z are arranged side by side in this order without any gaps. The three coil structures 30X, 30Y, and 30Z are arranged side by side in the width direction of each coil structure. The three coil structures 30X, 30Y, and 30Z are integrated by molding using a molding material, forming an intervening part 50 (movable element 20). The intervening part 50 has a rectangular plate shape with the direction of arrangement of the three coil structures 30X, 30Y, and 30Z as its length direction.

[0069] The coil structure 30X includes a first coil set 31X for one phase and a second coil set 32X for two phases. The coil structure 30Y includes a first coil set 31Y for one phase and a second coil set 32Y for two phases. The coil structure 30Z includes a first coil set 31Z for one phase and a second coil set 32Z for two phases. Since each of the coil structures 30X, 30Y, and 30Z has the same configuration as the coil structure 30 described above, a detailed explanation will be omitted.

[0070] In the linear motor 100 according to Embodiment 3, the first coil set 31X of the coil structure 30X is for the V phase, the first coil set 31Y of the coil structure 30Y is for the W phase, and the first coil set 31Z of the coil structure 30Z is for the U phase. That is, the first coil sets 31X, 31Y, and 31Z for one phase of the coil structures 30X, 30Y, and 30Z correspond to the V phase, W phase, and U phase, respectively.

[0071] However, the invention is not limited to the above description, and the movable element 20 may be configured to have two coil structures 30, or to have four or more coil structures 30.

[0072] Thus, when the movable element 20 has multiple coil structures 30, the first coil set 31 of each coil structure 30 is applied repeatedly in the order of V phase, W phase, and U phase along the parallel arrangement direction. For example, if the movable element 20 has two coil structures 30, the first coil set 31 of each coil structure 30 is applied to the V phase and W phase, respectively, along the direction in which the coil structures 30 are arranged side by side. If the movable element 20 has four or more coil structures 30, the first coil set 31 of each coil structure 30 is applied to the V phase, W phase, U phase, V phase, etc., respectively, along the direction in which the coil structures 30 are arranged side by side.

[0073] The disclosed embodiments 1-3 should be considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the claims rather than by the foregoing description, and all modifications within the meaning and scope equivalent to the claims are intended. [Explanation of symbols]

[0074] 13 Magnet Unit 30, 30X, 30Y, 30Z coil structure 31, 31X, 31Y, 31Z First Coil Set 31A First coil pair 32, 32X, 32Y, 32Z Second Coil Set 32B Second coil pair 100 Linear Motors 300A air-core coil 300B air-core coil 311, 312, 311A, 312A, 321, 322, 321B, 322B Long side 313A, 314A, 323B, 324B Short side 325B 315A Inner lead wire 326B 316A Outer lead wire 327B Connection section

Claims

1. In a coil structure having a rectangular air-core coil that is a single layer in the axial direction, The first coil set comprises two pairs of first coils, each consisting of two air-core coils with opposite winding directions stacked axially. Both ends of each first coil pair in the longitudinal direction are bent in the same direction in the axial direction. The two first coil pairs are stacked in the axial direction such that the bending directions of their respective ends are opposite to each other. A second coil set comprises two pairs of second coils, each having a long side and a short side, stacked axially, with two air-core coils having opposite winding directions. The two aforementioned second coil sets are arranged side by side with their axial directions parallel. The adjacent long sides of the two second coil sets are positioned inside the first coil set. A coil structure in which the end of one of the long sides of the two first coil pairs is interposed between the short sides of the two first coil pairs, and the long sides of the two first coil pairs are shorter than those of the second coil pair.

2. Each first coil pair has two long sides and two short sides that connect the ends of the two long sides. The coil structure according to claim 1, wherein both ends of the two long sides are bent in the axial direction within a range of 15° to 35°.

3. Each air-core coil of the first and second coil pairs has an inner lead wire and an outer lead wire. The coil structure according to claim 2, wherein the connection portion between the inner lead wires of the second coil pair is provided between the long side portion of the first coil set and the other long side portion of the second coil set.

4. The coil structure according to claim 3, wherein in the first and second coil pairs, the outer lead wire of one of the two air-core coils and the outer lead wire of the other air-core coil are provided on different long sides.

5. A coil structure according to any one of claims 1 to 4, Magnets are arranged on both sides of the coil structure so as to face each other in the axial direction of the first coil set. A linear motor equipped with [a specific feature].

6. In a method for manufacturing a coil structure having a rectangular air-core coil that is a single layer in the axial direction, Two air-core coils with opposite winding directions are stacked in the axial direction, and the ends of the air-core coils in the longitudinal direction are bent in the same direction in the axial direction to generate a first coil pair. Two air-core coils with opposite winding directions are stacked axially to create a second coil pair in which the long and short sides are located on the same plane, and the long side is longer than that of the first coil pair. Two of the aforementioned second coil pairs are stacked in the axial direction to generate a second coil set. The two aforementioned second coil sets are arranged side by side with their axial directions parallel, A method for manufacturing a coil structure, comprising stacking two first coil pairs in the axial direction such that the bending directions of the ends of each first coil pair are in opposite directions, and the end of one of the long sides of the two first coil pairs is interposed between the short sides of the two first coil pairs, so that the adjacent long sides of the two second coil sets are located inside the first coil pair.

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